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Building Engineering Services Association Installation and testing of:PART FIVECOLD WATERSERVICE TR/20 www.theBESA.com

Building Engineering Services AssociationInstallation and testing of: AcknowledgmentsPART FIVE Members of the drafting panel who compiled this guide BESA wishes to record its sincere thanksCOLD WATER to the following members of the TR/20 draftingSERVICE Sub-Committee, without whose direct input of knowledge, time and experience this publication would not have been TR/20 produced. John StClair Eric Innes Cliff Toft Geoffrey Robinson Alan Keating – Secretary Frank J Ferris - Consultant BESA also wishes to acknowledge the input from BSRIA, CIBSE, IoP, IGEM, OFTEC, plus the remaining members of the Technical Committee for their time, input and vetting. ISBN 0-903783-44-4 First published 2003 ©2003 BESA BESA Publications Old Mansion House Eamont Bridge Penrith CA10 2BX 01768 860405 [email protected]. www.theBESA.com

Building Engineering Services AssociationInstallation and testing of: ForewordPART FIVE TR/20 is published against a background of significant change within the building services engineering sectorCOLD WATER over recent years. Of particular note has been theSERVICE industry wide campaign to raise standards and performance through the Construction Best Practice TR/20 Programme. Much effort has been and continues to be made to raise the productivity, performance and competence standards of our sector. To support this programme BESA has undertaken to provide a number of measures designed to demonstrate and achieve positive differentiation of their members. One such measure has been to undertake a fundamental review of TR/10, the previous BESA standard for Installation work ‘Heating Hot and Cold Water Supply’. As a result of this review TR/20 replaces TR/10 and emerges as a new standard for ‘The Installation and Testing of Pipework Services’ for the building services engi- neering sector. It embraces a comprehensive range of pipework services and is structured as a set of 10 ‘stand alone’ sectionalised specifications. The objective of TR/20 is to provide a pipework installation specification that will ensure compliance with accepted good practice. It is intended that this standard specification will be used generally as a means of measurement and assessment of a contractor’s performance and, specifically, to demonstrate compliance and competence under the BESA Inspection and Assessment arrangements. It is envisaged that TR/20 be used either in the absence of a client specification or by specific reference as an integral part of such a specification. It is also proposed that TR/20 be used as a quality benchmark whereby any shortfall identified within an alternative specification is drawn to the client’s attention. Unlike its forerunner, TR/20 does not address design or commissioning requirements. These are considered to be very ably addressed by other industry documents already in place published by CIBSE, BSRIA, OFTEC and others, for which appropriate references are provided. TR/20 also excludes equipment incorporated within or connected to the pipework installation. The specification and selection of equipment is considered to be a responsibility of the system designer who should ensure that where appropriate the selection is compliant with the client’s brief. Additionally, it is not the policy of BESA to promote any particular product or manufacturer. During the review and drafting process the drafting Sub-committee has consulted widely with individuals and external organisations to ensure that the new standard fully reflects the industry’s current good practice. The resulting publication will, I believe, serve as a recognised benchmark for our industry sector and BESA members in particular. I take this opportunity to thank all who have contributed to its production and in particular the members of the TR/20 Sub-committee for their tireless efforts and collective contribution of invaluable knowledge and experience. John Hunt Former Chairman, BRSA Technical Committee www.theBESA.com

Installation and Testing of Pipework Systems Part Five – Cold Water ServiceCONTENTSSection 1 INTRODUCTION Page1.01.1 FOREWORD 71.2 OBJECTIVE 71.3 STANDARD OF QUALITY 71.4 QUALITY ASSURANCE 81.5 SCOPE 81.6 PUBLICATION AND REVIEW 81.7 OPERATING CONDITION 8 DESCRIPTION OF SERVICE 8 1.7.1 Direct Supply from main or equivalent 8 1.7.2 Supply from gravity cistern 8 1.7.3 Supply from storage cistern and pumped 8Section 2 MATERIALS AND JOINTING METHODS 92.1 92.2 PIPING MATERIALS 102.3 SELECTION TABLES 10 GALVANISED STEEL PIPE JOINTING 102.4 2.3.1 Threaded 10 2.3.2 Welded 102.5 2.3.3 Flanged 112.6 COPPER PIPE JOINTING 112.7 2.4.1 Compression Joints 11 2.4.2 Capillary Joints 11 2.4.3 Brazed Joints 11 2.4.4 Flanged 11 PUSH FIT JOINTING 12 PRESS FIT JOINTING PROPRIETARY SYSTEMS 12 12Section 3 GALVANISED STEEL PIPEWORK CONSTRUCTIONAND ASSEMBLY 123.1 123.2 PIPING MATERIALS 13 THREADED ASSEMBLY 133.3 3.2.1 Threaded Joints 13 3.2.2 Bends and Fittings 133.4 WELDED ASSEMBLY 143.5 3.3.1 Welding Methods 143.6 3.3.2 Welding Fittings FLANGED ASSEMBLY 15 SUPPORT AND FIXINGS 15 EXPANSION AND CONTRACTION 15 15Section 4 COPPER PIPEWORK CONSTRUCTION AND ASSEMBLY 154.1 15 PIPING MATERIALS 154.2 4.1.1 Grades and Types 15 4.1.2 Finish 154.3 CAPILLARY JOINT AND FITTING ASSEMBLY 16 4.2.1 Capillary Method of Assembly 164.4 4.2.2 Capillary Fittings 16 COMPRESSION JOINT AND FITTING ASSEMBLY 164.5 4.3.1 Compression Method 4.3.2 Compression Fittings BRAZED ASSEMBLY 4.4.1 Brazing Method 4.4.2 Brazing Fittings FLANGED JOINTS4

