Guide To Good Commercial Refrigerant Practice

Guide to Good Commercial
Refrigeration Practice

Part 4
System Installation

British Refrigeration Association

Institute of Refrigeration

Issue 1 October 2008
Guide to Good Commercial Refrigeration Practice Part 4
System Installation

CONTENTS
4.0.0 GENERAL

4.1.0 OPERATIVES RESPONSIBILITIES.
4.1.1 SITE RULES.
4.1.2 SITE CONDITIONS.
4.1.3 PROGRAMME OF WORK.
4.1.4 WORKMANSHIP.
4.1.5 LIAISON WITH CLIENT/ CO‐CONTRACTORS.
4.1.6 SITE REQUIREMENTS.

4.2.0 HEALTH & SAFETY REQUIREMENTS.
4.2.1 RISK ASSESSMENTS AND METHOD STATEMENTS
4.2.2 GENERAL SITE SAFETY.
4.2.3 SAFETY IN WORKING WITH OXY‐ACETYLENE BRAZING OR WELDING
EQUIPMENT
4.2.4 SAFETY IN PRESSURE TESTING.
4.2.5 SAFETY IN HANDLING REFRIGERANTS.
4.2.6 WORKING IN HAZARDOUS AREAS.
4.2.7 SAFETY REQUIREMENTS FOR UNLOADING AND POSITIONING OF PLANT
AND EQUIPMENT.
4.2.8 SAFETY IN POSITIONING OF ELECTRICAL EQUIPMENT.
4.2.9 SAFETY REQUIREMENTS FOR DRAINAGE.

4.3.0 LOCATIONS AND POSITIONING OF PLANT AND EQUIPMENT.
4.3.1 GENERAL DETAILS.
4.3.2 SETTING DOWN PLANT AND EQUIPMENT.

4.4.0 PIPEWORK ROUTING ARRANGEMENTS.
4.4.1 ROUTING OF PIPEWORK
4.4.2 PRESSURE EQUIPMENT DIRECTIVE (PED)

4.5.0 PIPEWORK INSTALLATION.
4.5.1 LEAK PREVENTION
4.5.2 COPPER TUBING.
4.5.3 COPPER TO COPPER PIPEWORK FITTINGS.
4.5.4 COPPER ‐ FLARE AND THREAD FITTINGS.
4.5.5 COPPER ‐TYPES OF JOINT.
British Refrigeration Association Institute of Refrigeration
2
System Installation

4.5.6 COPPER ‐INSTALLATION OF LINE COMPONENTS.
4.5.7 COPPER ‐ PIPEWORK SUPPORT METHODS FOR COPPER PIPEWORK.
4.5.8 COPPER ‐ METHODS OF CUTTING TUBES.
4.5.9 COPPER ‐ PIPE OR TUBE BENDING.
4.5.10 COPPER ‐ BRAZING OF PIPEWORK.
4.5.11 PIPEWORK INSULATION.
4.5.12 STEEL & STAINLESS STEEL PIPEWORK.

4.6.0 ELECTRICAL INSTALLATION WORK.
4.6.1 CABLES AND WIRING SYSTEMS.
4.6.2 MAIN SUPPLIES.
4.6.3 INTERCONNECTING WIRING AND CABLE ROUTE.
4.6.4 CABLE SIZING AND VOLTAGE DROP.
4.6.5 EARTHING AND TESTING.

4.7.0 CONDENSATE DRAINAGE.
4.7.1 CONDENSATE SYSTEM AND MATERIALS.
4.7.2 GRAVITY DRAINAGE.
4.7.3 PUMPED CONDENSATE DRAINAGE.

4.8.0 PRE‐COMMISSIONING SYSTEM TESTING AND PREPARATION.

4.9.0 DRAWINGS
4.10.0 APPENDICES

3
System Installation

4.0.0 GENERAL

The appearance of the refrigeration installation engineer/operative and their attitude to
clients, colleagues and co‐contractors, is of great importance in presenting the image of a
company. He/she should present themselves in a pleasant manner ensuring they are
wearing clean and tidy work‐wear at all times. Users of company vehicles should ensure
these are kept in a clean and tidy condition.

4.1.0 OPERATIVES RESPONSIBILITIES ON SITE

4.1.1 SITE RULES

Installation Operatives are responsible for:

• obeying any site rules and safety regulations that may be in force

• ensuring the safety and tidiness of their work area

• for using in a safe manner any personal protective equipment or safety equipment
that has been made available for their use.

• working with safety as a prime consideration at all times

4.1.2 SITE CONDITIONS

All working areas are to be kept clean tidy, only sufficient materials for the work in progress
at the time are to be allowed in the working area. Other materials are to be stored in a safe
area agreed with client/principal contractor.

Prior to hand over, operatives should ensure that their working areas have been cleaned
and tidied to a reasonable standard.

All debris etc. should be removed from site or deposited in designated areas on site.
Particular attention should be paid to plant room plenum chambers, the tops of
coldrooms/coldstores, and the undersides of display cases. Care should be exercised with
the disposal of waste materials and substances, see the Environmental Protection Act 1990,
Duty of Care, section 34, and the company’s waste disposal procedures both which should
be complied with.

4.1.3 PROGRAMME OF WORK

Installation operatives should ensure they are familiar with the programme of works agreed
with client/principal contractor, for which they are responsible. They should make every
effort to ensure the programme is maintained. Operatives will be required to give progress
reports as and when required by their manager or the project engineer.

4
System Installation

In the event of major unforeseen problems on site, the engineer should contact their
management immediately to ensure difficulties are dealt with quickly and efficiently.

Operatives should record and report to their manager any verbal on site instructions given
by the client/principal contractor.

4.1.4 WORKMANSHIP

Operatives should be qualified and competent, able to demonstrate that all work is carried
out to the best of their ability and in accordance with the guidelines laid down in these
procedures.

4.1.5 LIAISON WITH CLIENT / CO‐CONTRACTORS

Contact with the client, principal contractor, or the other co‐contractors should be
maintained at the highest levels by the company’s personnel.

4.1.6 SITE REQUIREMENTS

Site operatives must ensure that the following requirements are maintained at all times:

• Contact client or principal contractor when first arriving at site.

• Sign in and out of site on a daily basis.

• Keep client/principal contractor informed of your work programme and safety
requirements which may affect other people.

• Do not work in a manner which may affect the health and safety of you and/or that
of other workers, or members of the general public.

• Report any accident or incident to your supervision and to the client/principal
contractor, and see that details are entered in Site Accident Book and Company
Accident Book.

• Do not use, or interfere with, any malfunctioning work equipment; report it to your
supervisor so that it can be replaced.

• Compliance with Permits to Work e.g. hot works, fire alarm isolation, electrical
isolation, restricted access, etc

• Maintain a site diary including a H&S file covering attendance record, site induction
record, induction of risk assessments record, H&S training and any Tool box talk
records

5
System Installation

4.2.0 HEATH AND SAFETY REQUIREMENTS

4.2.1 RISK ASSESSMENTS & METHOD STATEMENTS

For all site work to be completed by operatives, risk assessments and method statements
covering activities required and substances to be used are to be completed and submitted
within the site safety plan prior to commencement of any work. All operatives should be
inducted so fully understand the requirements and able to comply with the site safety plan.
For guidance refer to British Refrigeration Association’s publication “Task Procedures and
Risk Assessments

4.2.2 GENERAL SITE SAFETY

Certain safety rules apply to all sites, some of the more important ones, but not all of them,
are:

• Operatives should wear or use appropriate Personal Protective Equipment at all
times while they are on site.

