Chapter 10 - Hydronics

WHAT IS HYDRONICS?
Hydronics is the use of a liquid heat-transfer medium in heating
and cooling systems. The working fluid is typically water, glycol,
or mineral oil. Some of the oldest and most common examples
are steam and hot-water radiators. Historically, in large-scale
commercial buildings such as high-rise and campus facilities, a
hydronic system may include both a chilled and a heated water loop,
to provide for both heating and air conditioning. Chillers and cooling
towers are used either separately or together as means to provide
water cooling, while boilers heat water. A recent innovation is
the chiller boiler system, which provides an efficient form
of HVAC for homes and smaller commercial spaces.
Part 1 – Steam and Water Piping
Steam and Water piping systems that are part of a
heating or cooling system shall comply with the
following requirements.
Those piping systems which the pressure does not
exceed 160psig(1,103kPa) and the temperature does not
exceed 250°F (121°C) shall comply with the following
requirements:
 Materials and Construction
• Pipe - Pipe shall be brass, copper, cast iron, galvanized or black
wrought iron, galvanized or black steeal.
• Tubing - Tubing shall be copper water tube.
• Valves - Valves up through 2 inch (50 mm) in size shall be brass,
malleable iron, or steel bodies. Each gate valve shall be full-way with
working parts of non-corrosive metal.
• Fittings – Plain screwed fittings shall be brass, bronze, cast iron.
Fittings also for copper tubing shall be wrought copper/bronze.
• Pipe Joint Compound – Pipe Join compound shall be non corrosive
and insoluble in the material being carried in the pipe.
• Protective Coatings – Protective coatings shall be watertight,
durable, heat resistant, electrically nonconductive, and tightly
adherent to the pipe.
• Fluxes – Fluxes for solder, sweat , and brazed joints shall be a
noncorrosive type and suitable for the use intended.
 Materials and Construction
• Insulation – Coverings or insulation used on hot water or steam
pipes shall be materials suitable for the operating temperature of
the system. Insulation coverings and linings shall not flame, glow,
smolder or smoke when tested. In no case the test shall be
temperature below 250°F(121°C).
• Flashing Material - Flashings shall be lead, copper, galvanized iron.
• Gaskets – Flange gaskets shall be metal or asbestos.
• Sleeves - Sleeves shall be steel , cast iron, wrought iron pipe or tile.
• Marking – Materials and devices shall be suitably identified. In
addition to the incised marking required in standards, all hard
drawn copper in accordance with the applicable standard.
Color coding :
Type L – Blue Type K – Green
Type M – Red Type ACR – Blue
Type DWV - Yellow
 Fabrication of Joints
• Screwed Joints - Threads on iron pipe size shall be standard taper
pipe threads. All burrs shall be removed. Pipe ends shall be reamed
or filed out to the full size of bore, and all chips shall be removed.
• Solder Joints – Surface to be joined b soldering shall be cleaned
bright by manual or mechanical means. The joint shall be properly
fluxed.
• Welded Joints - Welding shall be performed in accordance with
nationally recognized standards.
• Flanged Joints - Flanged joints shall be tightened evenly and
provided with suitable nuts, bolts and gaskets.
 Connections
• Brass and Copper Piping / Cast-Iron Piping / Black Wrought Iron
Piping / Black Steel Piping – Joints in brass and copper piping shall
be threaded, brazed, welded, flanged or mechanical type.
• Asbestos Cement Piping – Joints in asbestos cement piping shall be
mechanical type and suitable for the service temperature intended.
• Copper Water Tubing – Joints in copper tubing shall be soldered,
brazed or flared, except that joints under a building and in or under
any concrete slab resting on the ground shall be silver brazed, or
equal and fittings shall be wrought copper.
• Piping to Tubing – Joints connecting piping to tubing shall be made
with adapter fittings.
 CHANGES IN DIRECTION
- Changes in direction shall be made by the appropriate use of
fittings, except that changes in direction in copper tubing may be made
with bends having a radius not less than 6 diameters of the tubing,
provided such bends are made by the use of forming equipment that
does not deform or reduce appreciably the cross-sectional area of the
tubing.
HANGERS AND SUPPORT
- All piping and equipment shall be adequately supported to the
satisfaction of Authority Having Jurisdiction. Hot Water and steam
piping shall be supported, anchored and provided with swing joints,
avoid excessive strain piping, equipment or the building structure.
• Vertical Piping Attachment - vertical piping and tubing shall be
secured at sufficiently close intervals to keep the pipe in alignment
and carry the weight of the pipe and contents.
• Horizontal Piping - Piping and tubing in the ground shall be laid
on a firm bed for its entire length.
 Installation
• Same Materials Required – All piping materials used, except valves
and similar devices, shall be of like material except as otherwise
acceptable to the Authority Having Jurisdiction.
• Wall Thickness
• - Piping shall be at least standard weight of the brass or copper, Class
150 cast iron, standard weight of the wrought iron, ASTM schedule 40
steel or suitable asbestos cement of adequate pressure rating.
• - Tubing shall be at least TYPE K for condensate return lines; TYPE L
for steam condenser cooling water lines, underground water lines, and
aboveground waterlines; TYPE M for aboveground water lines not
embedded in concrete or masonry.
• Piping Embedded in Structure – Piping shall not built into or
embedded in concrete or masonry, except where used for
radiant panel heating or cooling.
• Cutting Structure – Structural members shall not be seriously
weakened or impaired by cutting or notching.
 Installation
• Providing for Expansion Contraction and Settling – Piping shall be
installed so that piping, connection and equipment shall not be
subjected to excessive strains or stresses, and provisions shall be
made for expansion, contraction, shrinkage & structural settelement
• Circulation – Piping shall provide adequate circulation. Piping shal
be graded so that all gases can move in the direction of the water
flow to a vented section of the system.
• Under ground Piping
• - Cinders and Other Corrosive Material Fills- All piping shall be
passing through or under cinders or other corrosive fill materials shall
be protected from corrosion.
• - Beneath Building – Piping installed within a building resting on the
ground shall installed follows: Ferrous Piping, Copper Tubing,
Asbestos Cement.
• - Outside of the Building – Black wrought iron and black steel ,
Asbestos cement.
- Under Walls or Foundations - piping passing under walls or
foundations shall be protected from breakage.
- Openings into Buildings – Voids around piping passing
through concrete or masonry floors or walls shall be
appropriately sealed at the opening into the building.

