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

Building Engineering Services AssociationInstallation and testing of: AcknowledgmentsPART FOUR Members of the drafting panel who compiled this guide BESA wishes to record its sincere thanksHOT 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 0-903783-43-6 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 FOUR TR/20 is published against a background of significant change within the building services engineering sectorHOT 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 Four – Hot Water ServiceCONTENTS PageSection 1 INTRODUCTION 71.0 71.1 FOREWORD 71.2 OBJECTIVE 71.3 STANDARD OF QUALITY 81.4 QUALITY ASSURANCE 81.5 SCOPE 81.6 PUBLICATION AND REVIEW 81.7 OPERATING CONDITION DESCRIPTION OF SERVICESection 2 MATERIALS AND JOINTING METHODS 92.1 92.2 PIPING MATERIALS 102.3 SELECTION TABLE “A” 10 GALVANIZED STEEL PIPE JOINTING 102.4 2.3.1 Threaded 10 2.3.2 Welded and Galvanized after Fabrication 102.5 2.3.3 Flanged 102.6 COPPER PIPE JOINTING 112.7 2.4.1 Compression 11 2.4.2 Capillary 11 2.4.3 Brazed 11 2.4.4 Flanged 12 PUSH FIT JOINTING 12 PRESS FIT JOINTING PROPRIETARY SYSTEMSSection 3 GALVANIZED STEEL PIPEWORK CONSTRUCTION AND ASSEMBLY 123.1 123.2 PIPING MATERIALS DETAILS 12 THREADED ASSEMBLY 123.3 3.2.1 Threaded Joints 13 3.2.2 Bends and Fittings 133.4 WELDED ASSEMBLY 133.5 3.3.1 Welding Methods 133.6 3.3.2 Welding Fittings 14 FLANGED ASSEMBLY 14 SUPPORT AND FIXINGS 15 EXPANSION AND CONTRACTION 15 3.6.1 Natural Flexibility 15 3.6.2 Expansion Devices 15 3.6.3 Anchors and Guides 3.6.4 Cold DrawSection 4 COPPER PIPEWORK CONSTRUCTION AND ASSEMBLY 154.1 15 PIPING MATERIALS 154.2 4.1.1 Grades and Types 164.3 4.1.2 Finish 16 ASSEMBLY METHODS 164.4 COMPRESSION ASSEMBLY 16 4.3.1 Compression Method 164.5 4.3.2 Compression Fittings 16 CAPILLARY ASSEMBLY 164.6 4.4.1 Capillary Method 16 4.4.2 Capillary Fittings 16 BRAZED ASSEMBLY 16 4.5.1 Brazing Method 16 4.5.2 Brazing Fittings FLANGED JOINTS4

Installation and Testing of Pipework Systems Part Four – Hot Water Service4.7 PUSH FIT ASSEMBLY Page 4.7.1 Push Fit Method4.8 4.7.2 Push Fit Fittings 17 PRESS FIT ASSEMBLY 174.9 4.8.1 Press Fit Method 174.10 4.8.2 Press Fit Fitting 174.11 PULLED BENDS 17 SUPPORT AND FIXINGS 17 EXPANSION AND CONTRACTION 17 4.11.1 Natural Flexibility 17 4.11.2 Expansion Devices 18 4.11.3 Anchors and Guides 18 4.11.4 Cold Draw 18 18Section 5 STAINLESS STEEL PIPEWORK CONSTRUCTION AND ASSEMBLY 18Section 6 PLASTIC PIPEWORK CONSTRUCTION AND ASSEMBLY 196.16.2 INTRODUCTION 196.3 APPLICATION SELECTION TABLE 19 JOINTING METHODS SELECTION 206.4 6.3.1 Threaded 206.5 6.3.2 Solvent Welding 206.6 6.3.3 Flanged 216.7 6.3.4 Thermal Fusion 216.8 6.3.5 Butt Welding 216.9 6.3.6 Socket Welding 226.10 6.3.7 Electrofusion 226.11 6.3.8 Compression Fittings 226.12 6.3.9 Push-Fit 226.13 ELECTRICAL CONDUCTIVITY 226.14 EXPANSION AND CONTRACTION RATES 226.15 SUPPORTS 22 ULTRA-VIOLET LIGHT 23 MIXING OF PIPES AND FITTINGS 23 HANDLING 23 THERMAL INSULATION AND TRACE HEATING 23 LOCATION OF PIPEWORK 23 PRESSURE AND TEMPERATURE RELATIONSHIP 24 CHEMICAL CLEANING 24 HIDDEN PIPEWORK 24 IDENTIFICATION 24Section 7 GENERAL REQUIREMENTS 247.1 247.2 MAIN EQUIPOTENTIAL BONDING 247.3 DRAINING 257.4 VENTING 257.5 EXPANSION AND CONTRACTION 25 PROTECTION 257.6 7.5.1 Physical 25 7.5.2 Corrosion 257.7 CONNECTIONS TO EQUIPMENT 257.8 7.6.1 Connections to Existing 25 7.6.2 Connections for Future Use 25 7.6.3 Connections to Draw-offs 25 EXTERNAL FABRIC PENETRATIONS 25 CONSTRUCTION AND ASSEMBLY PROCEDURES 26 7.8.1 Cleanliness 26 7.8.2 Pipe Sleeves 26 7.8.3 Alignment 7.8.4 Spacing and Clearance 5

Installation and Testing of Pipework Systems Part Four – Hot Water ServiceSection 8 ACCESSORIES AND PIPELINE ANCILLARIES 278.1 GENERAL REQUIREMENTS 278.2 VALVE LOCATIONS AND FUNCTION 278.3 8.2.1 Isolating Valves 27 8.2.2 Regulating valves 288.4 PIPELINE ANCILLARIES 28 8.3.1 Safety Valves 28 8.3.2 Ball Float Valves 28 8.3.3 Non-return Valves 28 8.3.4 Strainers 28 8.3.5 Instrumentation and Test Points 28 8.3.6 Pressure Gauges 28 8.3.7 Thermometers 28 IDENTIFICATION 29 8.4.1 Pipelines 29 8.4.2 Valves and Plant 29 30Section 9 TESTING 30 30Section 10 THERMAL INSULATION 31 3110.1 APPLICATION 31 32 10.1.1 Installation Considerations 32 10.1.2 Workmanship 32 TRACE HEATING 3210.2 32 32 10.2.1 Pre-installation Guidelines 32 10.2.2 Installation 33 10.2.3 Heating Cable Connection 33 10.2.4 Heating Cable Testing 33 33Section 11 FLUSHING, CLEANING AND WATER TREATMENT 34 3511.1 APPLICATION 3511.2 SYSTEM CLEANLINESS 11.2.1 Introduction 11.2.2 Delivery and Storage 11.2.3 During Installation 11.2.4 On Completion 11.2.5 During Testing 11.2.6 Dynamic Flushing CHEMICAL CLEANING11.3Section 12 BIBLIOGRAPHY AND SOURCES12.1 REFERENCES12.2 ABBREVIATIONS12.3 MISCELLANEOUS6