~

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The Chartered Institution of Building ServicesEngineers Delta House, 222 Balham High Road, London SW12 9BS

i'

First published 1989 Revised edition

Registeredcharity number 2781 04

ISBN 0900953675

Typesetby CIBSE Technical Deparlment

Foreword
The effective operation of any water system is highly dependent on satisfactory circuit balancing and co/hermmissioning. It is important, therefore, to havea designobjective that ensurescommissioningrequirementsare taken fully into accountatthe conceptualstage. Designers should ensure that these requirements are reflected in an unequivocal specification so that satisfactory commissioning can be assured.Discussions at an early stage with an approved and accredited commissioning specialist will assistthe designerto this end. Procedures for the balancing and commissioning of water systemshave evolved over the last two decades are now acknowledgedasbeing an essentialfactor in the completion of and a designthrough to the final handoverstage. The CIBSE Commissioning Code W represents standards of good practice which are presented in the form of recommendations and guidance generally accepted within the building servicesindustry. The 1989 edition has been completely reviewed and updated adding more technical information and advice that not only sets out to create a superior Codefor water regulation but also points out those extremely imponant areas where design and installation techniquesare vital in aiding commissioning. The latest technologicalimprovements to componentshave beenconsidered,together with the most up-to-date methods employed by commissioning specialists.Where appropriate thesehave beenincluded in this revised Code. The tolerancestatementsin previous Codes havetended to be somewhat exacting, requiring too much time and effort to be expended in working to close tolerances,with very litde apparent environmental benefit. A completely new section has widened the tolerance requirements appropriate to differing performanceeffectsand the particular temperature of the medium. R M Bishop (Chairman)

Task Group
RM Bishop(Chairman) I G Allan
A Black

J F Coppin
R Clark

RJ Oughton

Publications Secretary
K J Butcher

Editor
R Yarham

Note from the publisher

This publication is primarily intended to provide guidance to those responsible for the. design, installation, commissioning, operation and maintenance of building services. It is not intended to be exhaustiveor definitive and it will be necessary usersof the guidance for given to exercisetheir own professional judgement when deciding whether to abide by or depart from it.

Contents
Introduction
WO.l WO.2 WO.3 WO.4 WO.5 WO.6 Scope Definitions Specification Inspection Commissioningrecords Responsibilitv 2 3 3 3 3
Precommissioning checks

1
1

Wl

WI.I
WI.2 WI.3 Wl.4 WI.S WI.6 WI.7 Wl.8

Objective
Stateof the system Checksbeforefilling Systemflushing and cleaning Systemfilling and venting Mechanical checks Electrical checks Static completion records
to work

3
3

3 3 4 5

6
6 7

W2

Setting

W2.1 W2.2 W2.3 W2.4

Checksbefore pump start Initial run Further venting Completion certification

7 7 7 8 8

Balancing water flow rates W3.1 Objective

W3.2 W3.3 W3.4 W3.5 W3.6 W3.7 W3.8 W3.9 Flow rate measurement tolerances Basis ofbalancing Pump shut-off head test Preliminary flow rate check Constant-volumesystems Variable-volume systems Balancing by compensated method Regulation by temperaturebalance

8 8 8 8
10

10 10 12 14 15 15
systems

W3.10 Commissioning certification

Evaluation and witnessing of commissioned

W4.1 W4.2 W4.3 W 4.4

Objective Witnessing arrangements Duties of witnessing agent Commissioning documentation

15
15

15
16 16

Appendices WAl Design

W AI.I Design requirement WAI.2 Designconsiderations WAI.3 Provisions for measuringpressureand determining flow rate WAI.4 Easeofaccess WAI.S Flushing and cleaning WAI.6 Chemical cleaning W AI.7 Design information required

17
17
17 18 19 19 19 19

WA2 Installation
WA2.1 Installation requirement W A2.2 Installation cleanliness W A2.3 Installation inspection W A2.4 Pressure testing

20
20 20

20 20 20 20
21

WA3

Flow measurement and regulation WA3.1 Flow measurement devices WA3.2 Factors affecting measurement accuracy WA3.3 Double-regulating valve W A3.4 Accessto flow measurement regulating devices and WA3.5 Constantflow regulator (CPR) WA3.6 Instrumentation WA3.7 Flow coefficients

22 22
22 23 23

References

24
24 26

Bibliography Index

wo
WO.l

Introduction
Scope

Accuracy -flow

measuring

device volume flow rate from the true tolerances in the flow measur-

The variation in indicated value due to manufacturing ing device.

.')
v

This Codedealswith the work involved in balancing water flow rates in water distribution systems.All allied mechanical and electrical servicesand devicesmust be thoroughly checked and proved to enable this to be carried out. This whole procedure is known as commissioning. This Code represents standards of good practice which are presented in the form of recommendations and guidance generally acceptedwithin the building engineeringservicesindustry. Unless adequate provision has been made by both the designerand the installer of a water distribution system, it may not be possibleto balanceand commission the system in accordancewith this Code.Appendix sections W Al and WA2 therefore draw the systeQldesigner's and installer's attention to the requirements which will ensurethat a water systemcan be balancedand commissioned.

Note: a manufacturer's stated accuracy is the probable accuracy that can be achieved and should be stated as a percentage of the designed signal flow coefficient (kys)of the device.
Accuracy -instrument

The variation in reading from the true value due to manufacturing tolerancesin the instrument. Note: a manufacturer's stated accuracy is the probable accuracy that can be achieved and be should stated as a percentageof the full scaledeflection.
Balancing

The Code sets out to inform on the requirements for accurately balancing and commissioning water systems.A manual published by the Building Services Researchand
A\ '" Information AssociationCI) describes the practical aspects in a step by step format.

The process of adjusting the flow rates of a fluid in a distribution systemto achievethe design flow rates within the specifiedtolerances. Capacity testing

WO.2
apply.
Accuracy

Definitions

For the purposeof this Codethe following definitions

Demonstrating the capacity of an installation or component to achieve and maintain the performance criteria required by the specification.
Chemical cleaning

The internal treatment of a pipework installation according to a formal procedurewith chemicalfluids. Commission able systems Systemsdesigned, installed and prepared to specified requirements in sucha mannerasto enablecommissioning to be carried out. Commissioning

The overall accuracyis a compounding of the following factors: instrument accuracy; flow measuring device accuracy; measurementaccuracy. Refer to the BSRIA Application Guide 2/89 The commissioning water systems of in buildings(sectionA6) for further information(lJ. Accuracy -error measurement

Any error in instrument reading due to inaccuracy of operator observation such as errors of parallax or the instrument reading being subjectto pulsations.

The advancementof an installation from the stageof static completion to full working order to specifiedrequirements.

WATER DISTRIBUTION SYSTEMS

Commissioningmanagement The planning, organisation, co-ordination and control of commissioning activities. Commissioningmanager

Precomm;ss;on;ng

Specifiedsystematicchecking of a completed installation to confinn its suitability for commissioning. Note: precommissioning is a post-installation completion

activity.
Pressure and leakage testing

!he firm (or person) appointed manage commissionto the mgprocess.

Commissioningspecialist The firm (or person)appointed to carry out specifiedduties in connection with commissioning engineeringservices.
Commissioning specification

The measurementand recording of a specified pressure retention or loss within a systemor systemcomponent. Settingto work The processof setting astatic systeminto operation Static completion The state of a systemwhen it is installed in accordancewith the specification, i.e. cleanand ready for setting to work. In the caseof water systemsthis includes flushing, cleaning, pressuretesting, filling and venting.

The document which prescribes the requirements with which the various commissioningservices haveto comply. Note: the specification must refer to drawings, schedules and relevant parts of the Code,manuals, guides and other standards.
Design criteria

'1

System
A set of connectedcomponentsfor heating, cooling, ventilation or air conditioning consisting of plant, distribution ducting, piping and terminal units and arrangements to control their operation. -

The specified numerical quantity together with allowable

tolerances.
System proving
Diversity

The ratio between the design maximum systemload and the summation of all terminal loads.
Fine tuning

Measuring, recording, evaluating and reporting on the seasonal performanceof the systemagainstdesigncriteria.
Testing

Local adjustment to the systemwhere usageand system proving have shown sucha need.This may alsoinclude the re-assessment control set points and values to achieve of optimum performance.
Flow rate -measured

The measurementof the performance characteristics of an installation or parts of an installation. Note: this includes off-site testing.
Tolerance (for balancing procedures)

The flow rate derived a known characteristic. . pipeline devicehaving from an instrument connectedto a

The permissiblerangeof variation which is acceptablefrom the design value of a measurablecharacteristic. For fluid flow rates this is usually expressedas a percentage of the designvalue. Note: designersshould specify tolerances in their design

Flushing The washing out of an installation with water to a formal procedureto removedetritus.
Installation

criteria.

WO.3

Specification

A system placed in position as required by the design or

specification.

This Code assumes that the systemis completeand properly constructed to an agreed specification. This specification must state the tolerances within which the installation should operate, and to which the system should be balanced.

PRECOMMISSIONINGCHECKS

WO.4

Inspection

wo.s
Wl

Precommissioning checks
Obiective

Wl.l
~~

WO.6

Responsibility Wl.2

State of the system

WO.7

Practical considerations rate balancing

of flow

The measurement,regulation and balancing of flow rates in a water distribution system as applied in commissioning proceduresis a meansto an end. The prime objective is to ensure that the heating or cooling output of a commissioned installation can maintain the spaceenvironmental conditions specified by the designerwith optimum system efficiency. The degree of accuracyin flow rate balancing required to meet this objective will depend on a number of factors. These include the assumptions made by the designer in arriving at the specified heating or cooling loads for the conditioned spaceand the performance characteristics of the heat exchangers or terminal units serving the conditioned space.The difference betweenthe temperature of the circulated fluid and the spacetemperature influences these performance characteristics. Consideration should also be given to UK climatic conditions which fluctuate more rapidly than those for large continental land masses, hence placing greaterdemandson systemperformance.

Wl.3
Particular ensuring checks should include, but not be limited to, that the following have been fulfilled.

(a)

All equipment and componentshave beeninstalled in accordancewith the manufacturers'instructions for the medium used(e.g.chilled, low-, medium- or high-temperature hot water). Pump and valve gland packing and special valve lubricants are compatible with any chemical to be used in the cleaning, flushing and corrosion inhibition of the system. Permanentwaterconnectionshave beenmade. Flow measurementdevices have been installed in accordance with manufacturers' instructions and sectionWA3 of this Code.

(b)

(c) (d)

WATER DISTRIBUTION SYSTEMS

(e) (f)

Probe pockets, pressure gauges, siphons and test points have been installed.

