1、PUBLISHED DOCUMENTPD CEN/TR 15545:2006Guide to the use of EN 545ICS 23.040.10; 23.040.40g49g50g3g38g50g51g60g44g49g42g3g58g44g55g43g50g56g55g3g37g54g44g3g51g40g53g48g44g54g54g44g50g49g3g40g59g38g40g51g55g3g36g54g3g51g40g53g48g44g55g55g40g39g3g37g60g3g38g50g51g60g53g44g42g43g55g3g47g36g58PD CEN/TR 15
2、545:2006This Published Document was published under the authority of the Standards Policy and Strategy Committee on 28 February 2007 BSI 2007ISBN 978 0 580 50146 3National forewordThis Published Document was published by BSI. It is the UK implementation of CEN/TR 15545:2006.The UK participation in i
3、ts preparation was entrusted to Technical Committee PSE/10, Iron pipes and fittings.A list of organizations represented on PSE/10 can be obtained on request to its secretary.This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct
4、 application.Amendments issued since publicationAmd. No. Date CommentsTECHNICAL REPORTRAPPORT TECHNIQUETECHNISCHER BERICHTCEN/TR 15545December 2006ICS 23.040.10; 23.040.40English VersionGuide to the use of EN 545Guide dutilisation de lEN 545 Anleitung zur Anwendung der Norm EN 545This Technical Repo
5、rt was approved by CEN on 28 August 2006. It has been drawn up by the Technical Committee CEN/TC 203.CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxe
6、mbourg, Malta, Netherlands, Norway, Poland, Portugal, Romania,Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMIT EUROPEN DE NORMALISATIONEUROPISCHES KOMITEE FR NORMUNGManagement Centre: rue de Stassart, 36 B-1050 Brussels 2006 CEN All rights
7、 of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. CEN/TR 15545:2006: E2 Contents Page Foreword3 1 Scope 4 4.1.4 Materials in contact with water intended for human consumption4 6.6 Zinc mass .4 7 Performance test methods .5 7.1 Compressive strength of t
8、he cement mortar lining .5 7.2 Leak tightness of flexible joints to positive internal pressure5 7.3 Leak tightness of flexible joints to negative internal pressure.6 7.4 Leak tightness of flexible push-in joints to positive external pressure.6 7.5 Leak tightness of flexible joints to dynamic interna
9、l pressure.6 7.6 Leak tightness and mechanical resistance of flanged joints6 7.7 Leak tightness and mechanical resistance of screwed and welded flanges 6 Annex F (informative) Quality assurance.7 F.1 Performance tests 7 F.2 Manufacturing process 7 F.2.1 Quality Control.7 F.2.2 Initial performance te
10、sting7 F.2.3 Factory Production Control System8 F.2.3.1 Organisation8 F.2.3.2 Control system8 F.2.3.3. Document control10 F.2.3.4 Process control.11 F.2.3.5 Inspection and testing .11 F.2.3.6 Non-conforming products .11 Bibliography 12 CEN/TR 15545:20063 Foreword This document (CEN/TR 15545:2006) ha
11、s been prepared by Technical Committee CEN/TC 203 “Cast iron pipes, fittings and their accessories”, the secretariat of which is held by AFNOR. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN and/or CENELEC shall not be held r
12、esponsible for identifying any or all such patent rights. EN 545 deals with components of piping systems for water - pipes, fittings and joints which, together, form the part of a water network. Each of these components can be manufactured by a different supplier, which is often the reality; the per
13、formances and the tests required by EN 545, although perfectly comprehensive, are not always formulated with enough accuracy to be easily used in every real situation occurring the market. In regard to quality assurance, the attestations and certifications of conformity to the standards available on
14、 the markets: attestation of compliance to the performance tests; certification of conformity of the products of a batch; certification of conformity to EN ISO 9001 of the supplier; national quality or conformity marks; third party certification of conformity of products to a standard, self-declarat
15、ion of conformity to a standard by the supplier for products that he sells, have different meanings for the customer, who generally needs all products to be fully in compliance with this standard. CEN/TR 15545:20064 1 Scope EN 545 specifies the requirements and associated test methods applicable to
16、ductile iron pipes, fittings, accessories and their joints for the construction of pipelines: to convey water (e.g. potable water); with or without pressure; to be installed below or above ground. In respect to potential adverse effects on the quality of water intended for human consumption, caused
17、by the product covered by this standard: this standard provides no information as to whether the product may be used without restriction in any of the member states of the EU or EFTA; it should be noted that, while awaiting the adoption of verifiable European criteria, existing national regulations
