Building Engineering Services Association Installation and testing of:PART ONELOW TEMPERATUREHOT WATERHEATINGPIPEWORK SYSTEMS TR/20 www.theBESA.com
Building Engineering Services Association AcknowledgmentsInstallation and testing of: Members of the drafting panel who compiled this guide, BESA wishes to record its sincerePART ONE thanks to the following members of the TR/20 draftingLOW TEMPERATURE Sub-Committee, without whose direct input of knowledge,HOT WATER time and experience this publication would not have beenHEATING produced.PIPEWORK SYSTEMS John StClair TR/20 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 0-903783-40-1 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 Association ForewordInstallation and testing of: TR/20 is published against a background of significant change within the building services engineering sectorPART ONE over recent years. Of particular note has been theLOW TEMPERATURE industry wide campaign to raise standards andHOT WATER performance through the Construction Best PracticeHEATING Programme. Much effort has been and continues to bePIPEWORK SYSTEMS made to raise the productivity, performance and competence standards of our sector. TR/20 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 One – Low Temperature Hot Water HeatingCONTENTSSection 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 heating systems. 8 1.7.3 Gravity circulating heating systems. 8 1.7.4 Fully pumped systems. 8Section 2 MATERIALS AND JOINTING METHODS 92.1 92.2 PIPING MATERIALS 102.3 SELECTION TABLE “A” 10 STEEL PIPE JOINTING 102.4 2.3.1 Threaded 10 2.3.2 Welded 102.5 2.3.3 Flanged 112.6 2.3.4 Grooved 112.7 COPPER PIPE JOINTING 11 2.4.1 Compression 12 2.4.2 Capillary 12 2.4.3 Brazed 12 2.4.4 Flanged 12 PUSH FIT JOINTING 12 PRESSED FIT JOINTING PROPRIETARY SYSTEMS JOINTING 13 13Section 3 STEEL PIPEWORK CONSTRUCTION AND ASSEMBLY 133.1 133.2 PIPING MATERIAL DETAILS 13 3.1.1 Pipe Finish 133.3 THREADED ASSEMBLY 13 3.2.1 Threaded Joints 143.4 3.2.2 Bends and Fittings 143.5 WELDED ASSEMBLY 14 3.3.1 Welding Methods 143.6 3.3.2 Welding Fittings 153.7 FLANGED ASSEMBLY 153.8 GROOVED ASSEMBLY 15 3.5.1 Joints 16 3.5.2 Fittings 16 PRESS FIT ASSEMBLY 16 SUPPORT AND FIXINGS 17 EXPANSION AND CONTRACTION 17 3.8.1 Natural Flexibility 3.8.2 Expansion Devices 17 3.8.3 Anchors and Guides 17 3.8.4 Cold Draw 17Section 4 COPPER PIPEWORK CONSTRUCTION AND ASSEMBLY4.1 PIPING MATERIALS 4.1.1 Grades and Types 4.1.2 Finish4