Manual air vents and automatic air vents, where specified,have beenfitted at high points including continuous venting at low-velocity sections. Drain valvesand overflows of the Correctsize have beenfitted. (SeesectionWI.4.) Connections to heater and cooler batteries and other heat exchangershave beenmade correctly in relation to the designair and water flow directions. Control, double-regulating and non-return valves are installed in accordancewith the flow direction arrows or other indications marked on the devices. Relief valveshave beeninstalled to operatewithout restriction and in accordancewith the manufacturers' instructions. The outlets suitable drain points. are piped away to

f;
Wl.4.2
Flushing procedure

(g) (h)

(i)

(j)

Systems should be cleanedand flushed in accordancewith an agreed and approved method plan. Throughout the cleaning and flushing process, the carrying out of procedures in accordance with the method plan should be verified by the installing contractor and inspected by the relcvantwitnessing authority. Satisfactorycompliance may be ensured by certification. Additionally, the commissioning specialistshould be satisfied that the systemhas been adequatelycleaned, by referenceto the certification, by assurancefrom the witnessing authority or by witnessingaspectsof the work him/herself. The following proceduresare recommended. (a) (b) Flushing should be supervised only by qualified

(k)

Expansion devices are aligned and free from obstruction and installed to manufacturers' instructions including anchorpoints and guides. Strainers with the specified mesh have been installed in an isolatable section(seesectionWI.4). Changeoverdevicesfor duplex strainers are fitted. (Drain-down cocks are recommended for larger strainers.) Access and lifting facilities have been adequately provided for. All washers, cisterns, tanks, nozzles and fittings have beeninspectedfor cleanliness. All valves and cocks have been set in the operational position as given in the valve schedule(e.g. openor closed). The cold feed or mains connectionhas beenlocated correctly. All pipework and fittings have been adequately supported, and, where provided, spring supports correctly adjustedto fully support the weight 'of the pipework, components and water content in accordancewith the specification. All testpoints areaccessible probes. to All pipework has been correctly identified and

(1)

staff.
A flushing scheduleshould be provided by the installation contractor and approved by the designer beforethe physicalprocesscommences. The scheduleshould be based on schematic drawings with all sub-circuits, branches and terminals uniquely identified. All valves, coils, tubes and other equipmentliable to choking should be clearly

(m)
(n)

(c)

(0)

(P)

identified.
(d) (e)

Flushing should be carried out methodically from the top to the bottom of the system. Equipment liable to choking should be bypassed, isolated or completely removed and replaced by a spool piece to ensure system flow continuity. The use of flexible connections on terminal units may provide an easymeans of bypassingthe terminal. It may, however, be economic to install permanent bypasses. Note: in the unlikely event of sensitive equipment not being works pressure tested, the equipment should be pressure tested with clean water on an individual basis on-site before connecting to the system.Seesection WA2.4.

(q) (r)

marked.
(s) Adequate access maintained to all manual valve is handwheelsand to actuators on automatically controlled valves. The systemis safeto fill and that personnelare kept clear of areaswhich might be hazardousdue to unforeseen failure during filling. (f)

(t)

Wl.4
Wl.4.1

System flushing and cleaning

General

Care must be taken during construction to keepthe internal surfacesof pipework systemsas clean as possible. Serious blockagesin equipment will prove damagingand expensive

Every effort should be made for the flushing water velocity to be generatedexternally and not by use of the systempumps. It is recommended that system pumps be bypassed,isolated or removed and the circuit completed. To ensure effective flushing, velocities should be in accordance with BSRIA Application Guide 8/91 Pre-commission cleaning of watersystems(3),highlighted in Part C: Systemdyas namic flushing.

PRECOMMISSIONINGCHECKS

(g)

The pipework distribution system should be separated into isolated sections of high to low points.

with details of jointing and gland materials used in pumps, valves,lubrication materials of cocksand similar material. (a) Chemical cleaning should be preceded by flushing and carried out in a similar manner to that described in sectionWl.4.2, but with frequent sample testing asnecessary specialist chemical cleaning by practitioners. The system must be completely flushed and passivated immediately after chemical cleaning to inhibit metal surfacecorrosion. Systemsshould not be left empty. Frost protection systems must be active after chemical cleaning to avoid system drainage and the loss of chemicals during cold periods. Where the whole system is not being chemically cleanedat the sametime it is recommendedthat the isolating valves be locked in order to avoid pollution from untreatedsections.

(k)

Each sectionshould incorporate a drain valve at its lowest point. The full bore valve should be of line size and at least 50 mm on larger diameters all having access drainage. to
Each section should fill point. incorporate a suitable quick-

(i)

(b)

(J)

Each section should be flushed in tUrn, starting with the highest point. The section valves should be open, including bypassand drain valves; commenceflushing downwards. Each section should be isolated in tUrn until test samplesdo not contain significant signs of detritUs. Strainers should be inspected at regular intervals during this process. After the final high-velocity flush, the system should be filled with clean water together with suitable cleaningadditives. Circulation through the systemto be cleaned should be in accordancewith the recommendations made by the specialist sup~ plier and the cleaning and flushing method plan. This procedure should assist in removing the sludge, which adheresto the pipe wall, and keep it in suspension draining. for Once the systemis clean it should be drained and fllled immediately from the bottom up. Filling should be slow, taking care to remove air from extremities and high points. The system should then be dosedto prevent further corrosion and left circulating. Dosing and venting should be monitored frequently in the earlystagesof system. On no account should any part of the systembe drained and left empty and wet for longer than 24 hours after cleaning, as this will promote rapid corrosion and possibly necessitate are-clean. Where chemical cleaning is not specified,the drain valves and the water inlet 'should be closed. All items which have beenremoved or isolated should be replaced or reinstated. This work should be carried out beforethe commissioning specialist balances the system. Evidence should be produced to show that flushing and cleaning have been done effectively, since system cleanlinesshas a marked bearing on balancing and systemperformance.

(c)

(k)

(d)

(1)

Reference 5 recommends that water introduced into a building water systemfor commissioning purposesshould be completely drained awayunless the systemis to be put into serviceimmediately. It should be noted that for closed water systems,at low risk of disseminating Legionnaires' disease, practice would be both costly and unnecessary. this SeealsoReferences and 7. 6

(m)

Wl.4.4

Water treatment

Dosing pots and other water treatment apparatus must be filled and set up in accordancewith specialistinstructions by the installing engineer.

(n)

Wl.5

System filling and venting

(0)

(P)

Fill the system with water (treated, where specified) in accordancewith an agreedmethod statement,prepared by the installing contractor. To ensure effective venting fill slowly from the bottom upwards, thus forcing the air to high points for venting to atmosphere. Careful consideration should be given to the setting of valvesand air vents before and during filling to avoid airlocks and excessive spillage, particularly where the fill is treated.Take care not to exceedthe working pressureof the systemwhen filling from a high-pressure source. When the whole system is filled, disconnect the filling source, open the permanent supplyconnectionsand adjustthe feed tank waterlevels. On complex systems consider the use of proprietary air separators. Consideration should also be given to the variQustechniques available to limit air and other venting

Wl.4.3

Chemical cleaning

This is a specialisedoperation and should only be carried out by a competent operator using establishedmethods as defined by the Health and Safety Executive. Refer to the CIBSE Guide(4) Section B7 Corrosion protection and water treatment. Before chemical cleaning is commenceda complete list of materials must be provided by the designer and installer. This should include all metals used in the systemtogether

problems.
Mter static filling and venting the pumps should be operated for a period of about one hour and the venting repeated.Completesystemventing may take up to a weekto

complete.
Safety warning: do not attempt to fill the system via a pressurisationset. A pressurisationset should only be used for final systemtop-up.

WATER DISTRIBUTION SYSTEMS

Wl.5.1

Frost precautions

(b) (c) (d)

(e)

that the valve spindles are free to move the bearing lubrication the rigidity of the mountings the valve stroke, mechanical couplingsand linkages for correct geometry for freedom from excessive play in the linkage the fit of pins the tightness of locking devices that actuators have been fitted to manufacturers' recommendationswith access electrical connecto

Where the work described in sections,Wl.4, Wl.5, Wl.6 and W A2.4 is being carried out in cold weather it is essentialthat any equipment susceptibleto frost damage be protected, by heating the systemwater, by local spaceheating, or by draining down during prolonged non-working periods. Draining down should be avoided as damp internal surfacescanbe a primary causeof corrosioD:.

(f)
(g) (h)

W1.6
Wl.6.1

Mechanical checks
Pumps

(i)

tions.

The following checks should be made with the systemfull of water. Checkthat: (a) (b) (c) external parts of the pump are clean flow direction is correct all components,bolts, fIXings and fittings aresecure and that no distortion has takenplace on the basein tightening the impeller is free to rotate the level and plumb of pump and motor shaft and slide rails are correct; direct-driven pumps require particular attention in this respect, widl reference to manufacturers'recommendations the anti-vibration mountings have correct de-

W1.6.3

General system check

Checkeverymovingpieceof equipmentvisuallyfor freedomof movement.

I)

W1.7

Electrical checks

(d) (e)

Before the first operation of any electrical component or appliance the following procedure should be adopted. All requirements of the Electricity at Work Regulations1989(8), the Health and Safetyat Work etc.Acr<9) regarding the safety of the specialist and other personnel must be strictly ob-

served.
The lEE Regulations electrical installations(lO) for require a 'permit to work' procedure for some operations. Ensure that all earth bonding has beentested and complied with in accordance with the lEE Regulations.

(f) (g) (h) (i) (j) (k) (1) (m) (n)

flection
the correctdrive hasbeenfitted the pipework imposesno strain at the pump connections pulleys and couplings are secure and their alignment is correct the belts are tensionedand matched the bearingsare clean the lubricant is of the correctgradeand is fresh the coolantis available at the bearing or seal the glands,where fitted, have been correctly packed and the gland nuts are not more than finger tight, pending adjustment to correct drip rate after start-

Wl.7.1

Checks with all electrical supplies isolated

Checkto ensurethat: (a) (b) (c) (d) (e) (f) (g) (h) applianceand control circuits are locally isolated there arc no uDshroudedlive components within the panels panelsand switchgearare clean appliancesand surrounding areas clean and dry are transit packing has been removed from contactors and other equipment there is no mechanicaldamageto switchgear all connections on busbarsand wiring are tight all power and control wiring has beencompleted in detail in accordance with the circuit diagram, paying special attention to circuits for star-deltaconnectedand speciallywound motors all fuse ratings are correct all mechanical checks on the pump, motor and automatic valvesare complete(seesectionWl.6) on-site insulation tests on the motor have been performed satisfactorily

up
(0) (P) .drive guards have been securelyfitted with proper access tachometerreadingsand belt changes for pressure test points have been fitted at both the suction and dischargepoints of the pump to facilitate head tests to confirm inferred pump performance.

W1.6.2
Check:

Automatic control valves

(i) (,) (k)

(a)

that the valve ports are correcdy orientated with respectto water flow

SETTING TO WORK

internallinks onthe starter correct are

(m)
(n)

W2

starter overloads are set to the motor full load current (FLC) dashpots (where used) are charged with the correct fluid and the time adjustment levels are identical

(0)

the adjustable thermal cut-outs are set correctly (checkmanufacturers' test certificates) all electrical water heating appliancesare free from damage and all associatedthermostatic controls have a suitable temperature range (see section

(P)

Note: where a secondarysystemis included, this should be isolated in its entirety throughout the following checks on the primary system,i.e. sectionsW2.1 to W2.2.4.

W2.1)
(q)

W2.1
(a)

C'--ecks before pump start

all 'normally open' valvesare fully open all bypass and 'normally closed' valves are fully

all the coverplatesarereplaced. Checks with electrical supply available

With the systemfilled checkthat:

W1.7.2

(b)
(c)

closed
all thermostatically controlled valvesare fully open and will not be affected either by ambient air or water temperature during balancingprocedures a method of operating automatic control valves is
available operating and mode that these are motored to normal

(a)

Check that correct provisionhas beenmade for

local isolation of plant for both electrical and mechanicalsafety.

(b)
(c)

Check that the declared voltage is available on ail

(d) .,

supply phases.
Where motor power ratings are substantial, reduced voltage starting is used, or complex interlocks are involved, the control circuit logic and statter operation should be testedbefore the motor is rotated. The supply should first be isolated by withdrawing two power fuses not associatedwith the control circuit, or by disconnectingcables.The control circuit fuse must be checkedto ensure that it is rated to give the correct discriminatory protection to the control circuit cables. The control circuit should be actuated and the starter operation observed, adjusting the timers where necessary.Check for positive operation of all contactors, relaysand interlocks. When these checkshavebeen made,open isolators, reinstate power fusesand closeisolators.
(d)

I (e) (f)

the pump suction and return valvesare fully open on the selectedpump the delivery valve is closed on any standby pump unless non-return valves are fitted; the suction valve should be left open (it is not good practice to leave any vesselfull of water and completely isolated, asa temperaturerise could cause excessive an build-up ofpressure) the pump casingis vented of air the selectedpump dischargeor flow valve is partially closedto limit the initial start current.