• Work areas should be kept in a tidy condition and all hazards removed as far as
practicable. Where any hazards remain, a risk assessment should be made and
control methods employed to reduce the risk e.g., safe systems of work, safety signs
etc. If certain work processes are going to affect others working in the area, they
should be advised and, if necessary, the area cleared before work is allowed to
commence.

• Permits to Work. In certain areas where hazardous situations can arise, a system
known as a “Permit to Work” may be required. Operatives should be aware of this
requirement and check with the site management before commencing work in any
of the following situations:

(i) Working at height,
(ii) Work involving hot work, (brazing).
(iii) Working with abrasive wheels.
(iv) Working with hazardous substances, (where this may affect others in
work).
(v) Working in confined spaces.
(vi) Working on live electrical equipment.

Further details on Permits to Work can be located in the British Refrigeration Association’s
publication Task Procedures and Risk Assessments.

Permits to work are usually administered by the client or principal contractor. It is prudent
to train operatives to be able to administer a self‐raising permit allowing them, and the
client or principle contractor to sign, particularly when small work is involved and/or site

6
System Installation

management does not have a permit system in place. Some Contractor’s company warranty
insurance may become invalid if permit is not in place prior to commencement of work.

• Safe storage of materials and equipment. Before work has commenced on site,
arrangements should be made with the client/principal contractor for the storage of
materials to be used for the installation, together with any work equipment which may
be used. Hazardous chemicals, gases, etc. need to be stored in a secure, well ventilated
area away from the normal working areas of the site. Only sufficient materials for the
work in progress should be maintained within the work area. Likewise any hazardous
materials or equipment should be removed from the area at the end of the working day.

4.2.3 SAFETY IN WORKING WITH OXY‐ACETYLENE, BRAZING OR WELDING EQUIPMENT

Oxy‐Acetylene equipment presents many safety problems if not used or maintained
properly. Following are the requirements for satisfactory use and operation:

• Cylinders to be secured to a purpose built trolley mounted in a vertical position,
when in use.

• Equipment should be visually checked at the beginning of each working day for
damage, malfunction and leaks etc.

• Anti‐flash back arrestors must be fitted to equipment at all times and changed every
5 years.

• Do not use lines longer than are necessary to reach inaccessible work areas, (assess
if the cylinder trolley can be moved to a nearer location).

• Use appropriate Personal Protective Equipment including heat resistant gloves,
goggles and arm protection, as necessary.
• Ensure adequate ventilation to the work area. If necessary additional ventilation
must be made available.

• Check that suitable fire precautions are taken and that fire extinguishers are
available ready for use.

• Purge both oxygen and acetylene lines before lighting up.

• Always uncoil lines fully, do not coil excess hose around cylinders or regulators.

• Move cylinders only using an appropriate trolley. Never transport cylinders with
regulators and hoses attached unless on a purpose‐designed trolley or carrier.

7
System Installation

• During carriage of cylinders by road. Ensure all concerned are aware of which gases
are being carried and which are flammable, toxic or corrosive by displaying
appropriate safety signs.

• Ensure that relevant safety data, TREM Cards and COSHH sheets are carried for each
type of gas or substance. This information must be available in an emergency and
visible in the driving compartment.

• Make sure cylinders are properly loaded and secured so that they cannot move
about. Ensure all gauges and lines etc, are removed.

• Do not smoke or ignite flammable materials. Oxy‐acetylene equipment is subject to
examination annually by a competent person.

4.2.4 SAFETY IN PRESSURE TESTING

The main safety requirements for the pressure testing of refrigeration systems are: That
access to the area where the testing is being carried out should be restricted to the
personnel concerned with the testing. Oxygen Free Nitrogen (OFN) used for the testing must
be introduced into the system via a steel braided hose. (Demanded on the majority of
construction sites giving resistance to kinking and damage by possible third parties) Any
pressure gauges used for reading the system pressure must be fitted remote from the
charging line, (no refrigeration lines to be used for charging the OFN).

In addition to system integrity pressure testing there is a requirement for leak tightness
testing. This is usually carried out with lower pressures. The distinction between the two
tests is covered in section 4.8.0. A good practice guide is the IOR Service Engineers Guide 24
– Leak Tightness Testing.

For further guidance and compliance refer: BS EN 378‐2:2008 'Pressure Requirements and
Pressure Vessels’ ‐‐ BRA Task Procedure Risk Assessment R10 covering Pressure Testing of
Refrigeration Pipe‐work Systems ‐‐ HSE GN4 Safety in Pressure Testing ISBN0717616290.

4.2.5 SAFETY IN HANDLING REFRIGERANTS

The deliberate venting of refrigerants to the atmosphere has been prohibited since 1990,
under the terms of the Environmental Protection Act. This is because of the affect that
HFC’s and other refrigerants have on Global Warming and Ozone Depletion. This has led to
the introduction of the Safe Handling of Refrigerant Assessments for operatives installing,
servicing and maintaining refrigeration equipment and systems.

It is a legal requirement that all operatives handling HCFC and HFC refrigerants are trained
and their competence demonstrated by obtaining C&G 2078, (At appropriate time through
UK legislation C&G 2078 will be superseded by C&G 2079) or CITB qualification. All
operatives with one of these qualifications should then register with ACRIB (Air

8
System Installation

Conditioning, Refrigeration Industry Board) to allow Clients and End‐Users access to check
credentials

It is highly recommended that operatives do not handle any refrigerant including
hydrocarbon, carbon dioxide, or ammonia without proper training and the ability the
demonstrate competence

4.2.6 WORKING IN HAZARDOUS AREAS

As previously mentioned in 4.2.1, working in hazardous areas usually requires a Permit to
Work system. Operatives should check before commencing work to see if such a system is
required. Further information on working in hazardous areas can be found in the British
Refrigeration Association's Task Procedures and Risk Assessments.

4.2.7 SAFETY REQUIREMENTS FOR UNLOADING AND POSITIONING OF PLANT AND EQUIPMENT.

Before delivery of the main items of refrigeration equipment for a project, a thorough site
survey needs to be carried out to ensure both a safe and level area is available for unloading
to take place, and clear unobstructed routes can be found to the final positions where the
equipment is to be installed.

Where lifting operations to high levels are required, these are normally carried out by a
mobile crane (usually hired for the occasion). The responsibility for the operation and
movement of the crane rests with the operator, but the user/hirer needs to assure
themselves that all the appropriate regulations and codes of practice are being complied
with. Crane operator should make available prior to commencement of work a completed
Risk Assessment with method statements

The final positioning of equipment (e.g, refrigeration packs, condensing units, condensers,
cabinets, etc.) often comes down to manual handling by a team of workers. Care should be
exercised at all times if injury is to be prevented. It is important that all members of the
team understand how and when to lift. Risk Assessments with method statements should
be completed prior to commencement of work, for further information of lifting operations
refer to the BRA Task Procedures and Risk Assessments.

4.2.8 SAFETY IN POSITIONING OF ELECTRICAL EQUIPMENT

During the design stage of the project, in order to allow sufficient access for servicing and
maintenance purposes, thought must be given to the positioning of items of equipment
such as packs, electrical control panels. The Electricity at Work Regulations requires a
minimum of 1 metre clear space to the front and the sides for persons working on live
electrical equipment.

9
System Installation

4.2.9 SAFETY REQUIREMENTS FOR DRAINAGE

Again at the design stage it must be ensured that a suitable drainage system is available in
which to discharge the condensate from evaporators. This applies particularly to
refrigerated cabinets using secondary refrigerants. These require a special drainage system,
where filters and scrubbers prevent discharge of pollutants into the sewage system.