Installation and Testing of Pipework Systems Part One – Low Temperature Hot Water4.2 COMPRESSION JOINT AND FITTING ASSEMBLY Page 4.2.1 Compression Method4.3 4.2.2 Compression Fittings 18 CAPILLARY JOINT AND FITTING ASSEMBLY 184.4 4.3.1 Capillary Method of Assembly 18 4.3.2 Capillary Fittings 184.5 BRAZED ASSEMBLY 184.6 4.4.1 Brazing Method 18 4.4.2 Brazing Fittings 184.7 FLANGED ASSEMBLY 18 PUSH FIT ASSEMBLY 184.8 4.6.1 Push Fit Method 184.9 4.6.2 Push Fit Fittings 194.10 PRESS FIT ASSEMBLY 19 4.7.1 Press Method 19 4.7.2 Press Fitting 19 PULLED BENDS 19 SUPPORT AND FIXINGS 19 EXPANSION AND CONTRACTION 19 4.10.1 Natural Flexibility 19 4.10.2 Expansion Devices 20 4.10.3 Anchors and Guides 20 4.10.4 Cold Draw 20 20Section 5 STAINLESS STEEL PIPEWORK CONSTRUCTION AND ASSEMBLY 20Section 6 PLASTIC PIPEWORK CONSTRUCTION AND ASSEMBLY 216.16.2 INTRODUCTION 226.3 APPLICATION SELECTION TABLE 22 JOINTING METHODS SELECTION 226.4 6.3.1 Threaded 236.5 6.3.2 Solvent Welding 236.6 6.3.3 Flanged 236.7 6.3.4 Thermal Fusion 236.8 6.3.5 Butt Welding 246.9 6.3.6 Socket Welding 246.10 6.3.7 Electrofusion 246.11 6.3.8 Compression Fittings 246.12 6.3.9 Push-Fit 246.13 ELECTRICAL CONDUCTIVITY 246.14 EXPANSION AND CONTRACTION RATES 246.15 SUPPORTS 256.16 ULTRA-VIOLET LIGHT 25 MIXING OF PIPES AND FITTINGS 25 PRESSURE FLUCTUATION 25 HANDLING 25 LOCATION OF PIPEWORK 25 PRESSURE AND TEMPERATURE RELATIONSHIP 25 CHEMICAL CLEANING 26 HIDDEN PIPEWORK 26 PLASTIC PIPEWORK AND HEATING SYSTEMS 26 IDENTIFICATION 26Section 7 GENERAL REQUIREMENTS CONSTRUCTION AND ASSEMBLY 267.1 267.2 MAIN EQUIPOTENTIAL BONDING 267.3 DRAINING 277.4 VENTING EXPANSION AND CONTRACTION 5
Installation and Testing of Pipework Systems Part One – Low Temperature Hot Water Heating7.5 PROTECTION Page 7.5.1 Physical 7.5.2 Corrosion 27 277.6 CONNECTIONS TO EQUIPMENT 27 7.6.1 Connections to Existing 27 7.6.2 Connections for Future Extensions 27 277.7 EXTERNAL FABRIC PENETRATIONS 277.8 CONSTRUCTION AND ASSEMBLY PROCEDURES 27 27 7.8.1 Cleanliness 28 7.8.2 Pipe Sleeves 28 7.8.3 Alignment 28 7.8.4 Spacing and Clearances 29Section 8 ACCESSORIES AND PIPELINE ANCILLARIES 298.1 298.2 GENERAL REQUIREMENTS 298.3 VALVE LOCATIONS AND FUNCTION 298.4 8.2.1 Isolating Valves 29 8.2.2 Regulating valves 308.5 THERMOSTATIC RADIATOR VALVES 30 PIPELINE ANCILLARIES 30 8.4.1 Safety Valves 30 8.4.2 Ball Float Valves 30 8.4.3 Non-return Valves 30 8.4.4 Strainers 30 8.4.5 Instrumentation and Test Points 31 8.4.6 Pressure Gauges 31 8.4.7 Thermometers 31 IDENTIFICATION 8.5.1 Pipelines 31 8.5.2 Valves and Plant 32Section 9 TESTING 32 32Section 10 THERMAL INSULATION 33 3310.1 APPLICATION 33 34 10.1.1 Installation Considerations 34 10.1.2 Workmanship 34 3410.2 TRACE HEATING 34 34 10.2.1 Pre-installation Guidelines 34 35 10.2.2 Installation 35 35 10.2.3 Heating Cable Connection 35 36 10.2.4 Heating Cable Testing 36Section 11 FLUSHING, CLEANING AND WATER TREATMENT 38 3811.1 APPLICATION11.2 SYSTEM CLEANLINESS 11.2.1 Introduction 11.2.2 Delivery and Storage 11.2.3 During Installation 11.2.4 During Testing 11.2.5 Dynamic Flushing11.3 FILLING SYSTEM11.4 CHEMICAL CLEANING11.5 WATER TREATMENTSection 12 BIBLIOGRAPHY AND SOURCES12.1 REFERENCES12.2 ABBREVIATIONS12.3 MISCELLANEOUS6
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