• Aboveground Piping
- Sleeves – sleeves shall be provided to protect all piping through
concrete and masonry walls.
- Insulation – Temperature of surfaces within normal reach shall not
exceed 140°F (60°C) unless they are protected by suitable insulation.
- Lining – Combustible portions of unventilated spaces that contain
piping or devices whose outside temperature, including insulation
exceeds 140°F shall be line with gauge No. 24.
- Clearance – There shall be at least 1 inch clearance around pipes.
- Exposed Piping – Exposed piping subject to excessive corrosion shall
be suitable protected.
- Asbestos Cement – Piping shall not be installed within building.
- Roof and Wall Openings – Joints at the roof around pipes or
appurtenances shall be made watertight by the use of approved
flashings or flashing material. Exterior wall openings shall be
watertight.
- Drainage – means shall be provided to drain all the pipings.
TRENCHES AND TUNNELS
 Protection of Structure – trenches deeper than the footings of a

building or structure and paralleling the same.

 Mechanical Equipment – use of mechanical excavating equipment

is prohibited within 2 ft. of existing piping or appurtenances.

 Tunneling and Driving – Tunnels shall, before backfilling, have a

clear height of 2feet above the pipe and shall be limited in legth
one-half the depth of the trench , with the max. height of 8ft.
 Backfilling – Excavations shall be completely backfilled as soon

after inspection as practicable. Adequate precaution shall be taken

to ensure proper compaction of backfill around piping without
damage to such piping. Trenches shall be backfilled in thin layers to
12 inches above the top of the piping with clean earth that shall not
contain stones, boulders, cinder fill, or other materials that would
damage, break the piping or cause corrosive action.
 PRESSURE TESTING
 Responsibility – The equipment, material, and labor
necessary for inspection or test shall be furnished by the
person to whom the permit is issued or by whom inspection
requested
 Media – The piping shall be tested with water.
 Pressure Test - Piping shall be tested with a hydrostatic
pressure of not less than 100psig(689kPa) but at least 50
psig (345kPa) greater than operating pressure. This
pressure shall be maintained for at least 30mins. Required
test shall be conducted by the owner or contractor in the
presence of an authorized inspector.
 Exceptions – In cases where it would be impractical to
provide the aforementioned tests, or for minor installations
and repairs.
 - Those portion of the hot water piping systems in which
the continuous pressure temperature relationship does not
exceed the following maybe constructed of Polybutylene pipe
or tubing of SDR-11 conforming to specifications ASTM D
3309.

Temperature Pressure
°F °C Psi kPa
73 23 200 1379
180 82 100 689
200 93 8 55

Polybutylene also may be used for applications requiring up to 1

year total exposure at conditions of 210°F(99°C) 150psi
(1027kPa) typical conditons for temperature and pressure relief
valve discharge line in heating systems.
Part 2 – Hydronic Panel Cooling Systems

SCOPE. The purpose of this part is to establish and provide

minimum standards for the protection of the public health,
welfare, and property by regulating and controlling the design
and installation of panel cooling system.

INSTALLATION. Panel systems shall be designed and

installed in accordance with installation standards, and
requirements of this code. Piping to be embedded in concrete
shall be pressured tested prior to pouring concrete. During
pouring, the pipe shall be maintained at the proposed
operating pressure.
 PIPING MATERIALS
PANELS. Piping for cooling panels shall be standard wight
steel pipe, TYPE L copper tubing or approved plastic pipe or
tubing rated at 100psi(689kPa) at 180°F(82°C)
COOLING WATER SUPPLY LINES. Piping for cooling water
supply lines shall be installed according to requirements.
PIPING JOINTS. Joints of the pipe or tubing forming the panel
that are embedded in a portion of the building, for example
concrete or plaster, shall be in accordance with the ff:
Steel pipe welded with electrical arc or oxygen or acetylene
method. Copper tubing joined with the brazing alloys having a
melting point above 1000°F(538°C).
HEAT SOURCES. Cooling sources for generating cold water
for use in hydronic panel radiant cooling system in Chapter 12,
air/water or water/water heat pumps , or solar heat cooling
systems. The latter system may include booster or backup
cooling units. Systems also shall be protected by pressure
temperature relief values.
TESTING. Approved piping or tubing installed as a portion of
a radiant panel system that will be embedded in the walls,
floors , or ceilings of the building it is designed to cool shall be
tested for leaks by the hydrostatic test method by applying at
least 100psi ( 689kPa) water pressure or 1.5 times the operating
pressure, whichever is greater.
For metal piping, a pressure gauge shall be connected to
the piping, and after the pressure has been raised, the
hydrostatic pressure connection shall be discontinued and the
sysytems under pressure shall remain at the test pressre for a
sufficient period of time to determine whether any leaks exists
in the system. Leaks indicated by pressure drop on the gauge.
The minimum test period shall be 30mins.
For plastic piping, the test pressure shall be applied a
period of 30mins. During this time, the system shall be
maintained at the test pressure by the periodic addition of
makeup water to compensate for the initial stretching of the
pipe. The system shall then be visually inspected the tightness.