4.3.0 LOCATIONS AND POSITIONING OF PLANT AND EQUIPMENT

4.3.1 GENERAL DETAILS

In many cases the location of the refrigeration plant for a project will have already been
decided before commencement of work on site. It is the designer’s responsibility under
CDM Regulations to assess the situation and to stress to the client his responsibilities under
Health & Safety Law (e.g., PUWER: 1998, CDM: 2007, and the Health & Safety at Work Act:
1974, etc.). Account should be taken of any access problems which may arise for
maintenance, service and decommissioning, noise problems when plant is running, also the
plant or equipment must have adequate ventilation and weather proofing.

In the case of “small works”, where a designer has not been employed, or the work does
not fall within the requirements of CDM: 2007, the “Installation Engineer” may be required
to select the locations/positions for such items as condensing units, air cooled condensers,
pumps, control panels etc., and agree these with the client. The following good practices
are recommended:

• Care must be taken to ensure condensing equipment is sited in a well ventilated
area with adequate weather protection.

• Do not site condensing equipment in roof wells. In hot weather these will form a
heat trap and effect the operation of the equipment (e.g. high head pressure and
nuisance tripping of HP switch).

• When choosing the location and position of refrigeration and air conditioning
equipment, thought needs to be given to access for service and maintenance
purposes. E.g., how can heavy items, such as compressors, be brought in and
out? Is there enough space around the equipment for a person to work safely?
Too often end users want equipment to be installed where service technicians
are placing themselves in hazardous situations in order to carry out service of
maintenance operations. Reference to CDM Regulations and the Health & Safety
at Work Act is recommended.

• Adequate weather protection must be provided, either in the form of individual
housings or purpose built plant rooms, for packs or racked condensing unit
systems. Further information on this can be found in Section Two ‐ Design.

10
System Installation

4.3.2 SETTING DOWN PLANT AND EQUIPMENT

Refrigeration equipment needs to be set down on adequate surfaces or fixing points, to
prevent problems of noise, vibration, and leakages of refrigerant at a later stage in the life of
the plant. The following points need to be observed to achieve this:

• Bases should be constructed from concrete wherever possible, and have a
smooth and level surface on which the equipment is to sit.

• If equipment is to be situated on a wooden floor, insulation material such as cork
or fire retardant composite board should be placed between the equipment and
the floor.

• Wherever possible, it will be an advantage to supply and fit proprietary anti‐
vibration mounts.

• Where equipment is situated on cantilever wall brackets, ensure that the
construction of the wall is such that it will support the weight of the brackets and
the equipment.

• In outside locations, the surface of the base needs to be raised above ground
level by at least 100 mm to prevent flooding in storm conditions.

• Wherever possible, equipment should be fixed firmly to the surface on which it is
located. Equipment situated at height (i.e. on wall brackets), should always be
fixed in order to prevent movement.

4.4.0 PIPEWORK ROUTING ARRANGEMENTS

4.4.1 ROUTING OF PIPEWORK

The route of the pipework between the evaporator and the condensing unit or compressor,
and remote condenser, should be as direct and as short a distance as possible. All pipework
should be designed and installed to give liquid and oil a “drain” flow with no traps. Traps
should only be used to obtain oil entrainment in vertical risers. Traps and bends which can
create pressure drops in the system should be kept to a minimum.

Consideration should be given to allow for expansion in long lengths of discharge line.
Distortion due to expansion can cause working of joints at the connection points leading to
refrigerant leaks

Wherever possible, pipework should utilise “pulled” bends and sets using patented
mechanical tube bending equipment. The use of manufactured elbows produces greater
pressure drops when the system is operating.

11
System Installation

4.4.2 PRESSURE EQUIPMENT DIRECTIVE (PED)

Pressure Equipment Directive (PED 97/23/EC) covers a number of areas with regard to
refrigeration and air conditioning piping and vessels. Engineers may require assessment
qualifications to be able to complete brazing e.g. BRA – Jointing of Copper Pipework for
Refrigeration Systems, or equivalent/better alternative. Refer paragraph 4.5.9
PED requires systems operating with 0.5 bar and greater, that design processes and site
work methods demonstrate compliance with the regulations and hence the safety pressures
declared for that system. Dependent upon the system declared safety pressures and into
which category of certification this fall, there may be a requirement for elements of design
and site work methods to be assessed and approved by a “Notifiable Body”. These are
organisations that are responsible for setting standards or auditing to standards such as
insurance companies’ e.g. Lloyds or in standards, BSI. Design documentation and site work
instructions should state if the system is subject to Notifiable Body attendance to audit and
approve compliance

4.5.0 PIPEWORK INSTALLATION

4.5.1 LEAK PREVENTION

F‐Gas Regulations 842/2008 details requirements for refrigerant containment. Pipework and
component installation is a major process where following recommended industry good
practice in conjunction with current codes and regulations should give a system that is at
least risk to leak. Specifications and processes along with reference to codes and regulations
are covered in the following paragraphs with the aim of achieving a leak tight system

4.5.2 COPPER TUBING

With the introduction of refrigerants that operate at higher pressures care is necessary
when considering the strength of the copper tube to be used. Design documentation should
show tube sizes with wall thickness and these should be checked prior to commencing
installation.

To conform to EN378:2008 the majority of copper tube suppliers now label tubing by
marking to the external surface or the tubing is supplied certificated.

For practical help to ensure the correct pipe wall thickness is used for the appropriate
refrigerant two guides are available with selection tables: 1) BRA Fact finder no7 A Guide to
Selecting Copper Tube and Fittings for New Refrigeration and Air Conditioning Systems. 2)
IOR Service Engineers’ Section Datasheet no 4 Copper Pipe Wall Sizing and New Refrigerants

Copper tube used for refrigeration systems must conform to the following specifications: BS
EN12735‐1 These specifications cover seamless (Refrigeration & Air Conditioning Grade)
copper tubing in soft, half hard, and hard tempers, it is normally available sizes listed below
(all based on Outside Diameters ‐ OD):‐

12
System Installation

Soft Drawn
U

1/8”, 3/16”. 1/4”, 3/8”, 1/2”, 5/8”, 3/4”, 7/8” ‐ in 6 metre and 15 metre coils.

Half Hard Temper
U

3/8”, 1/2”, 5/8”, 3/4”, 7/8”, 1 1/8”, 1 3/8”, 1 5/8”, 2 1/8” ‐ in 3 metre and 6 metre lengths.

Hard Temper
U

2 5/8”, 3 1/8”, 3 5/8”, 4 1/8” ‐ in 3 metre and 6 metre lengths.

All refrigeration grades copper tubing is marketed as clean, dehydrated and sealed at the
ends.

4.5.3 COPPER TO COPPER PIPEWORK FITTINGS

There are several ranges available. Again these fittings are manufactured specifically for the
refrigeration industry and are based on OD sizes. These fittings are used to join various
lengths and sizes of copper tube together, thus forming the pipework system. The method
of joining is by manual flame brazing. These fittings conform to ASME D16.22.‐1995.

Types of fittings are:‐

• Long Radius Elbows
• Short Radius Elbows
• Tee Pieces (Equal and reducing)
• Couplings (Equal and reducing)
• Reducing Elbows
• 45° Elbows
• Caps
• Return Bends
• “P” Traps

4.5.4 COPPER ‐ FLARE AND THREAD FITTINGS

For the smaller sizes of soft drawn pipework a range of brass flare fittings are available. The
use of these should be kept to a minimum due to their susceptibility to leakage of
refrigerant and the effects this has on the environment. These fittings conform to SAEJ513.

