1、BS EN 489:2009ICS 23.040.01; 91.140.60NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAWBRITISH STANDARDDistrict heating pipes Preinsulated bondedpipe systems fordirectly buried hotwater networks Joint assembly forsteel service pipes,polyurethane thermalinsulation and outercasing
2、 of polyethyleneThis British Standardwas published under theauthority of the StandardsPolicy and StrategyCommittee on 31 May 2009 BSI 2009ISBN 978 0 580 57358 3Amendments/corrigenda issued since publicationDate CommentsBS EN 489:2009National forewordThis British Standard is the UK implementation of
3、EN 489:2009. Itsupersedes BS EN 489:2003 which is withdrawn.The UK participation in its preparation was entrusted to TechnicalCommittee RHE/9, Insulated underground pipelines.A list of organizations represented on this committee can be obtained onrequest to its secretary.This publication does not pu
4、rport to include all the necessary provisionsof a contract. Users are responsible for its correct application.Compliance with a British Standard cannot confer immunityfrom legal obligations.BS EN 489:2009EUROPEAN STANDARDNORME EUROPENNEEUROPISCHE NORMEN 489March 2009ICS 23.040.01 Supersedes EN 489:2
5、003 English VersionDistrict heating pipes - Preinsulated bonded pipe systems fordirectly buried hot water networks - Joint assembly for steelservice pipes, polyurethane thermal insulation and outer casingof polyethyleneTuyaux de chauffage urbain - Systmes bloqus de tuyauxprisols pour les rseaux deau
6、 chaude enterrsdirectement - Assemblage prisol pour tube de service enacier, isolation thermique en polyurthane et tube deprotection en polythylneFernwrmerohre - Werkmig gedmmteVerbundmantelrohrsysteme fr direkt erdverlegteFernwrmenetze - Rohrverbindungen fr Stahlmediumrohremit Polyurethan-Wrmedmmun
7、g und Auenmantel ausPolyethylenThis European Standard was approved by CEN on 31 January 2009.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date
8、lists and bibliographical references concerning such nationalstandards may be obtained on application to the CEN Management Centre or to any CEN member.This European Standard exists in three official versions (English, French, German). A version in any other language made by translationunder the res
9、ponsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as theofficial versions.CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,France, Germany, Greece, Hungary, Ice
10、land, Ireland, Italy, Latvia, Lithuania, Luxembourg, 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: Avenue Mar
11、nix 17, B-1000 Brussels 2009 CEN All rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 489:2009: EBS EN 489:2009EN 489:2009 (E) 2 Contents page Foreword 4Introduction . 51 Scope 72 Normative references 73 Terms and definitions . 84 Requirement
12、s . 84.1 General requirements 84.1.1 General requirements for the joint . 84.1.2 Installation of the joint 94.1.3 Competence of the welder and fitter 94.1.4 Expected thermal life and long term temperature resistance . 94.1.5 Steel service pipe weld . 94.1.6 Polyurethane rigid foam insulation (PUR) 9
13、4.1.7 Joint casing 94.2 Type test requirements . 104.2.1 Water tightness 104.2.2 Soil stress test . 104.2.3 Polyurethane rigid foam insulation (PUR) properties 104.2.4 Weld joint stress crack resistance . 104.3 Installation instructions 114.3.1 General 114.3.2 Work environment . 114.3.3 Cleaning 114
14、.3.4 Surveillance system 114.3.5 Steel site weld 114.3.6 Joint casing 114.3.7 Joint insulation 115 Methods for type tests 125.1 Soil stress test . 125.2 Water impermeability test . 155.3 Weld joint stress crack resistance test . 155.4 Polyurethane rigid foam insulation (PUR) 155.4.1 General 155.4.2
15、Test specimens 155.4.3 Sampling . 165.4.4 Ageing resistance 165.4.5 Cell structure 165.4.6 Foam density 165.4.7 Water absorption at elevated temperature 176 Marking . 176.1 General 176.2 Joint casing 176.3 Plugs . 176.4 Joint insulation system . 18Annex A (normative) Fusion welding of steel service
16、pipes on site 19A.1 General 19A.2 Material . 19A.3 Welding process 19BS EN 489:2009EN 489:2009 (E) 3 A.4 Preparation for welding and lining up . 19A.5 Qualification of welders 19A.6 Steel weld inspection 20A.6.1 General 20A.6.2 Leak-tightness test with air/gas . 20A.6.3 Leak-tightness test with wate
17、r . 20A.6.4 Radiographic examination 20A.6.5 Ultrasonic examination . 20Annex B (informative) General guidelines for inspection of the joint on site 21Annex C (informative) Qualification of fitters installing joints in preinsulated bonded pipe networks 23C.1 Knowledge and skills 23C.2 Background for