18、concerning the use and/or the characteristics of this product remain in force. This technical report: explains in more detail the process of testing for the performance tests; explains in more detail the definitions of the different types/levels of attestation to enable customers to ensure their req
19、uirements are fulfilled; explains in more detail the ways of certification of conformity with EN 545 for a reliable evaluation of the performance of the products. In order to make the use of this Technical Report easier, the clauses of this document refer to the corresponding clause numbers in EN 54
20、5. 4.1.4 Materials in contact with water intended for human consumption A comprehensive potability regulation concerning components of pipes systems means: regulatory obligation ( i.e.: decree, law.); technical specifications; tests methods to verify the compliance with the technical specifications;
21、 directory of approved laboratories able to carry out these tests. On October the 1st2005, there was a national regulation in the following countries: Austria, France, Germany, Italy, Netherlands, Switzerland and United Kingdom. In all cases, the national regulations remain in force and must be foll
22、owed. 6.6 Zinc mass EN 545 states that a rectangular token of known weight per unit area shall be attached longitudinally along the axis of the pipe before passing through the coating equipment. After zinc coating and trimming, the size of the CEN/TR 15545:20065 token shall be 500 mm x 50 mm. It sha
23、ll be weighed on a scale having an error limit of 0,01g. The mean mass is then determined in accordance with the remainder of clause 6.6. As this test can only be carried out in the factory, conformity certification using this test method can only be acquired and granted in the factory during the ma
24、nufacturing process and not on a batch of finished products. 7 Performance test methods 7.1 Compressive strength of the cement mortar lining This test should be carried out using the actual constituents used in the manufacture of the cement mortar for the pipes. As such the sand, cement and water sh
25、ould be sampled from the dispensing/holding facilities in the factory. Similarly, the sand/cement/water ratios should be identical to those used in the manufacturing process (in the case of the sprayed mortar process, these ratios are identical to the ratio in the mortar mixer, whereas for the centr
26、ifugal process, these ratios are those found in the compacted lining after centrifugal spinning). Third party accreditation can thus only be granted once these strict conditions have been established and it is for this reason that it is recommended that these tests be only carried out in the factory
27、. 7.2 Leak tightness of flexible joints to positive internal pressure The test shall be carried out in accordance with clause 7.2 of EN 545 on an assembled joint comprising two pipe sections, each at least 1 m long. It shall be carried out separately for other components such as fittings if their so
28、cket differs from that of the spun pipes. For such a test a flange-socket fitting (see 8.3.1 of EN 545) shall be bolted to a flanged pipe of sufficient length to satisfy the requirements of clause 7.2. Tests shall be carried out on both unrestrained and restrained joints as necessary. Short and long
29、 term characteristics of the rubber for the gaskets shall be shown to be in compliance with EN 681-1. Relevant designs of socket and gasket throughout all possible tolerance combinations shall: ensure leak tightness at minimum compression under shear and/or angular deflection; ensure both leak tight
30、ness and satisfactory anchorage under shear and/or angular deflection. The short and long term characteristics of the rubber for the gaskets shall be shown to be in compliance with EN 681-1. Using an established gasket, the relevant designs of sockets/spigots shall be shown to be compatible througho
31、ut all possible tolerance combinations (see clause 7.2.3) and shall: ensure leak tightness at minimum compression under shear and/or angular deflection; ensure both leak tightness and satisfactory anchorage (restrained joint) under shear and/or angular deflection especially important where different
32、 suppliers of pipes/fittings and gaskets are involved. The following joint parameters are considered vital to the performance of a joint and shall be checked to be in accordance with the relevant specifications: wall thickness; external diameter of spigot; socket internal functional diameters; depth
33、 of socket; gasket diameters and thicknesses. CEN/TR 15545:20066 7.3 Leak tightness of flexible joints to negative internal pressure See 7.2 7.4 Leak tightness of flexible push-in joints to positive external pressure See 7.2 7.5 Leak tightness of flexible joints to dynamic internal pressure See 7.2