4.5.5 COPPER ‐ TYPES OF JOINT

There are many ways of joining copper pipework for refrigeration systems. Some of the
more common ones are listed and explained here:

13
System Installation

• Flared Joint: These joints should only be used where other means of jointing are
impractical due to the weakness of this type of joint and the environmental
impact of refrigerants. This is achieved by the use of a flare nut for the respective
size of pipe (1/4” OD, 1/2” OD, etc.) being slipped over a prepared end of copper
tube. The end of the copper tube is then flared outward to an angle of
approximately 45°. The flare nut is then connected to a flared fitting or
component, forming a vapour proof joint.

• Swaged Joints: Swaging of joints in copper pipework permits two pieces of tube
of the same diameter to be joined together without the use of fittings, it being
more convenient to braze one joint than two with the use of connectors and
improves risk against leakage. Less joints, less leaks, containment being the
major requirement of the F‐Gas regulations.

To achieve a swaged joint, one piece of tubing is swaged out to the outside
diameter of the other piece. As a general rule the length of overlap should equal
the outside diameter of the tube.

Generally the use of swaged joints in copper pipework is acceptable, however on
the larger sizes there is a possibility of thinning the wall of the tube, thereby
leading to problems of leakages later. Therefore the maximum size of pipe
where swaging is acceptable is 1 5/8". All pipework above this diameter shall be
joined using standard copper‐to‐copper couplings. Two types of swaging tools
are commonly used; the punch type for smaller diameter tubes and the
mechanical expander type. With both types, different tool sizes are available for
use with the many sizes of copper tubing. The swage is then brazed to achieve a
leak proof joint. See also Section 10 sub‐section 29 relating to pulled tees.

• Flanged Joints: Where pipework has to bolt onto items of equipment, such as
compressors, a flange joint is used. The actual joint being formed by a gasket
which sits between the two flanges, thus forming a leak proof joint. The jointing
of the copper pipework to the flange is achieved by brazing.

• Lok‐Ring: Brass Lokring fittings are now available to suit refrigeration and air
conditioning pipework up to 7/8”. Designed for working pressures up to 50 bar
and therefore a preferred acceptable alternative to brazing particularly in
locations where hot works is prohibited

4.5.6 COPPER ‐ INSTALLATION OF LINE COMPONENTS

Before any components are fitted into a refrigeration system it is important that the
installer understands where within the system they have to be fitted, the correct methods
to be used to fit them and the correct orientation for satisfactory operation. Further
information on various components of the refrigeration system can be found in Section 2.

14
System Installation

4.5.7 COPPER ‐ PIPEWORK SUPPORT METHODS FOR COPPER PIPEWORK

Numerous methods of fixing have been developed over the years because of the many
situations in which refrigeration pipework is installed.. It is important to survey the site
thoroughly before work on site commences. This enables the route for the pipework be
established with others (e.g., Client/Co‐contractor etc.) and the methods of fixing
confirmed.

All piping should be adequately supported, the supports or hangers being sized to carry the
weight of the pipe including the contents, and where required the insulation. The
recommended distance between supports is as follows:

COPPER PIPE SIZES MAX, SPACING OF SUPPORTS
(mm) (inch) (m)

15‐22 1/2 ‐ 7/8 soft drawn 1
22‐54 1/2 ‐ 2 1/8 half hard 2
54‐67 2 1/8 ‐ 2 5/8 half hard 3

Pipework for installation may involve routing through floor ducts or fastened to walls or
ceiling, or at high level on supports suspended from roof purlins or rafters. Following are
recommended methods of fixing for the various situations.

• Floor Ducts: Where ducts have been formed to take the refrigeration, electrical or
plumbing services to a refrigerated fixture, or group of fixtures, there is normally no
need for clipping or fixing of pipework. It is laid in the bottom of the duct resting on
load bearing insulation materials. Care needs to be taken to ensure that the
pipework does not foul the corners of the ducts, or the other services where
crossovers of these occur. Cradles need to be made in order to prevent chaffing.
Where ducts hold a number of pipes and double stacking is necessary, load bearing
insulation needs to be placed between the layers of pipework.

• Fixing to Walls and Ceilings: If pipework has to run up or down a wall, or traverse a
ceiling, several methods of fixings are available as follows:‐

a) Pipe clips: Where pipework for a single system is involved, the suction and
liquid lines are fixed directly to the wall by means of pipe saddles clamping
over each of the pipes. As most suction lines are insulated, a saddle that is
slightly smaller than the outside diameter of the insulation needs to be
selected. This enables the pipework to be held satisfactorily, with only a
slight indentation of the insulation material.

b) Cable Trays: The use of cable trays allows for a tidy fixing of pipework,
particularly where a large number of pipes have to be run. The tray, which
can be obtained in standard sizes from 50 mm up to 60 mm, is fixed to the

15
System Installation

wall or ceiling with a spacer between the tray and the surface. The pipework,
and/or electrical services, are then clipped to the tray by means of special

nylon ties. Again, care must be exercised in fixing suction lines to ensure
insulation around the pipe is not distorted, and the vapour seal is not broken.
The advantages of using cable tray are that it gives the installation a tidy,
professional look, and enables the vapour seal on suction lines to be
maintained by gluing the lengths of insulation end on end. It is important
that where exposed copper pipework is run on galvanised cable tray some
means of insulating the pipework from the tray is used. This prevents
electrolytic action and corrosion.

c) Proprietary Fixing Systems: There are a number of fixing systems available.
These systems are very adaptable and can be used to fix or support single or
multiple pipework systems, whether fixed to a surface or suspended from
rafters or purlins. The pipework is fixed by means of insulated clamps to
support brackets cut and assembled on site to suit the particular
requirements.

Reference should be made to suppliers’ literature for fixing materials and insulation
for further information.

4.5.8 COPPER ‐ METHODS FOR CUTTING TUBE

To cut copper tube either a hacksaw or tube cutters may be used. Wherever possible tube
cutters should be used, the tubing should be cut squarely (90°). After the tubing has been
cut the ends of the pipe must be reamed and scraped, in order to remove any sharp burrs
on the inside and ends of the tube. If tube cutters are unavailable or inappropriate and a
hacksaw has to be used, a wave set blade of 32 teeth per inch is recommended. It is
important that filings or chips of any kind do not enter the pipework.
Whenever pipework is left with an exposed or unconnected end it needs to be sealed with a
suitable cap to prevent the ingress of moisture, dust etc.

4.5.9 COPPER ‐ PIPE OR TUBE BENDING

As explained in 4.4.1, wherever possible, refrigeration pipework should have any bends or
sets formed by means of mechanical tube bending equipment, this makes for a neater,
more professional installation and reduces the possibility of pressure drops when the
system is working.

There are several brands of mechanical tube bending equipment ranging from the smaller
hand held lever type (sizes 1/4” ‐ 5/8” OD), to the larger hydraulically operated (sizes 7/8”
OD ‐ 2 1/8” OD).

In order to achieve a consistent high standard of bends and sets in pipework, requires skill,
accuracy in measurement and lots of practice. If a bend is not formed satisfactorily the
16
System Installation

work may have to be done again (i.e. stretching of the wall of the tube, under or over
estimating the distances in which the pipework has to fit). This leads to increased cost in
both material and labour, therefore the following rules apply:

• Measure very accurately the distance between the centre of the joint into which the
pipework is going to fit, and the position where the outside of the bend is going to
finish; add an extra half diameter of the pipe size to this measurement (1 1/8” OD
pipe extra to measurement 9/16”. Line up this measurement with the outside edge
of the former. Carry out the forming of the bend, the pipework with the bend(s)
formed should accurately fit into the space measured.