18、 training and testing . 23C.3 Subjects for training and testing . 23C.3.1 General 23C.3.2 Casing of polyethylene (PE) . 24C.3.3 Surveillance 25C.3.4 PUR-foam system 25C.3.5 Joint types/jointing systems 26C.3.6 Installation of joints . 27Bibliography 31BS EN 489:2009EN 489:2009 (E) 4 Foreword This do
19、cument (EN 489:2009) has been prepared by Technical Committee CEN/TC 107 “Prefabricated district heating pipe systems”, the secretariat of which is held by DS. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at th
20、e latest by September 2009, and conflicting national standards shall be withdrawn at the latest by September 2009. 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 responsible for identifying an
21、y or all such patent rights. This document supersedes EN 489:2003. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, F
22、inland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom. BS EN 489:2009EN 489:2009 (E) 5 Introduction The first edition of EN 489 was
23、 approved in 1994 and updated in 2003. The main areas of this revision are the following: Requirements for welded joints have been added; Requirements for joints insulated with prefabricated joint insulation have been added; Requirements and test methods for PUR foam properties have been lifted from
24、 EN 253 into this standard; Requirements for marking of joints have been added. This specification is part of the series of standards for bonded systems using polyurethane foam thermal insulation applied to bond to a steel service pipe and a polyethylene casing. For information on the minimum expect
25、ed thermal life with operation at various temperatures with respect to PUR foam performance see EN 253:2009, Annex B. The other standards from TC 107 are: EN 253:2009, District heating pipes Preinsulated bonded pipe systems for directly buried hot water networks Pipe assembly of steel service pipe,
26、polyurethane thermal insulation and outer casing of polyethylene; EN 448:2009, District heating pipes Preinsulated bonded pipe systems for directly buried hot water networks Fitting assemblies of steel service pipes, polyurethane thermal insulation and outer casing of polyethylene; EN 488:2003, Dist
27、rict heating pipes Preinsulated bonded pipe systems for directly buried hot water networks Steel valve assembly for steel service pipes, polyurethane thermal insulation and outer casing of polyethylene; EN 13941:2003, Design and installation of preinsulated bonded pipe systems for district heating;
28、EN 14419:2009, District heating pipes Preinsulated bonded pipe systems for directly buried hot water networks Surveillance systems. As information to the users of this standard CEN/TC 107 has decided to mention that at the time of publication of this European Standard CEN/TC 107 had already conclude
29、d on the investigation and further preparation of the following topics: appropriate short- and long-term type tests for all jointing systems; incorporation of the findings of running research activities to introduce new test procedures and requirements; further preparation of Annex C aiming at makin
30、g this annex normative; further preparations of Annex B concerning on site joint inspection and establish suitable methods for field tests; requirements and test methods regarding the closure of foaming hole plugs. BS EN 489:2009EN 489:2009 (E) 6 The abovementioned items should be dealt with and the
31、 intention is to include the results in the next revision of this European Standard. BS EN 489:2009EN 489:2009 (E) 7 1 Scope This European Standard specifies requirements for joints made under field conditions between adjacent preinsulated pipes and/or fittings in district heating networks. The spec
32、ified general requirements are also valid for field-made T-branches, bends, reducers, caps, etc. This European Standard covers jointing of steel service pipes by means of fusion welding, the connecting of casing ends with joint casings and the thermal insulation with poured rigid PUR foam or prefabr
33、icated PUR-foam insulation. This European Standard specifies methods for type tests of complete joints and PUR-foam for joints under laboratory conditions. The requirements of this European Standard can also be applied to casing pipe weldings/connections of on site made fittings. The requirements of
34、 this European Standard aim to obtain a technical life of the joints of at least 30 years. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest editio