(g) (h)

l",

W2.2
W2.2.1

Initial run
Checks on activating the motor starter

Where small motors have direct on-line starting and simple control circuits, the starter operation etc. should be checked when first starting the motor. Electrical valve actuatorsshould neverbe energised until mechanicalchecksunder sectionWl.6.2 have beencompleted.

Where appropriate checkthat: (a) (b) (c) the direction and speed of rotation of the motor shaft are correct the motor, pump and drive are free from vibration and undue noise for star-delta starters the starter sequencetiming has beenadjustedasnecessary the light of motor in starting current the motor running current is balanced between phasesand does not exceed the motor nameplate statedrating there is no sparking at the commutator or slip rings where titted there is no overheatingof the motor

(e:

W1.8

Static completion records

(d)

Great importance is attached to the provision of static completion records to ensure that all defects have been rectified before setting to work and balancing. It is recommended that the results of all checks and any required remedial works be documented fully. (See sections W2.4 and W4.4.)

(e) (f)

WATER DISTRIBUTION SYSTEMS

(g)

there is no seepage lubricant from the housing of there is no overheatingof the bearings the water flow to water-cooledbearingsis sufficient on multi-speed motors, motor running currents are

W2.4

Completion cer1ification

(h)
(J)

u)
(k)

correct
the ventilation systems of air-cooled motors are operating correctly.

On the satisfactory compliance with the provisions of sections WI and W2 a cenificate should be completed by the installation contractor to that effect. The cenificate should be countersigned by the designer or his representative. Cenification should include the documents appenaining to chemical cleaning and flushing. Copies of these certificates should be passedto the commissioning specialistbeforethe systemis balanced.(SeesectionW4.4.)

W3

Balancing water flow

rates

W3.1

Obiective

W2.2.3

Running-in period

The aim of balancing is to apply a disciplined procedure of adjustmentto water flow rates throughout a systemto meet the particular requirements of the design.The balancing of water flow rates should be carried out to specified tolerances (which may vary for different sections of the same system).A typical schematiccircuit is illustrated in Figure

1.

The pumps must be 'run in' in accordancewith the manufacturer's instructions. Do not either leave pumps unattended or allow them to run outside working hours. Checkthat: (a) (b) (c) all bearing and motor temperaturesremain within manufacturers' specifications pump gland nuts are adjusted to give correct drip rates(this doesnot applyto mechanical seals) after four hours running all strainers are inspected and cleaned. If they are excessivelydirty then continue frequent inspection and cleaning.

W3.2

Flow rate measurement tolerances

It is the responsibility of the system designer to state acceptabletolerances for the balancing of flow rates for various sections of a particular system. In deciding on the appropriate tolerancesto set, the designer should bear in mind that the cost of regulation can increase significantly where close tolerances are specified. Tolerances are discussedin detail in sectionWAI.2.2. Where the commissioning specialist considers that the tolerance levels required by the system designer are impractical (e.g. due to inadequateprovisions in the system design)he/sheshould formally advisethe designerof this, clearlystating and explaining his/her reasons. Where flow rate tolerances are not stated in the design parameters, commissioning specialistshould obtain the the formal agreementof the system designer on the tolerance requirementsbefore commencingregulation.

W2.2.4

Standby pump(s)

The standby pump should be commissionedas detailed in sectionsW2.1 and W2.2.

W2.2.5

Secondary pump(s}

After checking the primary strainers, isolate the primary system.The secondarysystemvalvescanbe openedand the secondary pumps started. Initial running should be in accordancewith section W2. Re-openthe primary circuit valves.

W3.3

Basis of balancing

W2.3

Further venting

After initial running of the pumps (primary/secondary as applicable)the pumps should be stoppedand the systemrevented. It may be necessaryto repeat this a number of times. After applying heat to a heating system, further venting may alsobe required.

Prior to balancing the flow rates in a system the commissioning specialist should produce a written method statementwhich provides details of the intended balancing procedures. This method statement should be formally agreed with the principal contractor and system designer and form part of the overall commissioningplan. Proportional balancing ~sused for constant-volume systems and maximum flow for variable-volume systems. However, heatbalancemethods are sometimesnecessary in

BALANCING WATER FLOW RATES

f
Secondary VODR valve Secondary pump Secondary mixing valve

iI

Evaporator

::)

T"@'
Fixed bypass ...

~
Variable

...~' bypass

Low loss header

~~
Primary VODR valve

'I }ol'

, @
Primary pump

(Branch A using commissioning sets)

~-~ -~"!

tI

'1).11I

~
I p::,;

1
Key

-1(Branch Busing VODR valve)

Pressure/temperatu re tapping Strainer Commissioning set

Variable orifice double regulating (VODR) valve Flaw measuring orifice close coupled to an isolating valve Double regulating valve (DRY)

~
~ :
~
-+:f128

?" "V'-I

,';

I
2C

?"
8
(Branch C using fixed orifice close coupled to an isolating valve plus a DRY)

~
t--1-

-:t.T+

-H-

Air/water

heat exchanger

~~
~T~ '1).1'

-I

~~

, I

t'-

(3-way valve mixing)

(3-way valve diverting) ~T~ I

--I

(Wild cooling coil)

1i)IT+.

--~-1-

Figure 1 Typical schematiccircuit

I~~
! I

BALANCING WATER FLOW RATES

Make certain that the primary flow measuring station at the pump is indicating in excessof the DFR. This ensures that there is enough flow to balance the system to the designer's requirement within the specifiedtolerance.SeesectionWAI.2.2.
(g)

terminal and the most remote terminal are equal within the specified tolerance. Record the in, strument readings, DFRand valve settings for both terminals and lock the valves.
(e)

Starting from the pump, identify the mains, headers, risers, branches and terminals in the system which are receiving the highest flow rate in terms of DFR. This will be the most favouredcircuit. List the branches in descendingorder of DFR.The lowest DFR the least is favoured(index) circuit. Balancing consists of the progressive closure of regulating valves starting with the most favoured branch in the most favoured circuit. This reduces the excessflow rate in those areasto increase the flow rate in areaswith underflow. On review of the initial readings against design values, the commissioning specialist should iden-

(h)
(i)

Continue by adjusting the balancing valve for the next terminal towards the pump until the DFRfor this terminal is equal, within the specified tolerance, to that for either of the two terminals balanced in stage (d). This value will probably have altered from that recorded at stage(d) so it is essential to re-measurethe flow for every comparison of DFR values.Record instrument readings, DFR values and valve settings for both terminals and lock the valve. Continue balancing the upstream terminals towards the pump as in stage (e) using the same referenceterminal for comparison of the DFR values until all terminals on the branch arebalanced. If it is found that the balancing valve for the index terminal has to be adjusted to achievebalance, this indicates that the balancing valve on the most remote terminal was closed too far at stage (c). In this case open the balancing valve for the least favoured or index terminal, return to stage (c) and follow the procedureagain. Proceed to the next most favoured branch on the riser and carry out terminal balancing as in stages (a)to (g). For the completeriser, eachbranch terminal is now in balance with the other terminals on the same branch. Branchesnow haveto be balanced. The procedure for balancing branches on a riser is identical to that for balancing terminals on a branch. Stages(a) to (h)should therefore be followed after any branch valves closed at stage (a) have beenre-opened. When several risers are fed from a common header the sameprocedure should be used to balance the risers. At this stage each branch, riser, and header are proportionally balanced within the specified tolerances.Flow rates throughout the whole systemwill now retain the sameproportional relationship for any setting of the main regulating valve. Adjust either the main regulating valve or the pump speed to bring the total flow to the design flow within the specified tolerance. Lock the valve, record the instrument readings, the flow rate and the main balancingvalve or pump speedsetting. On completion of (m), all terminal and branch volumes should be recorded as final readings for documentationpurposes. Report to the design engineer any balancing valves that aremore than 75%closed(seesectionW4.4.1). Lock all balancing valves in their regulated position.

(f)

(j)

tify:
(i) whether any of the initial readingsindicate that excessive pressureloss is being caused in the circuit by any measuring/regulating

(g)

device
(ii) whether excessive throttling will be required to a large proportion of the circuit regulating devices in order to achieve a proportional balance.

(h)

If results indicate that either a regulating valve or measuring station has beenundersized, or that some other system factor is preventing correct flow, then considerationneeds to be given to removing the deviceand installing one which will havelessof an effecton the overall circuit. If a systemis over-regulatedthis can lead to pump, motor and/or impeller changesbeing required. SeesectionW3.6.2 paragraph(b).
W3.6.2 Balancing terminals, branches, risers and headers by proportional

(i)

(j)

(k)

flow

(a)
(b)

If the DFRfor a branch is above l500J0, reduce the branch flow rate to give DFR= 110%. Balancing or double-regulating valves should not be set less than 25% open (75% closed) or as recommended by the valve manufacturer. This minimises the risk of noise,cavitation, erosion and the collection of solids betweenthe seatand disc of the valve. SeesectionWA3.3. Identify the least favoured terminal, which is the one with the lowest DFR.This is defined as the branch index terminal. In a typical distribution systemthis will be the furthest measuringpoint on the branch. If it is not, reduce the flow to the most remote terminal until the DFR equalto that of the is index...terminal within the specified tolerance, i.e. the furthest terminal has now beenmadethe index. Adjust the balancing valve for the next terminal nearer the pump so that the DFRvalues for this

(1)

(m)

(c)

(n)

(0)
(P)

(d)

11

WATER DISTRIBUTION SYSTEMS

final branch or terminal distribution. This involves temperaturemeasurements. Safety warning: balancing a systemrequires the coupling of manometerprobes into pressuretestpoints. In a charged system, the water temperature must be below 55C when this is done. Under no circumstances must an MTHWor HTHW systembe commissioned at operating temperatureas serious injury may result. In MTHW and HTHW systems self-sealing pressure or temperature measuringpoints on valves or orifices must be preceded by a manually operated" isolating device (seeBS
7350<11)).

The reason for the low flow rate condition should be investigated and, where possible, corrective measuresimpfementedprior to balancingthe system.

W3.6

Constant-volume systems

The systemis balanced on the basis of the ratio of actual flow rate to designflow rate. In anyone branch the thermal emitter units are regulated to the same proportion as the leastfavoured (index) in that branch. This is also the case with eachbranch on one riser and eachriser on one header. This is achieved by measuring the pressure differential across flow measuring devices and regulating the flow to designflow requirementsby regulating valves.

W3.4

Pump shut-off head te~;t

W3.6.1

To verify the operational performance of a pump it is necessaryto check the measuredperformance against test dataprovided by the manufacturer. The performancetestshould be carried out asfollows. (a) Connect a suitable differential pressure gauge across the suction and discharge pressure test points of the pump. With the pump running, slowly closethe discharge valve. Do not run in this condition for longer than 15 min or the pump will overheat. Determine the 'shut-off' pressure differential, check against the manufacturer's data for zero flow then slowly re-openthe dischargevalve. Where the test result coincides with the manufacturer's test data proceedto paragraph(e).Where this is not the case, draw a curve parallel to that shown on the published data, starting at the shutoff headpressure. Record the total pressure with the differential pressuregauge at full flow rate and read the actual flow from the manufacturer's data, or from the corrected graphcurve asappropriate. If performance is inadequate refer to the installation contractor and designengineer.