• To aid the forming of bends and sets, lightly oil the slipper of the bending
equipment. This will help prevent ripples and scoring of the tube.

4.5.10 COPPER ‐ BRAZING OF PIPEWORK

Brazing is one of the best methods of joining together refrigeration pipework, it produces
strong, leak free joints, which stand up to the most extreme temperature conditions.

Only suitably qualified personnel should undertake brazing, e.g. holders of BRA Brazing
Assessment or CITB Assessment or an appropriate NVQ including this activity with
assessment.

Oxyacetylene brazing equipment provides the best means of achieving this with the
combined mixture of pure oxygen and acetylene producing a very hot flame (no less than
600°C). Brazing can be done relatively easily if the correct procedures are followed:

• Thoroughly degrease and clean parts and joints to be brazed.

• Support all parts and ensure the joints fit closely.

• Apply flux recommended for the brazing alloy, (if a flux is required). Follow the
manufacturer’s instructions.

• Heat the joint evenly to the recommended temperature. Keeps the torch moving
constantly in a circular motion.

• Apply the brazing alloy to the heated joint, do not melt the alloy with the torch.
• Allow the joint to cool.

• Clean the joint thoroughly, using warm water and a brush. Ensure all flux is
removed.

17
System Installation

• Pass oxygen free nitrogen (OFN) through the pipework being joined while the
brazing operation is taking place, this will reduce the scale build up on the inside of
the pipework.

• Use only brazing filler alloys which comply with EN 1044.

A more detailed guide to the brazing of refrigeration pipework may be found in the BRA
“guide to the joining of copper pipework for refrigeration systems”. The person carrying
out the brazing procedure must have an appropriate brazing assessment qualification, a
legal requirement within the European F‐Gas regulations, and either be or be supervised by
a person holding an F Gas qualification i.e. C&G 2079 or CITB equivalent

4.5.11 PIPEWORK INSULATION

All suction and hot saturated vapour defrost pipework must be fully insulated with the
correct sized insulation material in order to prevent ice and condensation forming on the
pipework.

When the pipework has been successfully pressure tested, the joints in the insulation may
then be glued together using an adhesive recommended by the manufacturer.

4.5.12 STEEL & STAINLESS STEEL PIPEWORK

General
Carbon, Carbon Manganese, low alloy and Austenitic stainless steel pipe and fittings are
regularly used within the refrigeration industry in particular for industrial ammonia systems.
These materials correctly applied offer a robust pipe work system with high pressure
integrity and are compatible with most refrigeration applications.
Unless purchased in large quantities these materials are not available with the same level of
cleanliness as found in refrigeration quality copper tube.
Further processing such as acid pickling or abrasive blasting should be employed to remove
the residue from manufacturing processes such a mill scale, protective lacquers and oxides.
Where this is not practical the introduction of additional serviceable filters with valves as
appropriate should be considered.

Materials
B
The material specification and grade shall be chosen with regard to the lowest temperatures
either in operation or at standstill. The specification and wall thickness should be
determined in accordance with an appropriate National or International standard such as BS
EN 14276‐ Part 2 Pressure equipment for refrigerating systems and heat pumps. Piping.
General requirements.
Traceability of steel pipe and fittings can be achieved by the recording of their markings.
These cast or heat numbers should then be cross referenced to the material test
certification to verify that the materials are in compliance with the specification and grade.
Test certificates should be to level 3.1B of BS EN 10204 Metallic materials.‐Types of

18
System Installation

inspection documents. Welding consumables that form part of the pressure containment
envelope should also be controlled by batch number and supplied with certificates of
conformity from the manufacturer.

Stainless Steel
B
Whilst stainless steel offers good low temperature ductility and corrosion resistance, it does
distort, more than carbon steels, due to welding stresses and if these residual fabrication

stresses are high they will cause stress fractures, particularly in thin wall materials. Also the
process operating conditions and environment should be checked for certain corrosive
elements such Acids, chlorides, bromine, cupric ions, ferric ions, sulphide ions etc that may
cause corrosion.

Dissimilar materials.
Special consideration needs to be given to the possible combinations of dissimilar materials,
their joining techniques and their operating environments. To prevent electrolytic action
between reactive materials such as some grades of stainless steel and copper/brass a
eutectic break should be considered. If joined by brazing the alloys of the brazing material
will also have to be considered to avoid the elements leaching out of the joint by electrolytic
action. Brazing and/or welding procedure specifications and qualifications were appropriate
should identify the material combinations applicable.

Pipe Connections
B
The number of joints should be kept to a minimum and fusion welded joints used in
preference to flanged or screwed connections.

Welded Joints
B
Welding should be carried out so far as practical in a controlled environment such as a
workshop and if practical strength tested prior to final assembly on site.
In situ ‘positional welds’ should be kept to a minimum and their location considered at the
design stage to ensure adequate access for welding, cleaning, and inspection including non‐
destructive testing (NDE).
As with all hot work extra care should be taken to remove flammable materials from the
work area, task risk assessment carried out and cooling down (fire watch) periods observed.

Joint design.
Preference should be shown for multi‐pass full penetration butt‐welded joints due to their
superior fatigue and brittle fracture resistance. Fillet welds should be avoided for low
temperature and or cyclic service.

Due to the difficulty of fabricating and achieving good joint geometry and distortion free
welds, size on size, off‐set and tangential branch welds should be avoided unless special
process conditions require their use. Proprietary weld fittings should be used where
possible; these should be to an applicable standard such as BS 1640‐1:1962 Specification for
steel butt‐welding pipe fittings for the petroleum industry. Wrought carbon and ferritic alloy
steel fittings or equivalent.
19
System Installation

Welded end caps to BS EN 10253‐2:2007 should also be used for the termination of pipe and
in particular headers. Where this is not possible the end closure should be formed from a
material to an appropriate specification and it’s thickness calculated in accordance with
PD5500: 2006 Specification for unfired fusion welded pressure vessels. The use an
appropriate NDE technique should be considered to check the weld quality.
Socket weld fittings to BS 3799:1974 Specification for steel pipe fittings, screwed and
socket‐welding for the petroleum industry up to DN40 can assist in achieving correct pipe
alignment and prevent contamination where access or site conditions are adverse.

Weld Procedure Specifications
B
An appropriate documented procedure should be produced to detail the material group (s)
being joined, size range, joint geometry and tolerances, welding parameters and
consumables specifications. Were either by contract or regulation these should be qualified
by a United Kingdom Accreditation Service (UKAS) approved third party to an appropriate
standard such as BS EN 15614‐1:2004 Specification and qualification of welding procedures
for metallic materials. Welding procedure test

Welding Operator Qualifications
B
The welding operators competence should also qualified where required either by contract
or regulation these should be qualified by a UCAS approved third party to an appropriate
standard such BS EN 287‐1:2004 Qualification test of welders. Fusion welding. Steels. The
extent of the qualification (s) should cover the range of materials, welding positions
diameter range, welding process and wall thickness and checked that the validity has not
time expired.

Welding Processes
B
Gas Tungsten Arc Welding (GTAW), sometimes referred to as TIG, Shielded Metal Arc
Welding (SMAW) Oxyfuel Gas Welding (OGW) and Gas Metal Arc Welding (GMAW)
sometimes called MIG are all commonly used.
Care should be taken to efficiently remove flux and spatter expelled during the welding
process. For single sided full penetration welds the GTAW (TIG) process should be
considered to minimise the build up of oxides on the second side (inside) of the pipes.
Stainless Steel, and elsewhere if required by the welding specification, will require an
appropriate shielding gas to be purged thought the inside of the pipe to prevent
unacceptable internal oxidisation and root weld defects.