35、n of the referenced document (including any amendments) applies. EN 253:2009, District heating pipes Preinsulated bonded pipe systems for directly buried hot water networks Pipe assembly of steel service pipe, polyurethane thermal insulation and outer casing of polyethylene EN 287-1, Qualification t
36、est of welders Fusion welding Part 1: Steels EN 444, Non-destructive testing General principles for radiographic examination of metallic materials by X- and gamma-rays EN 1435, Non-destructive examination of welds Radiographic examination of welded joints EN 12517-1:2006, Non-destructive testing of
37、welds Part 1: Evaluation of welded joints in steel, nickel, titanium and their alloys by radiography Acceptance levels EN 13941, Design and installation of preinsulated bonded pipe systems for district heating EN 14419, District heating pipes Preinsulated bonded pipe systems for directly buried hot
38、water networks Surveillance systems EN ISO 845, Cellular plastics and rubbers Determination of apparent (bulk) density (ISO 845:1988) EN ISO 4590:2003, Rigid cellular plastics Determination of the volume percentage of open cells and of closed cells (ISO 4590:2002) EN ISO 5817:2007, Welding Fusion-we
39、lded joints in steel, nickel, titanium and their alloys (beam welding excluded) Quality levels for imperfections (ISO 5817:2003, corrected version:2005, including Technical Corrigendum 1:2006) EN ISO 6520-1, Welding and allied processes Classification of geometric imperfections in metallic materials
40、 Part 1: Fusion welding (ISO 6520-1:2007) EN ISO 9692 (all parts), Welding and allied processes Recommendations for joint preparation (ISO 9692) EN ISO 15607:2003, Specification and qualification of welding procedures for metallic materials General rules (ISO 15607:2003) BS EN 489:2009EN 489:2009 (E
41、) 8 3 Terms and definitions For the purposes of this document, the terms and definitions given in EN 253:2009 and the following apply. 3.1 joint complete construction of the connection between adjacent pipes and/or fittings 3.2 joint casing part that connects the two pipe casing ends in a joint 3.3
42、joint insulation thermal insulation that fills the volume confined by the steel service pipe, the joint casing and the ends of the two connecting pipes 3.4 on site poured joint insulation joint insulation manufactured by pouring the liquid polyurethane foam components1)into the joint volume at the w
43、ork site 3.5 prefabricated joint insulation joint insulation manufactured by installing prefabricated elements of polyurethane foam in the joint volume prior to installation of the joint casing2)3.6 steel weld connection between the steel service pipes by welding 3.7 polyethylene weld fusion jointin
44、g of polyethylene to polyethylene under influence of heat, pressure and time 3.8 double sealing two-sealing systems independently installed on the same joint, not influencing each other negatively and thus independently functioning during the service life of the joint 3.9 surveillance system system
45、that consists of measuring sections and measuring instruments for surveillance of pipe systems 4 Requirements 4.1 General requirements NOTE The assumptions of EN 13941 have been taken as the base for these requirements. 4.1.1 General requirements for the joint The joint shall be: 1) Ernst Kaufmann,
46、050715. 2) Ernst Kaufmann, 050715. BS EN 489:2009EN 489:2009 (E) 9 watertight; able to withstand axial forces initiated by axial movements of the pipe in the ground; able to withstand radial forces and bending moments; able to withstand effects of temperature and temperature variations. In case of d
47、ouble sealing each one of the sealing systems and the combination of both systems shall fulfil the requirements of the type test as described in Clause 5. 4.1.2 Installation of the joint Each individual step in the installation of a joint shall follow the system suppliers installation instructions i
48、n order to ensure that the joint obtained is equivalent to the joint as previously type-tested. 4.1.3 Competence of the welder and fitter Persons installing joints on preinsulated pipe networks shall possess a valid evidence of qualification stating that they have received training relevant to the system and the type of joint. Steel service pipe welders shall possess a valid certificate in accordance with EN 287-1. Polyethylene welders shall possess a valid evidence of qualification which documents their a