Installation and Testing of Pipework Systems Part Five – Cold Water Service4.6 PUSH FIT ASSEMBLY Page 4.6.1 Push Fit Method4.7 4.6.2 Push Fit Fittings 16 PRESS FIT ASSEMBLY 164.8 4.7.1 Method 164.9 4.7.2 Fitting 164.10 PULLED BENDS 16 SUPPORT AND FIXINGS 16 EXPANSION AND CONTRACTION 17 17Section 5 STAINLESS STEEL PIPEWORK CONSTRUCTION AND ASSEMBLY 17Section 6 PLASTIC PIPEWORK CONSTRUCTION AND ASSEMBLY 186.16.2 INTRODUCTION 186.3 APPLICATION SELECTION TABLE 18 JOINTING METHODS 196.4 6.3.1 Threaded 196.5 6.3.2 Solvent Welding 196.6 6.3.3 Flanged 206.7 6.3.4 Thermal Fusion 206.8 6.3.5 Butt Welding 206.9 6.3.6 Socket Welding 216.10 6.3.7 Electrofusion 216.11 6.3.8 Compression Fittings 216.12 6.3.9 Push-Fit 216.13 ELECTRICAL CONDUCTIVITY 216.14 EXPANSION AND CONTRACTION RATES 21 SUPPORTS 21 ULTRA-VIOLET LIGHT 22 MIXING OF PIPES AND FITTINGS 22 PRESSURE FLUCTUATION 22 HANDLING 22 THERMAL INSULATION AND TRACE HEATING 22 LOCATION OF PIPEWORK 22 HIDDEN PIPEWORK 23 IDENTIFICATION 23Section 7 GENERAL REQUIREMENTS 237.1 237.2 MAIN EQUIPOTENTIAL BONDING 237.3 VENTING 237.4 DRAINING 23 PROTECTION 237.5 7.4.1 Physical 24 CONNECTIONS TO EQUIPMENT 247.6 7.5.1 Connections to Existing 247.7 7.5.2 Connections for Future Use 24 EXTERNAL FABRIC PENETRATIONS 24 CONSTRUCTION AND ASSEMBLY 24 7.7.1 Cleanliness 24 7.7.2 Pipe Sleeves 24 7.7.3 Alignment 7.7.4 Spacing and Clearance 25 25Section 8 ACCESSORIES AND PIPELINEANCILLARIES 258.1 258.2 GENERAL REQUIREMENTS 25 VALVE LOCATIONS AND FUNCTION 258.3 8.2.1 Isolating Valves PIPELINE ANCILLARIES 8.3.1 Ball Float Valves 8.3.2 Non-return Valves 5

Installation and Testing of Pipework Systems Part Five – Cold Water Service 8.3.3 Reduced Pressure Zone Valves Page 8.3.4 Strainers 25 8.3.5 Instrumentation and Test Points 25 8.3.6 Pressure Gauges 25 8.3.7 Thermometers 258.4 IDENTIFICATION 25 8.4.1 Pipeline 25 8.4.2 Valves and Plant 25 26Section 9 TESTING 26Section 10 THERMAL INSULATION 27 2710.1 APPLICATION 27 28 10.1.1 Installation Considerations 28 10.1.2 Workmanship 28 TRACE HEATING 2910.2 29 10.2.1 Pre-installation Guidelines 29 10.2.2 Installation 29 10.2.3 Heating Cable Connection 29 10.2.4 Heating Cable Testing 29 29Section 11 FLUSHING, CLEANING AND WATER TREATMENT 30 3011.1 APPLICATION 3011.2 SYSTEM CLEANLINESS 30 32 11.2.1 Introduction 32 11.2.2 Delivery and Storage 11.2.3 During Installation 11.2.4 During Testing 11.2.5 Dynamic Flushing 11.2.6 On CompletionSection 12 BIBLIOGRAPHY AND SOURCES12.1 REFERENCES12.2 ABBREVIATIONS12.3 MISCELLANEOUS6