Detachable Joints,
Flanges
B
Flange materials and bolting should be appropriate for the temperature either in service or
at standstill. Steel flanges should comply with BS EN 14276‐2
Bolting should be to BS EN 1515‐1:2000 Flanges and their joints. Bolting. Selection of bolting
or PD 5500:2006

Gaskets,
Flange gaskets should meet the requirements of BS EN 378:2008 and checked for
compatibility with the refrigerant and lubrication oils used.
20
System Installation

Pipe Threads
B
Taper threads should be restricted to DN40 and used to connect control, safety and
indicating devices. The fittings should of the correct pressure rating to an applicable
standard such as BS3799 Any sealing medium used should must be check with the
manufacture for compatibility with the refrigerant and lubricating oils used.
Threaded coupling welded to pipe should be checked for distortion and their threads chased
out as appropriate. Small diameter < DN10 threaded fittings are vulnerable to damage from
weld spatter and over tightening and care should be taken not to strip their threads.

Steel Pipe Supports and Hangers
B
All piping shall be adequately supported, the supports or hangers being designed to carry
the weight of pipe including its contents and, where required, insulation. Particular
attention should be paid to pipe work that could operate full of liquid.

The distance between supports depends on the size and service weight of the pipeline: a
recommended maximum spacing for steel pipes is as follows:

Steel pipe sizes Max. Spacing
of supports
DN Horizontal Vertical run
run (m) (m)
15‐25 2 2.4
32‐50 3 3.0
65‐80 4.5 4.6
100‐175 5 4.6
200‐350 6 8.5
400‐450 7 20.0

4.6.0 ELECTRICAL INSTALLATION WORK

GENERAL
Refer BS EN378‐3:2008 Section 6 “Electrical Installation”, and British Refrigeration
Association Fact Finder No 11 titled “Identification of Electrical Conductors in Fixed
Installations”

Electrical work for the larger refrigeration installations (e.g. supermarkets, large coldstores,
industrial installations), is usually carried out by an electrical contractor using qualified
electricians to install the wiring systems. However, in some “small works” the installation
engineer may be called upon to carry out the interconnecting wiring installation from the
fused isolator (provided by the client) to the various components of the refrigeration
system. It is important that the person carrying out this work understands the rules and
regulations of BS 7671: 2008 IEE Wiring Regulations, commonly known as 17th edition; and
the Electricity at Work Regulations 1989, and that the electrical installation is inspected and
tested by a qualified and competent electrician before the power is switched on.

21
System Installation

An inspection completion certificate must be issued to the client on completion of the
works. Accreditation of the contractor to the NICEIC (National Inspection Council for
Electrical Installation Contracting) is recommended but not essential.

4.6.1 CABLES AND WIRING SYSTEMS

This section identifies the types of cable and wiring systems suitable for use with
refrigeration equipment. It must be remembered that some of them are not suitable for
locations where the temperatures are constantly below 0°C, for example conduit, and
trunking systems.

• Steel Wire Armoured Cable (SWA): Suitable for most applications except in
locations constantly below 0°C. This cable manufactured to BS 6346 is in common
use within the refrigeration industry and is preferred wherever possible both from
the cost and suitability points of view. The method of fixing is by means of
clipping direct to the surface or clipping to the cable tray, the cable is terminated
using the appropriate glands for connection into the various components. SWA
can be purchased in a variety of cable sizes and cores (1.5 mm2 to 95 mm2 and 1
core to 19 cores are the most popular sizes).

• FP200 Fire Resistant Cable: This cable was developed primarily to offer improved
protection against fire and heat damage, allowing it to be installed in high
temperature locations and where there is a requirement for essential services.
However these properties lend themselves to refrigeration applications,
particularly in situations where the temperatures are constantly below 0°C (i.e.,
connection to evaporators and other components within a coldroom/coldstore).
This is mainly because of the butyl rubber insulation covering the cores; the outer
protection being made of plastic coated aluminium.

This type of cable is generally available in sizes 1.0 mm2 ‐ 2.5 mm2 and with a
number of cores from 2+ECC (Earth Conducting Core) to 4+ECC. Fixing is by
means of clips, either direct to a surface, or fastened with nylon cable ties to the
cable tray. On no account is the cable to be strapped to any refrigerant lines.
Termination ferrules are available for connecting to equipment.

• Conduit Systems: There are four types of electrical conduit system:

a) PVC ‐ High impact
b) Steel ‐ Galvanised
c) Steel ‐ Stainless
d) Steel ‐ Black enamelled

The steel versions are not recommended for locations which give rise to humidity
or where the temperatures are constantly below 0°C, for reasons previously
mentioned in this guide.

22
System Installation

Available in standard tubing sizes of 20 mm, 25 mm and 32 mm (OD), comes a
variety of fittings such as pipe saddles, bends, adaptors, reducers, tees and
circular boxes. All these enable the conduit wiring systems to be adapted and
fitted into the installation.
On completion of the conduit work, suitably interconnecting wiring is drawn
through the pipework and connected to the various electrical components. This
cable usually comprises of “single core” PVC or Butyl rubber insulated
conductors.

• Trunking Systems: Like conduit, trunking is available in PVC, galvanised steel,
stainless steel and enamelled steel. Galvanised steel being the one in most

common use. However, plastic trunking may be preferred for humid and
corrosive atmospheres. Sizes are normally available in 1” to 6” plastic, and 2” to
6” steel.

Trunking is appropriate where several electrical items are installed (e.g adjacent
control panels) with numerous cables converging (either from above or below)
from the various parts of the refrigeration system. The final connections with
the individual components being made with conduit or SWA etc.

• Other Forms of Electrical Wiring: These are less frequently used in refrigeration
electrical works.

a) Flexible concentric insulate copper braided cable CY type. This cable has
been used mainly in Europe but is becoming more available in the UK. It
is particularly useful in situations where movement is necessary, as with
connection to moving machinery. However, check the manufacturer’s
specification before installing it in situations where temperatures are
constantly below 0°C. It is available in sizes 0.75 mm2 to 2.5 mm2 and
with 3 to 18 cores.

b) Concentric PVC insulated steel braided cable SY type. As with the
copper braided type mentioned above, this cable has been used mostly in
Europe. With its steel braiding it is particularly suitable for locations
where there is a possibility of impact damage. As with the fabric braided
type or fixed with the special clips supplied by the manufacturer, it can
also run in trunking. The cable is terminated into the components by
means of cable glands, giving a water proof‐dust proof connections.
Available in sizes 0.75 mm to 6.0 mm and with 2 to 16 cores.
c) PVC insulated cable is not recommended for refrigeration purposes, it is
mostly used for domestic installations.

23
System Installation

4.6.2 MAINS SUPPLIES

It is important at the design stage for the correct electrical power supply details and
required loading to be established. An area that is often overlooked at the outset of a
project is the checking that there are sufficient available incoming supplies to meet those
required for the new equipment to be installed. Plus to ensure there is a provision for the
new supply to be brought to the position where the refrigeration equipment is to be
installed.

There are three main types of electrical power supply available in the United Kingdom.

a) 400 V + 10% ‐ 6% 3 Phase 50 Cycles
b) 400 V + 10% ‐ 6% 3 Phase and Neutral 50 Cycles
c) 230 V + 10% ‐ 6% Single Phase 50 Cycles

It should be noted that the voltage references will be ± 10% from January 2003. All
electrical supplies contain an earth.

Ensure that the equipment being installed will operate on one of these supplies.

