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BS EN 4892009 ICS 23.040.01; 91.140.60 NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW BRITISH STANDARD District heating pipes Preinsulated bonded pipe systems for directly buried hot water networks Joint assembly for steel service pipes, polyurethane thermal insulation and outer casing of polyethylene This British Standard was published under the authority of the Standards Policy and Strategy Committee on 31 May 2009 BSI 2009 ISBN 978 0 580 57358 3 Amendments/corrigenda issued since publication DateComments BS EN 4892009 National foreword This British Standard is the UK implementation of EN 4892009. It supersedes BS EN 4892003 which is withdrawn. The UK participation in its preparation was entrusted to Technical Committee RHE/9, Insulated underground pipelines. A list of organizations represented on this committee 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 application. Compliance with a British Standard cannot confer immunity from legal obligations. BS EN 4892009 EUROPEAN STANDARD NORME EUROPENNE EUROPISCHE NORM EN 489 March 2009 ICS 23.040.01Supersedes EN 4892003 English Version District heating pipes - Preinsulated bonded pipe systems for directly buried hot water networks - Joint assembly for steel service pipes, polyurethane thermal insulation and outer casing of polyethylene Tuyaux de chauffage urbain - Systmes bloqus de tuyaux prisols pour les rseaux deau chaude enterrs directement - Assemblage prisol pour tube de service en acier, isolation thermique en polyurthane et tube de protection en polythylne Fernwrmerohre - Werkmig gedmmte Verbundmantelrohrsysteme fr direkt erdverlegte Fernwrmenetze - Rohrverbindungen fr Stahlmediumrohre mit Polyurethan-Wrmedmmung und Auenmantel aus Polyethylen This 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 European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards 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 translation under the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as the official versions. CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom. EUROPEAN COMMITTEE FOR STANDARDIZATION COMIT EUROPEN DE NORMALISATION EUROPISCHES KOMITEE FR NORMUNG Management Centre Avenue Marnix 17, B-1000 Brussels 2009 CENAll rights of exploitation in any and by any means reserved worldwide for CEN national Members. Ref. No. EN 4892009 E BS EN 4892009 EN 4892009 E 2 Contents page Foreword ...................................................................................................................................................................... 4 Introduction ................................................................................................................................................................. 5 1Scope .............................................................................................................................................................. 7 2Normative references .................................................................................................................................... 7 3Terms and definitions ................................................................................................................................... 8 4Requirements ................................................................................................................................................. 8 4.1General requirements .................................................................................................................................... 8 4.1.1General requirements for the joint ............................................................................................................... 8 4.1.2Installation of the joint .................................................................................................................................. 9 4.1.3Competence of the welder and fitter............................................................................................................ 9 4.1.4Expected thermal life and long term temperature resistance ................................................................... 9 4.1.5Steel service pipe weld ................................................................................................................................. 9 4.1.6Polyurethane rigid foam insulation PUR .................................................................................................. 9 4.1.7Joint casing .................................................................................................................................................... 9 4.2Type test requirements ............................................................................................................................... 10 4.2.1Water tightness ............................................................................................................................................ 10 4.2.2Soil stress test ............................................................................................................................................. 10 4.2.3Polyurethane rigid foam insulation PUR properties .............................................................................. 10 4.2.4Weld joint stress crack resistance ............................................................................................................. 10 4.3Installation instructions .............................................................................................................................. 11 4.3.1General .......................................................................................................................................................... 11 4.3.2Work environment ....................................................................................................................................... 11 4.3.3Cleaning ........................................................................................................................................................ 11 4.3.4Surveillance system .................................................................................................................................... 11 4.3.5Steel site weld .............................................................................................................................................. 11 4.3.6Joint casing .................................................................................................................................................. 11 4.3.7Joint insulation ............................................................................................................................................ 11 5s for type tests ................................................................................................................................ 12 5.1Soil stress test ............................................................................................................................................. 12 5.2Water impermeability test ........................................................................................................................... 15 5.3Weld joint stress crack resistance test ..................................................................................................... 15 5.4Polyurethane rigid foam insulation PUR ................................................................................................ 15 5.4.1General .......................................................................................................................................................... 15 5.4.2Test specimens ............................................................................................................................................ 15 5.4.3Sampling ....................................................................................................................................................... 16 5.4.4Ageing resistance ........................................................................................................................................ 16 5.4.5Cell structure ................................................................................................................................................ 16 5.4.6Foam density ................................................................................................................................................ 16 5.4.7Water absorption at elevated temperature ................................................................................................ 17 6Marking ......................................................................................................................................................... 17 6.1General .......................................................................................................................................................... 17 6.2Joint casing .................................................................................................................................................. 17 6.3Plugs ............................................................................................................................................................. 17 6.4Joint insulation system ............................................................................................................................... 18 Annex A normative Fusion welding of steel service pipes on site .................................................................. 19 A.1General .......................................................................................................................................................... 19 A.2Material ......................................................................................................................................................... 19 A.3Welding process .......................................................................................................................................... 19 BS EN 4892009 EN 4892009 E 3 A.4Preparation for welding and lining up ....................................................................................................... 19 A.5Qualification of welders .............................................................................................................................. 19 A.6Steel weld inspection .................................................................................................................................. 20 A.6.1General.......................................................................................................................................................... 20 A.6.2Leak-tightness test with air/gas ................................................................................................................. 20 A.6.3Leak-tightness test with water ................................................................................................................... 20 A.6.4Radiographic examination .......................................................................................................................... 20 A.6.5Ultrasonic examination ............................................................................................................................... 20 Annex B inative General guidelines for inspection of the joint on site .................................................... 21 Annex C inative Qualification of fitters installing joints in preinsulated bonded pipe networks .......... 23 C.1Knowledge and skills .................................................................................................................................. 23 C.2Background for training and testing ......................................................................................................... 23 C.3Subjects for training and testing ............................................................................................................... 23 C.3.1General.......................................................................................................................................................... 23 C.3.2Casing of polyethylene PE ....................................................................................................................... 24 C.3.3Surveillance .................................................................................................................................................. 25 C.3.4PUR-foam system ........................................................................................................................................ 25 C.3.5Joint types/jointing systems ...................................................................................................................... 26 C.3.6Installation of joints ..................................................................................................................................... 27 Bibliography .............................................................................................................................................................. 31 BS EN 4892009 EN 4892009 E 4 Foreword This document EN 4892009 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 the 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 any or all such patent rights. This document supersedes EN 4892003. According to the CEN/CENELEC Internal Regulations, the national standard
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