Identification of least favoured (index) and most favoured circuits

Figure 2 illustrates the positions of the least favoured (index) and mostfavouredcircuits. (a) (b)
(c) (d)

Open all line circuit valves and close all bypass valves. Setautomatic control valvesmanually to full circuit flow. Startpump(s). Using a schematic drawing for referencepurposes, measurethe pressuredifferential at eachmeasuring station with a manometerto determine the flow rate and record results. In some instances it may be necessary arbitrarily throttle the most favoured to branchesto near designvalueswhere the measurement signals in leastfavoured branchesare too low for accurate results to be taken. Check against designvalues. For eachmeasuringstation evaluatethe design flow rate asa percentage DFR(%) lOOfa/fd = where fa is the actual flow rate and f d the design flow rate.

(b)

(c)

(d)

(e)

(e)

(f)

W3.5

Preliminary

flow rate Ch4~ck

With all valves fully open, measure and record the total actual flow rate and compare this with the total system design flow rate. Where necessary, close the main regulating valve to provide a flow of approximately 110%design flow rate. Seealso sectionW2.2.2 paragraph(c). Where the initial measured flow rate is less than 100% of the design flow rate with the systeD).ofully open, then a value of lessthan 100%will result at the conclusion of balancing . Regulation of a systemat lessthan 100%of designflow rate should not be attempted without formally advising the installing contractor and systemdesigner.

Figure 2 'Circuit identification

WATER DISTRIBUTION SYSTEMS

W3.6.3

Secondary regulation circuits

of bypass

Figure 3 illustrates the regulation cfbypass circuits. In constant-volume circuits which incorporate three-port control valves, the bypass regulating valve should be adjusted to give the same pressure differential acrossthe flow measuring station when the three-port valve is set to bypass asmeasuredwith the three-port valve on full flow to the system or the flow rate specified on the system schematic. Somesystemshave a fixed bypass and variable bypassboth of which needto be regulated.SeeFigure 4.

recirculation, measurethe injection rate from the primary circuit and calculateits DFR.Then regulate the primary injection regulating valve to bring the DFRwithin the specifiedtolerance for the secondary circuit. Note: while most injection circuits incorporate automatic three-port mixing control valves this need not alwaysbe the caseand some applications may utilise two-port motorised valves to perform this function. Some injection circuits may require security of shut-off and may, for example, use an automatic three-port control valve and two motorised two-port isolating valves. Proper analysis of eachsystemis required to ensure that the systemis in the desired mode of operation for eachphase of balancing.
(c)

t'

Close the secondary circuit automatic control valve(s)fully to primary circuit injection and open fully to secondary circuit recirculation. Regulate the recirculation regulating valve to provide the sameDFR obtained in paragraph(b)above. as

It should be noted that in some injection circuits the flow rate controlled by the automatic control valves may be smaller than the total flow required from the secondary circuit pumps. In such cases,a bypass circuit will parallel the recirculation control circuit and this bypass circuit must be regulated to provide a flow equal to the difference between the required circulation rate and the maximum required injection rate.

W3.7

Variable-volume systems

Fundamental to all variable-volume systemsis the application of two-port control valves. These two-port valves either modulate or open and close in accordance with thermal demands thus varying the flow rates through the terminal units servedwithin the overall pipework system.
Figure 3 Regulating bypasscircuits

In orderto ensuresystemstability, variable-volumesystems are usually dynamically controlled to ensure that the sys3

3 ~

.r::AJ

~--{~J~ !~~~-@_.!1_-Q -I I 9T .

I I

6
I

't
f

Key 1 2 3 Primary pipewark Secandarypipework Isolation valve

Llj~~t_k__~J::
4 Commissioning set 5 6 7 Three-port mixing valve Flow temperature detector Thermometer

8
9

Pumpset
Unions on screwed valve sets straight length

~
10

I.

11

.14

10:-[

10 Minimum

= 10 diometers
11 Minimum straight length = 5 diameters

Figure 4 Injection circuil

12
I

-M..
rf'f;T"

BALANCING WATER FLOW RATES

ternpressuresand/or flow ratesare stable under the varying demandsof the system. This dynamic control is achievedby devicesinstalled within the pipework systemand can take many forms depending on the systemcomplexity. Devices such as differential pressureregulators,flow control regulators,excess pressure relief valves,multiple- or variable-speed controls for pumps maybe applied for this purpose. Small systems,typically, have thermostatic radiator valves and excess pressure relief valves.Large systemshave zone differential pressure regulators (DPRs)and/or maximum flow control regulators (FCRs) combined with variablespeedpumping. Variable-volume system design frequently incorporates a diversity factor. This means that at no one time will the maximum flow rate be available simultaneously at all points in the system.Referto sectionWO.2. Becauseof the variation in design of variable-volume systems it is important that there is an agreedcommissioning procedure, documentedbefore commissioning starts. This must be approvedby the systemdesignengineer.

(a)

Do not attempt to balance this type of network upstream of the DPR FCR or with conventional regulating valvesas they will merely undermine control authority of the DPR FCR. or The DPRmust be set at the design pressure differential acrossthe branch it serves. The FCRmust be set at the maximum allowable designflow rate value for the branch it serves. Using tappings installed on eachside of the devices

(b)
(c)

(d)

provided:
(i) checkthe operation of eachDPR ensure it to controls the differential pressurewithin its control limits under varying load conditions and documentthe results checkthe operation of eachFCR ensure it to limits the flow rate to the maximum set value under varying load conditions and documentthe results.
Sub-systems downstream of differential pressure regulators and flow control regulators

(ii)

W3.7.2.

W3.7.1

Balancing

variable-volume

systems Each sub-system controlled by a DPR or FCRrequires the following commissioning procedure.

The techniques required to balance variable-volume systems differ from constant-volume systemsin that pressure differentials and flow rates in main branches are usually automatically controlled to meet the varying demands of the system.The main commissioning procedure is, therefore, not one of water balancing but of setting up and proving that the pressuredifferential differencesand maximum flow rates in the branches are controlled under varying conditions. Automatic regulation of the circulating pump drive may be provided to match the aggregateflow rate in the systemas required by the branchesand terminal units. This may be arranged by sensingpressurevariations at a representative point in the system and modulating the pump speed to maintain a nominally constantpressure.This control loop will require setting up and balancing in parallel with the proving of the automaticpressureand flow control devices. Proportional balancing of all sub-circuits will generallystill be required downstream of all automatic pressure or flow control regulators and should follow the appropriateprocedures asdetailed under sectionW3.6 above. Note: suitable pressuretappings should be provided at the measuringpositions on differential pressureor flow control regulatorsto monitor the controlled setpoint.

(a) (b)

The operation of two-pon control valves must be testedand recorded. Under normal operation, with all terminal two-port valves fully open, and using the pre-fitted pressure tappings installed olJ each side of the devices provided: (i) (ii) check and record the differential pressure acrosseachsub-systemDPR fitted check and record the flow rate across each sub-systemFCR fitted.

Note: if the values of either the pressureor flow are below design value due to system diversity, temporarily valve off other sub-systemsas necessary recording the actions taken.
(c)

With the sub-circuit DPRor FCRoperating at its design value, proportionally balance all branches and terminals downstream of the DPR FCR or starting from the most remote branch or terminal and following the procedure shown under sectionW3.6 above. Re-checkthe DPR FCR and operation after the downstream proportional balance and record pressures

Cd)

W3.7.2

Large single-building systems

(e)

andflowrates.
After setting up all differential pressure or maximum flow control regulated sub-circuits, ensure that any that were temporarily valved off to compensate for diversity, as listed on the record of actions taken, are re-opened. See note above in paragraph(b).

These are generally fitted with automatic differential pressure regulators (DPRS) automatic flow control regulators (FCRS) or on ~ sub-systems serving groups of terminals. The DPR or FCR automatically balances the main branch distribution upstream of its location.

WATER DISTRIBUTION SYSTEMS

W3.7.2.2

Main pump flow

branch valve (external to all terminal known as the 'partner valve'.

circuits) which is

The main pump flow and operating pressure should be measured, recorded and plotted on the pump curve at a minimum of four operating points: (a) (b) (c) with all two-port automatic valves fully open at design diversity flow with all two-port automatic valvesclosedat no flow (closedhead pump test) at two intermediate points, with sufficient two-port valvesclosed,to give approximately30%and 60% of designmaximum flow.

When the reference valve is a variable-orifice doubleregulating "Valvethis should be pre-set, by calculation, to give a minimum pressuredrop of 3 kPa at design flow rate and then locked in that position. Variable-orifice doubleregulatingvalvesare describedin sectionWA3.1.4. When the referencevalve is a fIXed-orifice double-regulating valve (commissioning set) it should be locked in the fully openposition.

W3.7.3

District heating and cooling systems

W3.8.1

Balancing a branch

These consist of large circulating mains serving a number of buildings. The installation within each building generally takes the form described in section W3.7.2 and similar balancing procedures to those listed in section W3.7.2 should be

A manometer is connected to the reference valve. The design flow in the reference valve is regulated by the partner valve. A second manometer should be used to set and adjust the terminal balaI!cing valves starting with the terminal next to the reference terminal and proceeding upstream. Adjust each terminal commissioning valve to give the designflow in that terminal but maintain observationof the referencevalve manometer. If this changesmore than 10% during the balancing process then bring the pressure differential back to the original by operating the partner valve only. Continue with all other commissioning valves in the branch, working upstream; observing the reference pressure drop and adjusting it with the partner valve. In this way all terminals on that branch will be in balanceat design

adopted.
Additional pump controls are frequently fitted to the systemto ensure minimum differential pressureis always available at the index building and these should be balanced and checked as part of the regulation processusing the following procedure.
(a) Establish the design pressure setting required for the sensing device.

(b)

Where the unit is not factory pre-set, adjust to the required pressureusing the manufacturer'sinstructions. Using portable test instruments to check the actual systempressureat the sensor,closeoff downstream valvesuntil actuation of pumped flow ratesoccur. Checkand record systempressureat actuation.

flow.
If, when adjusting a terminal valve, the design flow cannot be obtained with its balancing valve fully open, this terminal is termed the 'index unit'. In this case, measurethe actual maximum flow obtained in this terminal and determine the DFRas a percentage (see section W3.6.1 paragraph (e)). Re-adjust the referencc valve to give the sameDFR, then lock in position. The design flow in the reference valve is obtained by reopening the partner valve and the balancing procedure repeatedusing the newsetting on the referencevalve.

(c)

(d)

W3.8

Balancing by compensated

method
The compensatedmethodCl2) balancingis an extensionof of the proportional method described above and allows for balancing on constant-volume and pre-balancedvariablevolume systemsbefore they arecompleted. Provided that the pump circuit is operational,branchescan be balancedindividually, as they are completed,thus saving commissioning time and delay with balancingtaking place asthe systemis being installed. With pump connected,via a headerand riser to a completed branch and with all other riser valvesclosed,the completed branch can be balanced. The compensated method (see Figure 5) relies on the balancing valve in the furthest terminal (not necessarily the index) which is known as the 'reference valve' and the

Figure 5 Balancing bycompensated method

14

EVALUATION AND WITNESSING OF COMMISSIONED SYSTEMS

d W3.8.2

Balancing remainder

of system

W4

Evaluation and
witnessing of commissioned systems

By using the same methodology as in sectionW3.8.1, each branch, riser and header can be balanced as the system construction progresses.

W3.9

W4.1
Regulation by temperature

Obiective

balance
Where either a complete systemor part of a systemconsists of relatively small terminal units, e.g. radiators and convectors, it will often not be economic to install a flow measuring device at every terminal unit. The technique of proportional balancing given in sections W3.6 and W3.7 must thereforebe adaptedto the particular system. The temperature balance method should be confined to low-temperature hot water heating systems, where the same temperature difference is required through each terminal

The objective is to witness formally, on behalf of the client or his/her representative,the degreeto which the commissioning requirements of the specificationhave beenmet.