4.6.3 INTERCONNECTING WIRING AND CABLE ROUTES

The mains power supply is usually run to the condensing unit or pack position, terminating
in either a control panel mounted on the plantroom wall, or directly into the electrical
section of the refrigeration or air conditioning equipment. From these panels
interconnecting wiring is fed out to the various items of equipment making up the
refrigeration system.

In some instances, two separate power supplies are provided. One to operate the
condensing equipment, and the second to operate the cooling/evaporator section; this may
be situated a considerable distance away. With this arrangement interconnecting wiring is
not required, (system designed with facility to pump down).

In both cases it is important to ensure that the final sub circuits are protected by fuses of
the appropriate rating and where necessary with local “lock off” isolation to protect the
engineer safely when completing service or maintenance work.

4.6.4 CABLE SIZING AND VOLTAGE DROP

The dual purposes of sizing cables properly, is to:

(a) ensure that the temperature of the conductor’s insulation does not exceed the
temperature for which it was designed when carrying its rated current carrying
capacity.

24
System Installation

(b) to prevent an excessive drop in the voltage applied to the equipment to which it is
connected.

The current carrying capacity of the conductor is based on there being no obstruction to the
flow of heat from the conductor, thus an equilibrium is reached, and the conductor
maintains a steady temperature.

Full information on the current carrying capacity and voltage drop can be obtained from
Appendix 4 of BS 7671: 2008 (IEE Wiring Regulations) 17th Edition.

4.6.5 EARTHING AND TESTING

Regulation 8 of the Electricity at Work Regulations requires precautions to be taken to
ensure that any conductors of electricity which may become charged as a result of either,
use of a system, or a fault in a system, do not present a danger to persons or property. The
most commonly used method of achieving this is by means of earthing.

It is the practice in the UK for the Public Electricity Supply System to be referenced to earth
by a deliberate electrical connection made at sub stations or power transformer. It is this
means of “system earthing” that enables earth faults on electrical equipment to be detected
and the electrical supply to be cut off automatically. In order to ensure safe system earthing
the following factors must be observed:

• Electrical bonding of exposed conductive parts of refrigeration equipment and their
connection to earth services to limit the shock risk from transient voltages appearing
between various components in the system. Equipment earthing therefore
encompasses the bonding of metallic enclosures, cable armouring, conduits,
trunking etc., so that these conductors are electrically, continuously and securely
connected to the general mass of earth at one or more points.

• Equipotential Bonding: It is essential that all exposed extraneous conductors which
may become electrically charged from a fault on refrigeration equipment are also
connected to the main supply earthing system.

• Inspection and Testing: Before new installations or extensions to existing
installations are put into operation they must be inspected and tested upon
completion to verify that the requirements of the Electricity at Work Regulations and
BS 7671: 2008 (IEE Wiring Regulations) 17th Edition have been satisfied.

Guidance on Inspection and Testing may be found in Part 7 of BS 7671: 2008. On
completion of the inspection and testing process, forms as required by the
regulations must be completed by a qualified and competent person in respect to
the design, construction, and inspection and testing of the installation.

25
System Installation

4.7.0 CONDENSATE DRAINAGE

GENERAL
To ensure satisfactory disposal of condensate from refrigeration equipment, a properly
designed and fitted plumbing system must be installed. This is an area that often does not
get sufficient design consideration and inadequate condensate systems have been installed.
Care has to be taken to avoid fixing condensate pipework close to refrigeration pipework
with the possibility of the pipes becoming frozen and blocked at some stage. If there is no
alternative route away from the refrigeration pipes, then the condensate pipework must be
insulated. Since there is a possibility of sludge building up in the pipework (dust particles
and other objects), the largest size of pipe should be chosen. If blockages and drain
problems are to be avoided where pipework is run within the refrigerated space, it must be
insulated with a refrigeration grade insulation. On installations where the temperature is
0°C and below, a proprietary type of heater tape needs to be wrapped around the
condensate pipework prior to fitting the insulation. The type of heater tape used should be
one which is permanently “on”, therefore supplying a constant heat to the pipework.

At the design stage, notice should be taken of any local bye laws or regulations, particular
site conditions, and requirements for final connections into the mains drainage.

4.7.1 CONDENSATE SYSTEMS AND MATERIALS

Copper and plastic are the two main types of material from which condensate drainage
systems are constructed. Details are as follows:‐

• Copper: Copper tube and fittings manufactured to British Standard BS 2871 are
available in 3 metre and 6 metre lengths in nominal bore sizes from 15 mm
through to 159 mm. Fittings are available for sizes 15 mm ‐ 108 mm in both
solder joint and compression joint.

Pipework in installed using normal plumbing methods including bending of
pipework by mechanical tube bending equipment.

• Plastic: Plastic plumbing systems currently provide the most common method of
installing pipework for condensate drainage. It has several advantages over
other forms, e.g., costs, non corrosiveness, and ease of assembly.

There are several proprietary types on the market, all manufactured to a British
standard. Each type has three main methods of jointing as follows:‐

a) Solvent Weld: This is perhaps the best method utilised, provided care is
taken with the preparation of the joint before applying the solvent.
Pipework is joined by applying solvent to the ends of the pipe and
inserting this into the appropriate fitting i.e., socket, bend etc.

26
System Installation

The solvent bonds the two surfaces together forming a strong water tight
joint. A standard range of fittings and adaptors is available in nominal
bore sizes from 19 mm ‐ 50 mm, all manufactured to BS 5254.

b) Compression: This type of joint utilises a knurled nut and rubber collar
which fits over the pipe. The pipe is first inserted into the socket of the
appropriate fitting, with the knurled nut then tightened onto the
threaded portion of the fitting. The rubber collar is compressed between
the nut and the fitting forming the water tight joint. A standard range of
fittings and adaptors is available in nominal bore sizes 32, 40, 50 mm.

c) Push Fit Ring Seal Type: This form of joint relies on the neoprene ring
seal forming a water tight joint when the pipe end is inserted into the
socket of the fitting. Standard. fittings are available in nominal bore sizes
32, 40, 50 mm. Use of this plumbing system is not recommended for
refrigeration applications because of the susceptibility to movement, and
the weakness of this type of joint,.

4.7.2 GRAVITY DRAINAGE

This method of condensate drainage depends upon the fall or slope of the pipework away
from the equipment and is the most commonly used. This is particularly important where
there is restricted space (i.e., under refrigerated cases).

When installing a gravity drainage system some thought needs to be given during the
design, to dismantling for cleaning and maintenance purposes. Pipework also needs to be
fixed at appropriate points so that low points are not allowed to form. Finally the
connection into the mains drainage system must be “trapped” just before the connection.

4.7.3 PUMPED CONDENSATE DRAINAGE

There are numerous arrangements, from collection pans fitted with float switches which
control the operation of a pump to small self contained pumps (with electronic sensors)
which can be fitted directly into the air handling unit:

• The pipe or tubing used on this type of installation is of a small diameter, usually
between 6 mm and 12 mm nominal bore depending on the application and the size
of the pump. It is normally made from clear polythene, is very flexible, and is
supplied in standard 50 metre bundles. A more expensive type is available where
nylon braiding is laminated into the polythene tube to give more strength and less
susceptibility to kinking. Preferable condensate drainage tubing is Black plastic that
excludes daylight and hence discourages growth of slime inside, however is not
always available in the size/s required.

27
System Installation

• Where condensate pipework is to be connected into mains drainage system, a tun
dish which is connected into the mains drainage via a trapped gravity pipework
arrangement should be provided.

• A separate electrical supply (independent from the supply to refrigeration
equipment) should be installed for the condensate pump to allow the condensate to
be pumped away should the refrigeration electrical supply be interrupted.