34、7.6 Leak tightness and mechanical resistance of flanged joints This test shall be carried out in accordance with clause 7.6 of EN 545 on an assembly comprising two pipes or fittings with identical flanges, together with a relevant gasket and bolts recommended by the manufacturer. It is important tha
35、t rubber gaskets shall be shown to have the short and long term properties as defined in EN 681-1, in particular that the hardness (IRHD) is within specification. Similarly it is important that the manufacturers jointing instructions are followed for each particular gasket/material in regard to torq
36、ue values and lubrication for the bolts. The sealing of flange joints depends on many factors and the manufacturer should have written specifications for: flange joint faces surface finish, flatness, permissible irregularities; flange jointing materials bolt lengths/grades, recommended gasket materi
37、als; jointing instructions bolt torques, lubrication, bolt tightening sequence. 7.7 Leak tightness and mechanical resistance of screwed and welded flanges This test shall be carried out in accordance with clause 7.7 of EN 545 on an assembly comprising two pipes with identical flanges together with a
38、 relevant gasket and bolts. This test is primarily a strength test for the weld/screwed connection and as such is very demanding twice the working pressure (PFA) combined with four times the design bending moment. The test is carried out on a pipe purposely machined to its minimum thickness. The pip
39、es must be of sufficient length to allow the imposition of the high bending moment: minimum 6 DN or 4 000 mm, whichever is the smallest. Because the elevated pressures and bending moments, applied in the test, result in loadings well in excess of normal service, special gaskets and/or bolts may be u
40、sed for the test in order to attain the high stress on the weld/screwed connection. Because this is a specialist test on pipes that can only be welded/screwed by the manufacturer, the test can usually only be carried out and third party certified in the factory. CEN/TR 15545:20067 Annex F (informati
41、ve) Quality assurance EN 545 defines that the manufacturer has the responsibility to demonstrate the conformity of his or her products with this standard by: carrying out performance tests, and controlling the manufacturing process. F.1 Performance tests The performance tests specified in clauses 5
42、and 7 of EN 545 are carried out either by the manufacturer or, at his or her request, by a competent testing institute in order to demonstrate compliance with the requirements of that standard. Full reports of these performance tests are retained by the manufacturer as evidence of compliance. The pe
43、rformance tests alone are not proof of the product conformity with the standard; they are absolutely necessary, but are only one part of the much wider conformity requirements set out in EN 545. F.2 Manufacturing process F.2.1 Quality Control It is recommended that: manufacturers quality system conf
44、orms to EN ISO 9001; certification body is accredited to EN ISO/IEC 17021 by an accreditation body which has signed the European Accreditation agreement; If third party certification is involved to deliver an attestation of conformity of the products to EN 545, it is recommended that the certificati
45、on body is accredited to EN 45011 by an accreditation body which has signed the European Accreditation agreement F.2.2 Initial performance testing Samples of prototypes (pipes, fittings and joints) for each range of DN (see Table F.1) should pass all the performance tests listed in Table F.1 to demo
46、nstrate conformance with clause 5, before production commences. Tests are normally carried out with the manufacturers calibrated equipment. In case of significant changes in design of the product and/or in manufacturing process, which would change the properties of the finished product, the relevant
47、 performance tests should be repeated. In addition, the performance tests in accordance with clause 7 of EN 545 may be carried out by a competent third party, accredited in accordance with EN 45011 in order to demonstrate compliance with the requirements of EN 545. Full reports of these performance
48、tests are retained by the manufacturer as evidence of compliance and upon request are to be made available for examination. CEN/TR 15545:20068 Table F.1 Performance tests for pipes, fittings and joints Characteristic to be tested Number of samples (minimum) Test method in accordance with Requirement
49、s in accordance withInternal pressure strength 1 per DN Calculation Annex A 4.7 Leak tightness of joints 1 of each DN grouping To internal hydrostatic pressure To negative internal pressure To positive external pressure To cyclic internal pressure DN 40 to DN 250 DN 300 To DN 600 DN 700 to DN 1 000DN 1 100 To DN 2 000 7.2 7.3 7.4 7.5 5.2 and 5.3 Compressive strength of the cement mortar lining 6 per mortar type 7.1 4.4.3.2 Leak tightness of flanged joint 1 of each DN grouping like abov