W4.2
W4.2.1

Witnessing arrangements
Witnessing period

A specific period of time for client witnessing should be indicated in the initial project programme, with a written contingencyallowance.

unit.

W4.2.2 W3.9.1
Ca,

Witnessing requirements

Procedure

Operatethe systemat a moderateflow temperature. This will be governed to some extent by the ambient temperature but a minimum of 60C is suggested. If the system is controlled by an outdoor compensator this should be adjusted to ensure that a constant flow temperatureis maintained during the balancing. Throttle each terminal unit regulating valve until all returns register an equal temperaturemeasured by a contact thermometer consistentlyapplied.

(b:

All requirements for witnessing should be expressedin an agreedwritten format, copiesof which aremadeavailableto the commissioning specialist. This format must contain full details of the tolerances applicable to all parameters. Similarly, consideration should be given to permissible toleranceson repeatability of measurement readings. In deciding the detailed requirements for witnessing commissioning, the interaction of various aspects of an installation in determining its overall performance must be borne in mind. The commissioning of a water distribution systemmight be witnessed againstthe requirements of this Code and the project specification. However, witnessing the performance of heat exchangersconnected to water distribution systems, for example, would interact with the commissioning of air distribution and automatic control systemsaswell asof boiler and refrigeration plant. Witnessing is thus an all-embracing and interactive task and this must be reflected in the agreedwritten format.

W3.9.2

General

When using the heatbalancemethod a proceduresimilar to that recommendedfor balancingterminals fitted with flow measuringdevicesshould be adopted,that is, regulate from the index backtowardsthe pump. The heat balance and regulation on the terminals on any branch should be completedbefore the final regulation and flow measurementon that branch.

W4.2.3

Particular arrangements witnessing

for

W3.10

Commissioning certification

When the proceduresof sectionW3 havebeensatisfactorily completed the commissioning specialistshould certify that the systemhas beencommissionedin accordance with this Code and the project specification.The certificate should be countersigned by the accepting authority who may be the contractor, design engineer or client or some other witnessingauthority. The certificate should be accompaniedby the documents listed in sections WAI.7 and W4.4 together with copies of the static completion certificates.

An essential aspect of the agreed arrangements for witnessingis the provision of definitive statementsof the site attendance availability of the witnessing agent,the standards required, the extent of witnessing which will be performed and added requirements in the event of defaults (e.g. the number of additional items which must be witnessedfor everyone which fails to comply).

W4.2.4

Witnessing liaison

The witnessing agent should liaise in detail with the installer and the commissioning specialist, as necessary, with regardto: (a) the meansto be used to demonstrate that mass or volume flow rates are within the specified toler-

ances
1~

WATER DISTRIBUTION SYSTEMS

co-ordination requirementswhere the performance aspectsto be witnessedinteract with other systems or equipment.

Actual pressuredrop (kPa or mm H2O: Actual flow (Vs)

DFR Regulating DRYnumber

W4.3

Duties of witnessing agent

DRV setting position (should be fully open) Note: the formal recording of data in the intermediate stagesof balancingis alsorecommended.

Final scan
Final pressuredrop (kPa or mm H2O) Final flow rate (I/s)
Final DFR

thIl '-

Final setting position of DR (not more than 75% closed) V Bypasses (generallyseton final run only:

Valvenumber
Setting position for final DFR Comments

W4.4

Commissioning documentation

W4.4.3

Pump details

The design of standard proforma for the various requirements for commissioning records and certification is outside the scopeof this Code, is a matter for agreement and between parties. However, as a minimum, the following basic information should be detailed. The units and manner of presentation are typical conventions used in practice.

Serialnumber Drive type

Impeller diameter Pump speed(rev/s) Motor speed(rev/s) Motor full-load current (A) Motor power(kW) ae!

W4.4.1

Flow measurement, doubleregulating and automatic control devices

Measuring deviceposition number Type of measuringdevice Size (mm) Design flow rate (l/s or kg/g) Designpressuredrop (kPa or mm H2O) Manufacturers' performance data for measuring devices

Belt Pulleys
Manufacturers' performancedata/charts

used

W4.4.2
First scan

Flow rate balancing data

W4.4.4

Systemdata

.t 1..
VI'

A table in the form of Table 1 should be completed,

~b:

DESIGN

Table 1 Systemdata

Parameter values
Design Flow rate (I/s) Pump head(kPa or mm H2O) Actual %design

W4.4.5

Method used to determine flow rate

There should be a complete record of all instrumentation used in commissioning including manufacturers' serial numbers and, where appropriate, calibration dates.

W4.4.6

Conclusion

These documentsshould be signed, datedand witnessed,as a true certification of the full working order of the water

system.
Figure Al Flowrate versusthermal OUtpU1

Table Al

Flow rate deviation,performance effectand typical installation

WA1
WA1.1
Design requirement

applications effect Typicalinstallation Flow deviation Performance rate application Large Medium

Low
Medium

LTHWheating<11C~t
MTHW, HTHW

Effective operation of any system will depend on satisfactory commissioning. An important design objective is to ensure that balancing requirements are considered fully at the conceptUalstage. To facilitate this, design engineers are recommended to ensure that these requirements are taken into account and an unequivocal specificationis provided so that satisfactory balancing and commissioning are assured. Early discussions with the commissioning specialist will assist the design engineer.

LTHWheating> 11C ~t Chilled water, comfort air

conditioning
Heat reclaim Latent cooling with relative humidity Small

High

Chilled waterserving computer or process

installations

WA1.2
WA1.2.1

Design considerations
Perlormance effects

evaluate effectof deviations the from specifiedflow rates. (See FigureAI.)

An indication of the influence of deviation of volume flow rates on performance effect and suggestedrelationships with typical applications are given in Table AI.

Heat transfer performance of heat emitters and other heat exchangersis influenced by water flow rate in a non-linear manner. In someapplications, large variations in flow rate have only a small influence on heat exchangeperformance. For convenience, this is referred to as 'low performance effect'. Conversely the outpu~ of 'high performance effect' heat exchangerswill be affectedby only a small deviation in flow

WA1.2.2

Tolerances

Suggested ranges of practical tolerancesrelated to system performanceeffectsare given in TablesA2 and A3. Systems regulated to the appropriate toleranceband should be capable of meetingthe designintent in operationaluse. The nominal tolerancesapply to repeatablereadingsproduced by the measuring device with associatedinstrumentation and do not accountfor any inaccuracieswithin these components.

rate.
The design engineer should consider particular relationships between thermal output and fluid flow rate and

WATER DISTRIBUTION SYSTEMS

Where flow rates to terminals are very low and likely to generatepressuredifferentials of less than 1.0kPa, then the scopefor accurateand repeatablemeasurementof flow will be severely limited. Measurements will be affected by instrumentation accuracyand low velocity and it may be necessary make arbitrary tolerance allowancesin excess to of the rangesshownabove. Where proportional balancetolerancesare basedon design flow rates it should be noted that any subsequentincrease in total flow rate could lead to someaspectsof the balance exceedingthe stated upper tolerancelimit. (e.g. a terminal actually balanced to a 15% limit could exceedthis figure where the total flow rate is increased at the end of the regulating procedure).The design engineermust clarify in advance where this possibility is considered to be un-

Table A2 Tolerancesfor flow rate balancing in heating systems(%)

Mains

-0

-0

-0

+10

+10

+10

desirable.
Where proponional balancingis carried out to the extreme valuesof the upper and lower limits of the tolerancebands, it should be noted that the cumulative effect of successive tolerances (i.e. terminal, sub-branch, branch and total) may, in somecircumstances, lead to someaspects the balof ance being marginally outside the stated tolerance limits. Such an occurrence, therefore, need not infer that the regulation procedurehas not beenfollowed correctly. Tables A2 and A3 are basedon the accuracyofflXed orifice devicesand venturi. When using a variable-orifice regulating valve the pressuredifferential reading is usually taken across the seat of the valve; hence the accuracy of the measurementis affected by the position of the regulating disc in relation to the seat.With a correctly sized valve the normal regulating position should be betweenfully opento 50%closed.If the disc is in relatively closeproximity to the seat(less than 25% open) additional turbulence can occur which, in turn, may affectthe differential reading. For this reason,the allowable tolerancesshown in the tables above are only applicable to the measurementacrossthe seat of the valve when the valve is no more than 50%closed. BS 7350<11) and/or the valve manufactUrershould be consulted if the valve is closedfurther than this.

t Note: for aproponional balanceto be achieved,the upper and lower tolerance limits should not be exceeded. The lower value,i.e. the negativevalue,is the minimum value the leastfavoured or index unit should achieve. Whereverpossible the remainder of the proponional balanceshould be achievedwithin the overall tolerance and should aggregate a Ininimum 1000/0. to Table A3 Tolerance for flow rate balancing in chilled watersystems(%)

Component Low
Terminal units where flow rate <O.ll/s t AHU coils where flow rateis >O.ll/st Branchest -7.5

Perfonnance effect Medium High

:!:s
-0 +10 -0

+15
:-0

+10
-0

+10 Mains
t See note under Table A2
-0

+10
-0 +10

+10

WA1.3

Provisions for measuring pressure and determining

rate

flow

WA1.2.3

Flow velo,city

Pressure tappingsshould be included asfollows: (a) either within two pipe diameters up and downstream of the pump flange faces (i.e. between the pump and isolating valves) or installed in purposemade pump flange drillings flow and return connections at all major heat

The limiting minimum water velocities given in BSRIA Application Guide 8/91(3), sectionBl.13, should be adopted to minimise static air pockets in horizontal pipes at low velocity or noiseand cavitation at high velocity.

(b)

WA1.2.4

Pump flow rate margin

exchangers
(c) flow and return connections at all terminal units -(such as secondarycooling coils in fan coil units) where multiple identical units are connectedto selfbalancingpipework (d) upstreamand downstreamof main strainers to detect an increaseof pressuredifferential indicating a cloggedscreen (e) orifice devices,variable-orifice valves, venturi differential pressureregulators and control valves or other measuringdevices.

The pump should be sized to provide a flow rate in accordance with the mains requirement shown in Tables A2 and A3 againstthe calculatedpressuredrop of the index circuit.

WA1.2.5

Valve sizing

Double-regulating valves should be sized to provide the required flow regulation with the final setting not lessthan 25%open.(SeesectionW A3.3.)

DESIGN

WA1.4

Ease of access

The designengineer must provide access all pressuretest to points, flow measuring devices, double-regulating valves and concealed items of equipment requiring adjustment during commissioning and maintenance.

Note: where equipment selection is made by the installer and this differs from the designengineer'sspecification, the installer should amend, or add to, the document accordingly. The design engineer should be advised of all such variations from the specification.

WA1.7.1

Schematic drawings

WA1.S

Flushing and cleaning

The pipework system design should incorporate, where practicable, line-size drain points at the baseof eachisolatable circuit section. These drain points should be adjacent to suitable drainage gullies. Further guidance is given in BSRIA Application Guide 8/91(3).If discharge is below drainage levels additional temporary pumping arrangements needto be considered.(SeesectionW1.4.) Provision should alsobe madefor:
C ) (a) suitable flushing connections including temporary high-velocity flushing points.