• Any condensate drainage installed in coldrooms operating below 0C will require
trace heating

4.8.0 PRE‐COMMISSIONING SYSTEM TESTING AND PREPARATION

System testing and preparation must be included in the installation program and at an early
stage there must be determination whether or not to complete these tasks in phases, may
be due to access or requirement for part system start up, or at the end of all installation
work. These tasks shall be prior to the commencement of the commissioning stage and
putting systems into service.

System testing shall cover pressure testing for mechanical strength and leak tightness test to
permit detection of leaks.

Components, e.g. compressors, condensers, evaporators, pressure valves, safety valves and
control gear, which have been previously strength tested by a manufacturer need not be
subject to a further strength test. Manufacturer’s certificates should be obtained and
included to system and operation manuals.

Strength tests will normally be carried out before a leak tightness test, using oxygen free
nitrogen (OFN) or other inert gas. Oxygen, air, ammonia, fluorocarbons, combustible gas or
any combustible mixture shall not be used as a strength test medium

Refer to design documentation for details of pressures to be achieved with time periods for
the mechanical strength and leak tightness test. These shall comply with BSEN378:2008.
If there is a need to complete a leak tightness test prior to strength test to confirm system
or part system integrity this test shall be completed at very low pressure, say 5% of design.

The leak tightness test shall be carried out with oxygen free nitrogen (OFN) or a mixture of
OFN and a tracer. The tracer should be zero ODP and low GWP. Mixtures of HCFCs or HFCs
with air should not be used

All joints shall be checked for leaks using either a leak detecting bubble spray or an
electronic leak detector suitable for use with the tracer.

Following satisfactory testing, test certificates shall be completed and included to system
operation end user manual.

28
System Installation

The BRA Task Procedures & Risk Assessments cover the following tasks to be completed
prior to commencement of commissioning and system start up:‐

• A strength and leak pressure test must be carried out on the entire system. See task
procedure and risk assessment R10 and R14.

• A vacuum drawn on the whole system including condensing unit, pack etc to at least
2 mm HG. See task procedure and risk assessment R9.

• The correct grade of refrigeration oil should be added as required according to the
manufacturer’s instructions for the compressor, oil separator, and oil control system,
where fitted. See task procedure and risk assessment R15.

• The vacuum should be broken by charging the system with the correct refrigerant for
that particular application. See task procedure and risk assessment R6.

For further guidance on strength pressure and leak tightness testing refer to BSEN 378
1:2008 and BSEN 378 2:2008. In addition refer to the IOR Safety Code for Refrigerating

Systems using A1 Refrigerants which is a comprehensive guide bringing together a number
of regulations and directives that should be complied with.

Leak tightness pressure test to permit detection of leaks and then demonstrate system
integrity to contain refrigerant, along with refrigerant charging, reclaiming, leak detection
methods including labelling and records shall comply with the F‐Gas regulations No
842/2006. Refer to BRA Code of Practice for Refrigerant Leak Tightness published 2007 for a
comprehensive interpretation of regulation into practice.

4.9.0 DRAWINGS

Please refer to 'Section 4 Drawings' which is at the back of this document.
HU UH
Drawing titles are:‐

‐ Liquid Distribution ‐ Header Method
‐ Liquid Distribution ‐ Ring Main Method
‐ Liquid Distribution ‐ Reducing Method
‐ Liquid Trap
‐ Swaged Joints
‐ Standard Brazing Equipment

4.10.0 APPENDICES

Acknowledgement of References, Standards and Legislation

ACRIB Air Conditioning, Refrigeration Industry Board
BRA British Refrigeration Association
29
System Installation

CITB Construction Industry Training Board
C&G City & Guilds qualifications.
IOR Institute of Refrigeration
NICEIC National Inspection Council for Electrical Installation Contracting
TREM Transport Emergency Card
UKAS United Kingdom Accreditation Service

BRA Documents
Code of Practice for Refrigerant Leak Tightness in compliance with F‐Gas
regulations – issue 1.

Model Statements of Task Procedures and Risk Assessments for Commercial
Refrigeration – issue 3.

Jointing of Copper for Refrigeration Systems – issue 2.

Fact Finders, Good Practice Guides.

IOR Documents
Safety Code for Refrigerating Systems using A1 Refrigerants.

Service Engineer Guides

Regulations
CDM – Construction (Design & Management) 2007
COSHH ‐Control of Substances Hazardous to Health 2002
Electricity at Work 1989
Environmental Protection Act 1990
Environmental Protection (Control of substances that deplete the ozone
layer)
F‐Gas 842/2008
Health & Safety at Work Act 1974
PSS ‐Pressure Systems Safety Regulations: 2000
PED – Pressure Equipment Directive 97/23/EC
PUWER – Provision and Use of Work Equipment
GN4 – Safety in Pressure Testing guidance note

Standards
BS EN378:2008 parts 1/2/3/4, Refrigerating Systems and Heat Pumps – Safety
and Environmental requirements.
BS EN 12735‐1:2001 Copper Tube for Air Conditioning & Refrigeration.
BS 3799 – 1974 Specification for Steel Pipe Fittings, Screwed & Sockets.
BS EN 10204:2004 Metallic Materials.
BS EN 14276‐2:2007 Pressure Equipment for Refrigerating Systems and Heat
Pumps – Piping.
BS EN 287‐1:2004 – Approval Testing of Welders for Fusion Welding.
30
System Installation

BS EN 10253‐2:2007 Butt Welding Pipe Fittings. Non Alloy & Ferritic Alloy
Steels with Inspection Requirements.
BS EN 15614‐1:2004 Specification and Qualification of Welding procedures
for Metallic Materials.
BS EN 1515‐1:2000 Flanges and their Joints. Bolting.
BS 7671:2008 IEE Wiring Regulation – 17th Edition
BS 6346:1997 Electric cables
BS 5254:1976 Polypropylene Waste Pipe & Fittings
EN 1044:1999 Brazing, Filler Metals.
PD 5500:2006 Specification for unfired fusion welded pressure vessels

31
System Installation

Section 4 Drawings
32
System Installation
33
System Installation
34
System Installation
35
System Installation
36
System Installation

37
System Installation

38
System Installation

This Guide is published in the following Parts:

Part 1 Introduction
Part 2 System Design and Component Selection
Part 3 Safety Regulations, Standards and Directives
Part 4 System Installation
Part 5 System Commissioning
Part 6 System Maintenance and Service
Part 7 System and Component Decommissioning and Waste Disposal
Part 8 Refrigerants and Retrofitting
Part 9 Assessment of Skills Related Competence and Training

The BRA and IOR disclaim all liability to any person for anything or for the consequences of
anything done or omitted to be done wholly or partly in reliance upon the whole or any part
of the contents of this Guidance document.
39
System Installation

Published By:

British Refrigeration Association
2 Waltham Court, Milley Lane, Hare Hatch, Reading, Berkshire, RG10 9TH United Kingdom
Tel No: + 44 (0)118 940 3416 ‐ Fax No: + 44 (0)118 940 6258
e‐mail: [email protected]
HU U
Institute of Refrigeration
Kelvin House, 76 Mill Lane, Carshalton, Surrey SM5 2JR, Tel No: +44(0)2086477033 ‐ Fax
No: +44 (0)20 8773 0165
e‐mail: [email protected]
HU UH
40

Guide To Good Commercial Refrigerant Practice

Uploaded by

Copyright:

Available Formats

Guide To Good Commercial Refrigerant Practice

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Guide To Good Commercial Refrigerant Practice

Uploaded by

Copyright:

Available Formats

What safety precautions should be taken when installing refrigeration systems?

What are the responsibilities of operatives on site?

You might also like