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

Building Engineering Services AssociationInstallation and testing of: AcknowledgmentsPART TWO Members of the drafting panel whoMEDIUM compiled this guide BESA wishes to record its sincere thanksTEMPERATURE to the following members of the TR/20 draftingHOT WATER Sub-Committee, without whose direct input of knowledge,HEATING time and experience this publication would not have been produced. TR/20 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 0-903783-41-X 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 TWO TR/20 is published against a background of significantMEDIUM change within the building services engineering sectorTEMPERATURE over recent years. Of particular note has been theHOT WATER industry wide campaign to raise standards andHEATING performance through the Construction Best Practice Programme. Much effort has been and continues to be TR/20 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 Two – Medium Temperature Hot Water HeatingCONTENTSSection 1 INTRODUCTION Page1.01.1 FOREWORD 71.2 OBJECTIVE 71.3 STANDARD OF QUALITY 71.4 QUALITY ASSURANCE 71.5 SCOPE 81.6 PUBLICATION AND REVIEW 81.7 OPERATING CONDITION 8 DESCRIPTION OF SERVICE 8Section 2 MATERIALS AND JOINTING METHODS 92.1 92.2 PIPING MATERIALS 102.3 SELECTION TABLE 102.4 THREADING - STEEL PIPEWORK 102.5 WELDING - STEEL PIPEWORK 102.6 FLANGES 10 COMPRESSION, CAPILLARY, BRAZED JOINTS OR PRESS FIT 102.7 2.6.1 Compression Joints 10 2.6.2 Capillary Joints 11 2.6.3 Brazed Joints 11 2.6.4 Press Fit PROPRIETARY SYSTEMS 11 11Section 3 STEEL PIPEWORK CONSTRUCTION AND ASSEMBLY 123.1 123.2 PIPING MATERIALS 12 3.1.1 Pipe Finish 123.3 THREADED ASSEMBLY 12 3.2.1 Threaded Joints 123.4 3.2.2 Bends and Fittings 133.5 WELDED ASSEMBLY 133.6 3.3.1 Welding Methods 14 3.3.2 Welding Fitting 143.7 FLANGED ASSEMBLY 14 SUPPORT AND FIXINGS 14 EXPANSION AND CONTRACTION 14 3.6.1 Natural Flexibility 14 3.6.2 Expansion Devices 14 3.6.3 Anchors and Guides 15 3.6.4 Cold Draw 15 CONSTRUCTION AND ASSEMBLY 15 3.7.1 Cleanliness 3.7.2 Pipe Sleeves 16 3.7.3 Alignment 16 3.7.4 Spacing and Clearance 16Section 4 COPPER PIPEWORK4.1 CONSTRUCTION AND ASSEMBLY PIPING MATERIALS 4.1.1 Grades and Types 4.1.2 Finish4

Installation and Testing of Pipework Systems Part Two – Medium Temperature Hot Water Heating4.2 JOINTING METHODS Page4.3 CAPILLARY JOINT AND FITTING ASSEMBLY 4.3.1 Capillary Method of Assembly 164.4 4.3.2 Capillary Fittings 16 COMPRESSION JOINT AND FITTING ASSEMBLY 164.5 4.4.1 Compression Method 164.6 4.4.2 Compression Fittings 16 FLANGED JOINTS 164.7 BRAZED ASSEMBLY 17 4.6.1 Brazing Method 174.8 4.6.2 Brazing Fittings 174.9 PRESS FIT ASSEMBLY 174.10 4.7.1 Method 17 4.7.2 Fitting 174.11 PULLED BENDS 17 SUPPORT AND FIXINGS 17 EXPANSION AND CONTRACTION 17 4.10.1 Expansion of Copper Pipework 17 4.10.2 Expansion Devices 18 4.10.3 Anchors and Guides 18 4.10.4 Cold Draw 18 CONSTRUCTION AND ASSEMBLY 19 4.11.1 Cleanliness 19 4.11.2 Pipe Sleeves 19 4.11.3 Alignment 19 4.11.4 Spacing and Clearances 19 19Section 5 STAINLESS PIPE 20Section 6 GENERAL REQUIREMENTS 206.16.2 MAIN EQUIPOTENTIAL BONDING 216.3 VENTING 216.4 DRAINING 216.5 EXPANSION 21 PROTECTION 216.6 6.5.1 Physical 21 6.5.2 Corrosion 216.7 CONNECTIONS TO EQUIPMENT 21 6.6.1 Connections to Existing Equipment 22 6.6.2 Connections for Future Use 22 EXTERNAL FABRIC PENETRATIONS 22Section 7 ACCESSORIES AND PIPELINE ANCILLARIES 227.1 227.2 GENERAL REQUIREMENTS 22 VALVE LOCATIONS AND FUNCTION 237.3 7.2.1 Isolating Valves 23 7.2.2 Regulating valves 23 PIPELINE ANCILLARIES 23 7.3.1 Safety Valves 23 7.3.2 Ball Float Valves 23 7.3.3 Check Valves (non-return valves) 7.3.4 Strainers 5

Installation and Testing of Pipework Systems Part Two – Medium Temperature Hot Water Heating 7.3.5 Instrumentation and Test Points 23 7.3.6 Pressure Gauges 24 7.3.7 Thermometers 247.4 IDENTIFICATION 24 7.4.1 Pipeline 24 7.4.2 Valves and Plant 24Section 8 TESTING 25Section 9 THERMAL INSULATION 259.1 25 APPLICATION 269.2 9.1.1 Installation Considerations 26 9.1.2 Workmanship 26 TRACE HEATING 27 9.2.1 Pre-Installation Guidelines 27 9.2.2 Installation 27 9.2.3 Heating Cable Connections 9.2.4 Heating Cable Testing 28 28Section 10 FLUSHING, CLEANING AND WATER TREATMENT 28 2810.1 APPLICATION 28 2810.2 SYSTEM CLEANLINESS 28 29 10.2.1 Introduction 29 10.2.2 Delivery and Storage 30 32 10.2.3 During Installation 32 10.2.4 During Testing10.3 FILLING THE SYSTEM10.4 CHEMICAL CLEANING10.5 WATER TREATMENTSection 11 BIBLIOGRAPHY AND SOURCES11.1 REFERENCES11.2 MISCELLANEOUS PUBLICATIONS11.3 ABBREVIATIONS6