Complete schematics of all systems should be prepared using standard graphic symbolsBS 1192(15). The schematic

drawingsshould be included on the drawing or accompanying tabular matter. Theseshould include, wherepossible: (a) (b) (c) pipe sizes pump flow ratesand pressures the positions of all flow measuringdevices and the necessarystraight pipe runs upstream and downstream of thesedevices(seesectionW A3) the locations and sizes of all double-regulating

(d) (e)

valves
the system flow coefficients kvs should be noted against each flow measurement and regulating device(seesectionWA3.6) the flow rate and estimated systempressureloss for eachflow measuringdevice(seesectionW A3.1.6) the flow rate and an estimation of the pressure drop required across each double-regulating valve to compensate circuit imbalance for flow rates and either estimated or manufacturers' quoted pressure drops across heat emitters, heat exchangers otheritems of plant and flow rates in all branches of heat exchangestations and primary/secondarycircuit interconnections flow rates and either estimated or manufacturers' quotedpressuredrops at automatic control valves measuring station, double-regulating valve and automatic valve numbers from specification schedules with predicted settings of the valve indicated whereappropriate anticipated design pressure drops throughout the distribution systemcovering, as a minimum, the whole of the index circuit, risers and main branches the differential temperature used in the design calculations on composite designs,draw-off rates for cold water and domestic hot watersystems regulating devicesapproved by the local water company to control cold water and domestic hot water systems cold feed, pressurisationunit, feed and expansion tank points of connection control valve port identification to show correct flow direction provision for systemflushing and bypass connections to main plant, together with a typical terminal detail of the bypass

(b)

adequatewater supply; portable tankerswith backwash filters and pumps may sometimesbe neces-

sary
(c)
(d) (e) connections for bypassing plant components and other equipment during flushing

(f) (g)

water treatment and sampling asappropriate air separationand venting at low-velocity points in the system; the systemshould be designedfor continuous venting with adequatelysized fIll points at low level (seesectionWI.S) flushing, cleaningand venting should be completed before commissioningbegins.

(h)

(f)

(i) ())

WA1.6

Chemical cleaning
(k)

The design engineer should decide whether chemical cleaning of the distribution system is neededand ensure that the appropriate requirements are specified clearly, either in terms of performance or in more detail. The specification should state that chemical cleaning be carried out before the start of commissioning. (See section WAl.7.2, paragraph(k).)
Safety note: attention is drawn to the Health and Safety at Work etc. Act<9),the Environmental Protection ACt<13, and 14) other legislation that may apply, on the storage and disposal of all chemicals and associated treated water.

(1)

(m)

(n) (0)

WA1.7

Design information

required
(P)

To ensure that flow rate measurementand regulation can be carried out correctly, the following information should be properly documented by the design engineer in an installation and commissioning brief for transmission to the servicesinstaller and commissioning specialisttogether with a full description of the intended operation of the systemexplaining the control sequence logic. and

(q)

(r)

(1

WATER DISTRIBUTION SYSTEMS

(s)

for variable flow systems, systemdiversity. the

WA2.2

Installation

cleanliness

WA1.7.2
lows:
(a)

Documentation

Schedulesof all items of plant with technical data as folpumps: duty, impeller size,speedand characteristic

curves
(b) (c)

boilers: duty, operatingtemperaturesand pressure calorifiers: flow rate and pressure drop, primary and secondaryflow and return temperatures,shell and coil pressures refrigeration condensers: flow rates and pressure drops, flow and return temperatures refrigeration evaporators: flow rates and pressure drops, flow and return temperatures flow measuring devices: identification number, size, flow rate, pressure drop and signal k (see WA3.7) in the form of a schedule with m~ufacturers' graphical data double-regulating valves: identification number, size, flow rate, Pressuredro p and S ystem kv or kvmax schedulewith manufacturers' graphical data terminal units: identification number, flow rate with the tolerancesand pressuredrops control valves: identification number, flow rate and pressuredrop and ky heat exchangers: identification number, flow rate and pressuredrop, primary and secondaryflow and return temperaturesasinstalled highlighting of all glands and other components usedin the systemmade from materials likely to be affected by chemical cleaning (see sections WI.4 and W Al.6) for differential pressure control regulators, the maximum and minimum differential pressuresfor eachvalve,the designmaximum flow rate andky. Other information

Pipes shouldbe supplied fitted with end caps.They must be stored in suitable pipe racks so that, when installed, they are in a clean condition. Site building materials such as sand, cement etc. must be kept clear. Contaminated pipes should be cleaned internally by using a 'pull through' before fitting. Ends of cut and screwedpipe must be protected from damageand ingress of dirt by temporary end caps. During installation equal care should be taken to ensure that all components are kept clean. (See section

WI.4.)

Cd)

WA2.3

Installation

inspection

(e)

(f)

Inspections are required throughout the installation period (seesectionWI.2). Much time is spent at the commissioning stage in rectifying problems, principally as a result of dirt and foreign matter within the pipes, which should not haveoccurred.

WA2.4

(g)

Pressure testing

(h) (i)
(j)

Hydraulic pressuretesting of the systemshould be carried out in accordance with an HVCA Guide to good practice(16). As work proceedseach section should be tested in turn at the specifiedpressureand duration. Pipework pressure testing is not normally regarded as a commissioning operation; it is carried out during installation. However, the operation should be properly documented and included with other commissioning information. Pressuretesting entails filling the system with water and draining it afterwards.The procedure may be an important consideration when determining causes of corrosion in pipework. Avoid leaving pipework empty for long periods and consider using a corrosion inhibitor in the water (see' sectionWI.4).

(k)

(1)

WA 1.7.3 (a) (b)

WA3

Associated diagrams for electrical and pneumatic equipmentused with the water distribution system. Manufacturers' setting to work, operating and maintenanceinstructions for equipment.

Flow measurement regulation

and

All flow measuringand regulating devicesshould conform

toBS 7350<11).

WA3.1

Flow measurement

devices

WA2
WA2.1

Installation
Installation requirement

The objective is to interpret the design requirements correctly and so bring the system to static completion. Installation includes all cleaning and soundness testing before commissioning in accordance with the specification.

Manufacturers of flow measurementdevices should provide data describing the characteristics of the measuring device either in a graphical or a tabular form suitable for use by the commissioning specialist. The published data should be produced from component type testreadings and quote the accuracy toleranceof the device. The manufacturers' quality control procedures should be such that the quoted accuracycanbe traceableto standards.

'1

FLOW MEASUREMENT AND REGULATION

) WA3.1.1

Orifice plate

WA3.1.6

Selection and installation of flow measurement devices

This is a plate, within a carrier, having a circular opening of a diameter less than the internal bore of the pipe, which is inserted into the pipeline and positioned concentrically in accordance with the manufacturers' instructions. Each plate hasa kvs coefficient. Three types of orifice platesare available:

(a)
(b)
(c)

small sizescastin one piece having male and female threaded ends one-pieceflanged carrier ring with integral orifice waferplate fitted into a carrier ring.

Devicesshould be selectedso that the pressuredifferential signal is suitable for the measuring instruments to be used and appropriate to providing reproducible readings (see section WA3.6). As a general rule the signal measured should be betWeen kPa and 10 kPa. A measuredpressure 1 drop of less than 1 kPa indicates that the water flow could become critical and laminar, thus undermining the performanceof the measuringdevice. A confusedflow through a measuringdevice directly affects the pressuredifferential acrossit. This in tUrn will lead to a false flow rate inference. To minimise the tUrbulence through the measuringdevice, current practice is to have a straight pipe length equivalent to a minimum of 10 diameters upstreamand up to 5 diametersdownstreamclear of any distUrbing influences such as bends, tees, valves and vessels, unlessotherwisestatedby the manufactUrer. Where a flow measuringdevice of less than line size has to be usedto generatea pressuredifferential signal suitable for the relevant instrumentation, lengths of pipe of the device diameter equivalent to at least 10 diametersupstream and up to 5 diametersdownstreamshould be used,unlessotherwisestatedby the manufacturer.

Pressure tappings are fitted upstream and downstream of the orifice in accordancewith BS 7350<11) are used to and measure the pressure differential signal acrossthe orifice plate. In forms (a) and (b)above,the pressuretappings are corner tappings drilled integrally through the carrier ring.

WA3.1.2

Venturi meter

This is a carefully profiled wasp-waisted tube which is inserted into the pipe in accordance with the manufacturer's instructions. Its function is to accelerate and then deceleratethe fluid velocity with minimum pressureloss. Pressuretappings at the throat (maximum velocity) and at the maximum diameter (minimum velocity), in accordance with BS 1042(17), enable the pressure differential signal to be recorded for conversion to a flow rate using the flow coefficient kvsfactor for the device provided by the manufacturer.

WA3.2
WA3.2.1
(a)

Factors affecting measurement

accuracy
Incorrect pipe jointing
Screwedthreads: cut and threaded pipes must be deburred or reamed carefully where a threaded measuring device is to be screwed onto the pipe, otherwise the flow or pressuredrop characteristics of the device maybe affected. Jointing material: hemp and jointing compound or polytetrafluorethane (PTFE tape)on pipc cn& multl not protrude into the pipe bore. Flanged joints: joint rings usedwith flanged orifice plates must not protrude into the orifice chamber. Full-face rings of the correct size should be used so that the inside diameter of the ring is greater than the inside diameter of the orifice plate chamber. A flanged orifice plate should be centralised accurately to ensure that its axis is concentric with that of the pipe. Use of pipe other than 8S J387<18) medium grade

WA3.1.3

Orifice valve
(b)

This is a threaded or flanged pressure-tapped'Y'-pattern globe valve used with the disc in the fully open position. The seatof the valve actsasa measuringorifice.

(c)

WA3.1.4

Variable-orifice double-regulating valve

This is a threaded or flanged pressure-tapped'Y'-pattern globe valve provided with a calibrated disc to vary the area of seat available for fluid flow and titted with pressure tappings either side of the seat.

WA3.2.2

WA3.1.5
(a)

Variations to standard methods of me~surement

Commissioning set: an orifice plate or devicefitted to the upstream inlet of a double-regulatingvalve. Isolating orifice: an orifice plate or device fitted to the upstream inlet of a gate or other full flow isolatingvalve.

Manufacturers' performance charts are generally based on medium-grade steel pipe(18) unless otherwise stated. This givesa known inside diameter(within specifiedtolerances), from which the beta ratio of the orifice device is determined. The inside diameters of BS 1387heavygrade pipe, copper and plastic pipes, differ sufficiendy to alter the beta ratio

(b)

WATER DISTRIBUTION SYSTEMS

enough to require different flow rate data. The manufacturer should be consulted for either an amendedperformancegraph or a suitable conversionfactor.

WA3.3.1

Correct sizing and positioning of double-regulating valves

WA3.2.3

Use of anti-freeze mix

The presence of anti-freeze in water changesits specific gravity, viscosity and surface tension. The performance of the volume flow rate measuringdevice will vary according to the proportion of anti-freeze used. The device manufacturer should be consulted for a corrected performance graph or conversion factor appropriate to the anti-freeze

Double-regulating valves are used in system balancing to imposeadditional resistancein local sections of a systemso as to meet the design performance requirement for the whole system. To do this effectively a regulating valve should have an appropriate valve characteristic and, more importantly, should be chosento give authority appropriate to each particular application. Double-regulating valves should be selectedso that this authority operatesbetween 100%and 25% of maximum disc lift with ball and butterfly valvesbetween30%and 70% of opening. To minimise the risk of noise, cavitation, disc erosion by dissolved air and the build-up of solids between the disc and the seat,thesevalves should not be used with the disc less than 25%open.Valves of other than line sizeshould be considered for use where it is necessaryto obtain the authority required commensurate with the pressure drop acrossthe device. Double-regulating valves which are not used in association with flow measuring devices may be introduced anywhere in the systemand can be used with reducersimmediately connectedto them.

mix.

WA3.2.4

Venting of air

Aerated water has modified fluid flow characteristicsand the presence of air will severely affect reproducible measurements. Complete and thorough venting of the systemis of considerableimportance.

