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

Building Engineering Services AssociationInstallation and testing of: AcknowledgmentsPART SIX Members of the drafting panel who compiled this guide BESA wishes to record its sincere thanksCHILLED to the following members of the TR/20 draftingWATER 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 0-903783-45-2 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 SIX TR/20 is published against a background of significant change within the building services engineering sectorCHILLED over recent years. Of particular note has been theWATER 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 Six – Chilled WaterCONTENTSSection 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 Conventional feed and expansion tank systems. 8 1.7.2 Pressurised closed circuit systems. 8 1.7.3 Fully pumped systems. 8 1.7.4 Condensate Drain from Cooling Coils 8Section 2 MATERIALS AND JOINTING METHODS 92.1 92.2 PIPING MATERIALS 112.3 SELECTION TABLES - Chilled Water and Condensate Water Drains 112.4 THREADING - Steel 112.5 WELDING - Steel 112.6 FLANGES 112.7 GROOVED JOINTS 112.8 PRESSED FIT 11 COMPRESSION, CAPILLARY, BRAZED JOINTS OR PUSH FIT 122.9 2.8.1 Compression Joints 122.10 2.8.2 Capillary Joints 12 2.8.3 Brazed Joints 12 2.8.4 Push Fit 12 JOINTING GLASS - CONDENSATE DRAINS PROPRIETARY SYSTEMS 13 13Section 3 STEEL PIPEWORK CONSTRUCTION AND ASSEMBLY 133.1 13 PIPING MATERIALS 133.2 3.1.1 Pipe Finish 13 THREADED ASSEMBLY 133.3 3.2.1 Threaded Joints 14 3.2.2 Bends and Fittings 143.4 WELDED ASSEMBLY 143.5 3.3.1 Welding Methods 14 3.3.2 Welding Fittings 153.6 FLANGED ASSEMBLY 153.7 GROOVED ASSEMBLY 153.8 3.5.1 Joints 163.9 3.5.2 Fittings 16 PRESS FIT ASSEMBLY 16 SUPPORT AND FIXINGS 16 EXPANSION AND CONTRACTION 17 CONSTRUCTION AND ASSEMBLY 17 3.9.1 Cleanliness 3.9.2 Pipe Sleeves 17 3.9.3 Alignment 17 3.9.4 Spacing and Clearance 17Section 4 COPPER PIPEWORK CONSTRUCTION AND4.1 ASSEMBLY PIPING MATERIALS 4.1.1 Grades and Types 4.1.2 Finish4

Installation and Testing of Pipework Systems Part Six – Chilled Water4.2 JOINTING METHODS Page4.3 CAPILLARY JOINT AND FITTING ASSEMBLY 4.3.1 Capillary Method of Assembly 184.4 4.3.2 Capillary Fittings 18 COMPRESSION JOINT AND FITTING ASSEMBLY 184.5 4.4.1 Compression Method 184.6 4.4.2 Compression Fittings 18 FLANGED JOINTS 184.7 PUSH FIT ASSEMBLY 18 4.6.1 Push Fit Method 184.8 4.6.2 Push Fit Fittings 18 BRAZED ASSEMBLY 184.9 4.7.1 Brazing Method 194.10 4.7.2 Brazing Fittings 194.11 PRESS FIT ASSEMBLY 194.12 4.8.1 Method 19 4.8.2 Fitting 19 PULLED BENDS 19 SUPPORT AND FIXINGS 19 EXPANSION AND CONTRACTION 19 CONSTRUCTION AND ASSEMBLY 19 4.12.1 Cleanliness 20 4.12.2 Pipe Sleeves 20 4.12.3 Alignment 20 4.12.4 Spacing and Clearances 20 20Section 5 STAINLESS STEEL PIPEWORK CONSTRUCTION AND ASSEMBLY 21Section 6 PLASTIC PIPEWORK CONSTRUCTION AND ASSEMBLY 216.16.2 INTRODUCTION 22 APPLICATION SELECTION TABLE 226.3 6.2.1 Pressure and temperature relationship 22 JOINTING METHODS 236.4 6.3.1 Threaded 236.5 6.3.2 Solvent Welding 236.6 6.3.3 Flanges 246.7 6.3.4 Thermal Fusion 246.8 6.3.5 Butt Welding 246.9 6.3.6 Socket Welding 246.10 6.3.7 Electrofusion 256.11 6.3.8 Compression Fittings 256.12 6.3.9 Push-Fit 256.13 ELECTRICAL CONDUCTIVITY 256.14 EXPANSION AND CONTRACTION RATES 256.15 SUPPORTS 266.16 ULTRA-VIOLET LIGHT 26 MIXING OF PIPES AND FITTINGS 26 PRESSURE FLUCTUATION 26 HANDLING 26 THERMAL INSULATION AND TRACE HEATING 27 LOCATION OF PIPEWORK 27 CHEMICAL CLEANING 27 EXTERNAL INSULATION AND HIDDEN PIPEWORK 27 PLASTIC PIPEWORK AND CHILLED WATER SYSTEMS 27 IDENTIFICATION 27Section 7 GENERAL REQUIREMENTS 28 287.1 MAIN EQUIPOTENTIAL BONDING 287.2 VENTING7.3 DRAINING 5

Installation and Testing of Pipework Systems Part Six – Chilled Water7.4 EXPANSION AND CONTRACTION 287.5 PROTECTION 28 28 7.5.1 Physical 29 7.5.2 Corrosion 297.6 CONNECTIONS TO EQUIPMENT 29 7.6.1 Connections to Existing 29 7.6.2 Connections for Future Use 297.7 EXTERNAL FABRIC PENETRATIONS 29 29Section 8 ACCESSORIES AND PIPELINE ANCILLARIES 298.1 GENERAL REQUIREMENTS 298.2 VALVE LOCATIONS AND FUNCTION 308.3 8.2.1 Isolating Valves 30 8.2.2 Regulating Valves 308.4 PIPELINE ANCILLARIES 30 8.3.1 Safety Valves 30 8.3.2 Ball Float Valves 30 8.3.3 Non-return Valves 30 8.3.4 Strainers 31 8.3.5 Instrumentation and Test Points 31 8.3.6 Pressure Gauges 31 8.3.7 Thermometers 31 IDENTIFICATION 8.4.1 Pipelines 32 8.4.2 Valves and Plant 32 32Section 9 TESTING 33 33Section 10 THERMAL INSULATION 33 3410.1 APPLICATION 34 34 10.1.1 Installation Considerations 34 10.1.2 Workmanship 34 TRACE HEATING 3410.2 34 35 10.2.1 Pre-installation Guidelines 35 10.2.2 Installation 35 10.2.3 Heating Cable Connection 35 10.2.4 Heating Cable Testing 36 36Section 11 FLUSHING, CLEANING AND WATER TREATMENT 38 3811.1 APPLICATION11.2 SYSTEM 11.2.1 Introduction 11.2.2 Delivery and Storage 11.2.3 During Installation 11.2.4 During Testing 11.2.5 Dynamic Flushing FILLING SYSTEM11.311.4 CHEMICAL CLEANING11.5 WATER TREATMENTSection 12 BIBLIOGRAPHY AND SOURCES12.1 REFERENCES12.2 ABBREVIATIONS12.3 MISCELLANEOUS6