WA3.2.5

Direction of flow

All flow measuringdevicesshould be identified and installed correctly with respectto the flow direction.

WA3.4
WA3.4.1

Access to flow measurement and regulating devices

Pressure test point access

WA3.2.6

Oscillating manometer reading

Care should be taken when reading a water manometer gaugewith an oscillating manometric fluid meniscusasan average reading will haveto be taken.

WA3.2.7

Low-volume flow rates

Pressure test points on flow measuring devices require a minimum clearance of 100 mm from objects within the path of the axis of the pressure test point. This enablesthe commissioning engineer to insert and withdraw manometer probes without kinking the tube. Where adjacent pipework is laggedsufficient spacemust be left for commissioning probes.

At very low flow rates the measuring of a pressure differential signal can be affected by air bubbles or detritus collecting acrossthe measuring orifice. This problem will manifest itself more when using regulating valves of the globe valve type which are closed down more than 75%. (SeesectionW A3.3.1.)

WA3.4.2

Scale settings

The scalesettings on all types of double-regulating valves should be visible and accessible all instances. in

WA3.5 WA3.3
Double-regulating valve

Constant flow regulator

(CFR)

A double-regulating valve is a threaded or flanged 'Y'pattern globe valve with a seatreduced in diameter from that of the mating pipe bore. The valve has a disc-to-seat opening scaledevice to indicate the number of turns open, or the percentageopen, relative to the closedposition. The valve lift canbe set and locked at the regulated position by an external mechanical device so that the valve will close and re-opento the presetposition. Note: other types, such as needle,ball or butterfly valves, may be used providing the valve authority is sufficient for the circuit and that pre-settingdevicesareavailable.

These devices reduce the need for proportional water balancing on terminal units, thus shortening the commissioning time. They are analogousto constant-volume devices in air systems.CFRs maintain a constant flow within defined limits (usually :t5%) provided that the differential pressure across the CPR within the manufacturers' reis commendationsfor consistentand stableperformance. The principle of a systemwith all terminal flows controlled by these devices is that of automatic flow balancing. Incorrect balance could only occur if the pressuredifference across any device is outside the rated range or if solids .~.~, suspendedIn the systemwater cause blockageor sticking of ,,~ the regulating mechanism. These devices cannot provide flow measurementreadings.Where flow rates are reQuired

FLOW MEASUREMENTAND REGULATION

.for documentationand other purposesadditional flow measurement devices mustbeincluded.

WA3.6

Instrumentation

WA3.5.1

Commissioning procedure

There is limited experience in commissioning HVAC systems with constant flow devices.The following procedure is suggested. (a) (b) Normal pump and systempre-checks. Cleanliness of the system is of paramount importance if the CFR units are to function correctly. All cleaning and flushing of the systemshould be carried out with the CFR units removed or bypassed. When the systemhas been thoroughly flushed and is known to be clean, the CFR units should be refitted. When re-installing the CFR units, care must be taken to ensure that no PTFEor jointing compound is allowed to contaminate the systemor its components. The pump flow rate should showno more than 5% margin over the sum of the CFRflow rates. The pump pressureshould include a small margin for unpredictable systemchangesplus an allowance of 1.5 times the minimum pressuredifferential of the CFR order to ensure that all CFRs in operatewithin their pressureband. The pump flow rate and pressure,which should be measuredand recorded, should be within :t5% of the sum of the CFR units where measuringstations have been included as part of the systemdesign. Verification of the system terminal flow rates should be carried out and recorded
Further CFR commissioning

All instruments must be regularly cleanedand serviced in accordance with manufacturers' instructions and, where appropriate, instruments should be calibrated at periodic intervals by a recognised testing laboratory to traceable standards. The following instruments and accessories necessary are to carry out the commissioning proceduresprescribed in this

Code.

WA3.6.1

Manometers

The choice of manometerlisted in Table A4 will depend on the flow measurement deviceselected.
Table A4 Manometertypesand attribute

Fluorocarbon Mercury Digitalelectronict Analogue diaphragmt

1.88 13.6

(c)

t Should be calibrated regularly and a calibration cenificate issued.

(d)

WA3.6.2

Thermometers

Sling psychrometer(wet and dry bulb thermometer). Contactand immersion electronic thermometer.

WA3.6.3

Other instruments

WA3.5.2

guidance
Where there is a discrepancyin the pump flow and/orsigns 1) of lack of terminal thermal performance,a scanof pressure ," differentials across the CFRs and terminal flow rates is necessary.Record all measurementsand annotate those which lie outside the specifiedtolerances. Where the flow is lower than the design flow rate, with the pressuredifferential within the rated band, clean the cartridge or other internal componentsof the CPR. Where the pressure differentials are too high, de-rate the pump by speedchange,where possible, or by throttling or changingthe impeller. Where pressuredifferentials acrossall CFRs a particular on circuit are too high, throttle the affected circuit until all differentials are within the ratedband. Where flow and pressuredifferentials are both low, increase the pump duty. Throttling other circuits will not necessarily correctthis fault. .Further remedial action is generally only necessary the if systemis dirty or there have beenserious design or installation errors.

Multi-purpose electronic meter for measuringcurrent. Tachometer(revolution counter or stroboscope).

WA3.7

Flow coefficients

Flow coefficient ky is defined as the flow rate in cubic metres per hour (m3/h) at a pressure drop of one kilogram force per squarecentimetre (kgf/cm2).1 kgf/cm2is approximatelyequal to 1 bar. The signal flow coefficient kyS' constantfor a given device, a is proportional to the flow rate divided by the square root of the pressuredrop which occursacross measuringdevice the at the pressuretappings. This will be given by the manu-

facturers.
The systemflow coefficientkv' a constantfor a given device, measured 3 diameters upstream and 10 diameters downstream, is proportional to the flow rate divided by the squareroot of the pressuredrop imposed on the systemdue to the device. The system flow coefficient is normally higher (lower loss) than the signal flow coefficient due to static pressureregain, exceptwhere items are close-coupled and the system flow coefficient therefore could be appreciably less (higher loss). This should also be stated by the manufacturer.

WATER DISTRIBUTION SYSTEMS

WA3.7.1
-Q -kvs

Useful formulae

The control Guidance

of Legionellosis, including Legionnaires' HS(G)70 (1993) (London: Health and

disease Safety

These symbolsareusedin ~e following formulae: is the flow rate (Vs)-~ is the pressuredtop (kPa) is the signal flow coefficient. For use by the designengineer: To selecta device within an allowable~ band: kvs= 36Q/(~Y/2 Selectthe device with the next lower rated kvs. To find the signal ~!with a knownkvs: ~ = (36Q/kvsl I To find the flow velocity (v) from a known flow rate and the nominal pipe bore (bn): v = 1152.7Q1bn2
17 12 13
14

Note

Executive/HMSO)

8
9

Electricity at Work Regulations 1989 (London:

HMSO) (1989) HMSO) (1974)

Health and Safety at Work etc. Act 1974 (London:

10 11

Regulations for the electrical installations 16th edn (London: Institution ofE1ectrica1 Engineers) (1991) BS 7350: 1990 Specification for double regulating globe valves and flow measurement devices for heating and chilled water systems (London: British Standards Institution) (1990) Petitjean R Total hydronic balancing (Ljung, Sweden: Tour and Andersson AB) (1994) Environmental Protection Act 1990 (London: Wastemanagement-The HMSO) (1991) HMSO) (1990)

(a)

duty ofcare, a code of practice (London:

IS

BS 1192: Pan 3: 1987 Recommendations for symbols and other graphic conventions (London: (1987) British Standards Institution)

16

Guide to good practice for site pressure testing of pipework (London: Heating and Ventilating Contractors' Association) (1980)

'Jt

To find the nominal pipe bore from a known flow rate and velocity: bn = (1152.7Q!v)1/2 (b) For use by the commi$sioningengineer:
To find the actual flow coefficient: fl~w rate from a known signal

BS 1042: Measurement offluid flow in clased conduits (London: British Standards Institution) (1989) BS 1387: 1985 Specification for screwedand socketedsteel tubes and tubulars and for plain end steel tubes suitable for welding or for screwing to BS 21 pipe threads (London: British Standards Institution)(1985)

18

Bibliography
BS 2871: Part 1: Specification for copper and copper alloys. Tubes (London: British Standards Institution) (1971) BS 3528: Specification for convection Iype space heatersoperating with steam or hot water (London: British Standards Institution) (1977) BS 4856 Methods for testing and rating fan coil units, unit heaters and unit coolers(London: British Standards Institution) (1983) BS 4857 Methods for testingand rating terminal reheat units for air distribution systems (London: British Standards Institution) (1983)

Q = kvs(~)1/2/t36 To find signal flow cqefficient from a known flow rate and pressuredropt kvs= 36Q/(~r/2
References ..., I.

BS 4941: Specification for moror starters voltages up to and including 1000 V for AC and 1200 V DC (London: British Standards Institution) (1977/9) BS 5000: Part 10: 1978 (1984) General pu!:t'ose induction motors (London: British Standards Institution) (1984) BS 5000: Part 11: 1973 (1984) Small-power electric motors and generators (London: British Standards Institution) (1984)

Parsloe C J The commissioningof water systemsin buildings Application Guide 2/89 (~racknell: Building ServicesResearch and Information Association)(1989)

Wild

L J CommissioningHVAC

systems-Division

of

responsibilities Technical Memorandum 1/88 (Bracknell: Building ServicesResearch alndInformation Association)(1988)

BS 5316: Specification for acceptancetests centrijitgai, mixed flow and axial for pumps (London: British Standards Institution) (1977) and air-

Parsloe C J Pre-commission cleaning ofwater systems Application Guide 8/91 (Bracknell: $uilding Services Research and Information Association)(1991) CIBSE Guide Section B7: Corrosion protection and water treatment (London: Charte~d Institution of Building Services Engineers)(1986) Badenoch J SecondRepon of the Committee of Inquiry into the Outbreak of Legionnaires' Disease in Stafford in April 1985 (London: HMSO) (1986) Thepreventionor control ofLegionellosis (includingLegionnaires' disease) Approved Code of Practice L8 (London: Health and SafetyExecutive/HMSO) (1991)

BS 5643: 1984 Glossary of refrigeration, heating, ventilating conditioning terms (London: British Standards InstitUtion) (1984)

BS 5750: Quality systems (London:

British Standards Institution)

(1987) in

BS 5875: 1980 Glossary ofterms and symbolsfor measurement offluidflow closedconduits (London: British Standards Institution) (1980) BS 6683: 1985 Guide to installotion and use of valves (London: Standards Institution) (1985)

British

BS 6860: Code ofpractice for low temperature hot water heating systemsoutput greater than 45 kW(London: British Standards Institution) (1988) Automatic Institution controls Applications Manual AMI of Building Services Engineers) (1985) (London: Chartered

~jl, V

24

J'

BIBLIOGRAPHY

.Guide to practice in corrosioncontrol II Industry/HMSO) (1982)

(London:

Department of

CommissioningEngineers Compendium (Cambridge: Commissioning SpecialistsAssociation)(1991) Proc. Con! TESCOM '77 (London: Chartered Institution of Building ServicesEngineers)(1977) Proc. Con! Commissioning design(London: Chartered Institution of by Building ServicesEngineers)(1986) Proc. Con! Quality assurancein building services (Bracknell: Building ServicesResearch Information Association)(1986) and Quality managementsystemsApplications Manual AM9 CharteredInstitution of Building Services Engineers) (London:

Scheme approvingcommissioning for specialists HVAC (London: Propeny in ServicesAgency/HMSO)(1986) Stondardspecification (mechanical electrical)No.3 (London: Propeny and ServicesAgency/HMSO) (1986) Proceduralstandards testing,adjusting and balancing of environmental for systems (Vienna, VA: National Environmental Balancing Bureau)(1992) Hydronic systems: Analysisand evaluations (Atlanta, GA: American Society of Heating, Refrigerating and Air-conditioning Engineers)(1968)

't

iJ

WATER DISTRIBUTION SYSTEMS

Index
Accessto equipment Accuracy Section
WA3.4

Page

22 1
21
4

definition
Accurate measurement factors affecting Adequateaccess Aerated water WO.2

management, definition manager, definition records specialist definition

specification,definition Complexinterlocks

Section
WO.2 WO.2 WO.S WI.I WAI.7 WO.2 WO.2 WI.7 W2.2 W2.4 WA3.S WI.7 WI.3 WAI.7 WI.7 WI.7 WI.3

Page
2 2
3

3
19

Air
free ventilation of separation venting Anti-freeze

WA3.2 WI.3 WA3.2 W2.2 WAI.5 WAI.5 WA3.2 WA3.3 WI.3 WI.6 W3.6 W3.7 WAI.7 WAI.S
W3.3 W3.6 W3.8 W3.6 W3.6 W3.9 W3.7 W3

22
8

2
7 7
8

Commutator
Completion certification Constantflow regulators(CPR) Contactors Control valves Control circuit fuse Control wiring Cooler batteries Correctsizing orifice double-regulatingvalve Dashpots Declared voltage

19 19 21
22

22
6

mixture Authority ofvalve

Automatic air Vents control valves

4 19 7
6

4
6

10 13 19
19
8

WA3.2 WA3.3 WI.? WI.?

WO.2 WAI

21
22 7 7 1

Backwash filters Balancing

basisof

Definitions
Design Design considerations criteria, definition drawings flowrate (DFR) information required

17 17
2

branches
by compensated method by% proportion

11

14
11 10

constant-volume systems
temperaturemethod variable-volume Systems water flow rates

15
13
8

pressures
requirement
Differential Differential pressure regulators (DPR) temperature

Bibliography Boilers Branch indexterminal Busbars Bypass

24 WAI.7 W3.6 WI.7 WI.4 W2.1 W3.6 W4.4 WAI.7 WAI.S

WAl.7 WO.2 W3.6 20 11 6

Direction offlow DireCton-line starters

5
7

Diversity definition
Documentation Domestic hot water systems Dosingpots Double-regulatingvalves

WAI.2 WO.2 WI.2 W3.6 WAI.7 WAI.7 WAl.I W3.7 WAI.7 WA3.2 WI.7 WO.2 W4.4 WAl.7 WAl.7 Wl.4 Wl.3
WAl.7

3
10 19 19

17 13
19

22
7 2 16 20 19

12
16 19

Bypassing plant the

Calorifiers Capacitytesting

19
20

5
4 19 20 22 19 4 4

definition
Cavitation

1
11 18

Checks
beforefilling prior to pump starr Chemicalcleaning

WAI.2 WA3.3

22
3

Drawingsand schedules Drain valves Duplex strainers Easeof access Electrical actuators Electrical checks Electrically controlled valves Evaluationand witnessing Expansiondevices

WAl.7 WA3.3 WAl.7 Wl.3 Wl.3 WAI.4 WI.? WI.? W2.I W4 WI.3 W4.4

Wl.3
W2.1 WI.4
WAI.6

19
7 6 7

7 5 19

15
16 2 8
16 19

definition
Cisterns Coefficients

WAI.7

WO.2
WI.3 WO.2

20 1
4 1 23 19

Final run
Fine tUning

flow
Cold water Cold feed Commissionablesystem definition Commissioning certification contract definition

WA3.7 WAI.7 WI.3

WO.2 W3.IO

definition
First

WO.2
W2.2
W4.4

4
1

check scan
Fill points water Flanged joints Flow

WI.l
WO.2

15 3
1

WAl.5 WA3.2
WO.2

21 1

coefficient (k..)

WA3.7

23

"

INDEX confused criticalandlaminar instruments measurement measurement device

Section WA3.1 WA3.1 W4.4

Page
21 21 17 14 19 Isolatedpressuretappings Isolated sections Isolation of plant
Section

W3.7
WAI.7

W3.? WI.4 WI.?

Page 13 5 7 21

WI.3
WAI.7 WA3.1 WAI.7 WA3.1

3
20 20 19 21 13 10 16 15 2 18 8 17 21 18 23 4 19 2

Jointingmaterial
kyflow coefficient kvssignal coefficient ky systemcoefficient Live components Local isolation Lubricant seepage

WA3.2 WA3.7 WA3.7 WA3.7 WI.? WI.? W2.2 Wl.3

WA3.6

positioning
selection Flow control regulators(FCR)

Flow rate
data

W3.7
W3.6 W4.4 W4.2 WO.2 WAI.3

23 23 23
6 6

mass measured, definition

methodsusedto detennine

8
4 23

tolerance charts
10up and 5 downrule

W3.2
WAI.2

Mainsfeed Manometers
analogue

velocity
Fluorocarbon manometer

WA3.1
WAI.2 WA3.6

f)

Flushing definition procedure schedule water velocity

WI.4
WAI.7 WO.2 WI.4 WAI.5

4
19

digital fluorocarbon mercury Manualairvents Mechanical checks Minimumclearance Mostfavoured circuit branch
Motors direction of rotation

Wl.4 Wl.4
WAI.5 WA3.6 WA3.7 WA3.7 WA3.7

4
4 19 23 242424

WA3.6 23 WA3.6 23 WA3.6 23 WI3 4 WI.6 6 WA3.4 22 W3.6 10 W3.6 11

W3.6 11

Formulae for designers forcommissioning engineers Frost protection precautions Fuse rating Gland packing Graphs
Guide to goodpractice (HVCA) pressuretesting

overheating
power running current speedof rotation starter starting current vibration

WI.4 WI.5 WI.7 Wl.3 WA3.1 WA2.4 WAl.7 Wl.3 WAl.7 WAl.7 Wl.3

5 6 6

WI.? W2.2 W2.2 WI.? W2.2 W2.2 W2.2 W2.2

7
7 7 7

W2.2
W2.2 W3.6 WAI.2 WA3.3 WI.3 WI.3 WAl.7
WA3.1

7 7
7 7
11 18

Noise

3 20 20 Non-return valves
Nozzles Operating and maintenancemanuals Orifice plate or device Orifice valve Outdoor compensator Overflows Overheatingbearings Overheating motor Panelsand switchgear Partner valve Performanceeffect Pipework Pipe sizes Pipe jointing incorrect Pipe other types Practical considerationsof flow ratebalancing Precommissioning checks definition Preliminary flow rate check Pressure differential drop

22
4

fJ '
,

Heat emitters

exchangers

19 4 19

20
21 2l 15 4 8 7
6

Heater batteries High-velocitypumping Index circuit

20
4

Wl.4
W3.6 WAI.7 W3.6
W2.2 W3.6 W3.6 WO.4

WA3.1 W3.9 Wl.3 W2.2 W2.2 WI.7 W3.8 WAI.2 WI.3 WAI.7 WA3.2 WA3.2 WO.7

10
19

identification of Initial run scan Injectioncircuits Inspection Installation cleanliness definition inspection procedures requirement standards of
1/,'\ ' lEE Regulations for electrical installations

10
7

14
17
4

11 12
3

19
21

WA2.2

WO.2
WA2.3 WI.2 WA2.I WI.2 WI.7 WA3.6 WI.7 WI.7

20 2 20 3 20 3
6 23 6

21
3 3 2 10 21
19

Wl.3
WO.2

W3.5 WA3.1 WAI.7 WA3.1 WI.3

Vi

Instrumentation Insulation Interlocks

gauges

21
4

WATER DISTRIBUTION SYStEMS

isolation tappings testing Pressureand leakagetesting definition Primary circuit Primary regulating valves Probe pockets Proportional relationship Proportional balance Provisions for measuring flow

Section

Page

W2.1 W3.7 WA2.4 WO.2 W3.6 W3.6 WI.3 W3.6 W3.6 WAI.3

13 20
2 12

11
4 11 11

Pump
excessive pressure flow rate margins pressure running-in period shut-offhead test speedadjustment standby start suction Pumps

18
8

W2.2 WAI.7 WAI.2 WAI.7 W2.2 W3.4 W3.6 W2.2 W2.I W2.I WI.6 WI.7 WAI.7 Wo.S W3.6 WI.7 W3.8 WAI.7
W3.2 W3.6 WAI.7 W3.6 WAI.7 WI.7 WI.3 WO.6 W3.6

19

18
19

8
10

Static completion deflDition records Straightpipe nIn Starters,direct on-line Strainers Supports Switchgear System cleanliness coefficient,kv commissioning,definition definition description diversity filling and venting flushing and cleaning general

Section

Page
2 7 19 7

WO.2 WI.8 WAI.7 WI.7 WI.3 WI.3 WI.7

WI.4

4
4

WAI.7
WO.2 WO.2 WAI.7 WAI.7 WI.5

4 20 1
2

11 8
7 7
6 6

pressure loss
proving, definition Siphons

WI.4 WI.6
WAI.7 WO.2 WI.3

19 19 5 4
6 19
4 4

Tanks
Ten up andfive downrule Terminal units

19
3 11

Records Record instrument of readings Reduced voltage starting Reference valve Refrigeration Regulation

7
14

Testing definition Test points pressure

Thermometers Thermal cut-outs Thermos1:a-tieally eenttolled valves Thermostatic radiator valves

WI.3 WA3.1 W3.6 WAI.7

WO.2

21
11

,
.J

20
2
4

20

WI.3 W3.4
WA3.4 WA3.6

10

8
12 19 10 19 7

22
23 7 7 13

Regulating valve

WI.7 W2.1
W3.7

Relays Reliefvalves Responsibility Riser Running-in period pumps

Scalesettings Schematic drawings Screwedthreads Secondary

Timers
Transit packing Tolerance definition performanceeffect

WI.7 WI.7
WOo2

7
6 2 17

4 3
10

WAlo2

W2.2
WA3.4 WAl.7 WA3.2 W2.2 W3.6 W3.6 W3.6
WO.2 WAI.7 WA3.6 WI.3 WI.2 W2.2 WO.3 WO.2 W3.2 W3.6 W1.2 W2.I W2.2 WI.7 WI.7 W1.2

8
22

Valves authority double-regulating

19
21

pump
pump systems regulation of bypass three-port control valve Setting to work definition Signal flow coefficient, kvs

8 12 12 12
2

Siphons
Site cleanliness Slip rings Specification Specifiedtolerance

20 23 4 3 7
2 1

8
11

electricallycontrolled lubricant port identification primary regulating regulating sizing thermostat-controlled three-port control Variable-volume systems design regulating Variable-orifice double-regulatingvalves Venting continuous Venturi meter Washers

Wl.6 6 WA3.3 22 WI.3 4 WAI.7 19 WAI.7 20 WA3.3 22 WI.7 7 WI.3 3 WAI.7 19 W3.5 10 W3.5 10 WAI.2 18 W2.1 7 W3.6 12 W3.7 12 W3.7 13 W3.7 13 WA3.I 21 WAl.5 WA3.1 WI.3 WAI.7 W2.2 WI.7 WAI.5
19

J:

21
4

Standards ofinstallation Standby pumps

Starter

3
7
8

overload
Stateof the system

7 7

Water company cooled bearings

heatingappliances sampling

19
8

7 19

INDEX treatment Wiring diagrams

Witnessing arrangements requirements duties

Section Page WI.4 5 WAI.5 19 WI.7 6 WAI.7 19 W4.2 W4.2 W4.3

IS IS
16