SIST EN 489:2009

SLOVENSKI STANDARD
SIST EN 489:2009
01-maj-2009
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SIST EN 489:2004
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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
Fernwärmerohre - Werkmäßig gedämmte Verbundmantelrohrsysteme für direkt
erdverlegte Fernwärmenetze - Rohrverbindungen für Stahlmediumrohre mit Polyurethan-
Wärmedämmung und Außenmantel aus Polyethylen
Tuyaux de chauffage urbain - Systemes bloqués de tuyaux préisolés pour les réseaux
d'eau chaude enterrés directement - Assemblage préisolé pour tube de service en acier,
isolation thermique en polyuréthane et tube de protection en polyéthylene
Ta slovenski standard je istoveten z: EN 489:2009
ICS:
23.040.07 Cevovodi za daljinsko Pipeline and its parts for
ogrevanje in njihovi deli district heat
23.040.60 Prirobnice, oglavki in spojni Flanges, couplings and joints
elementi
91.140.65 Oprema za ogrevanje vode Water heating equipment
SIST EN 489:2009 en,fr
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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SIST EN 489:2009

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SIST EN 489:2009
EUROPEAN STANDARD
EN 489
NORME EUROPÉENNE
EUROPÄISCHE NORM
March 2009
ICS 23.040.01 Supersedes EN 489:2003
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 - Systèmes bloqués de tuyaux Fernwärmerohre - Werkmäßig gedämmte
préisolés pour les réseaux d'eau chaude enterrés Verbundmantelrohrsysteme für direkt erdverlegte
directement - Assemblage préisolé pour tube de service en Fernwärmenetze - Rohrverbindungen für Stahlmediumrohre
acier, isolation thermique en polyuréthane et tube de mit Polyurethan-Wärmedämmung und Außenmantel aus
protection en polyéthylène 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
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: Avenue Marnix 17, B-1000 Brussels
© 2009 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 489:2009: E
worldwide for CEN national Members.

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SIST EN 489:2009
EN 489:2009 (E)
Contents
page
Foreword . 4
Introduction . 5
1 Scope . 7
2 Normative references . 7
3 Terms and definitions . 8
4 Requirements . 8
4.1 General requirements . 8
4.1.1 General requirements for the joint . 8
4.1.2 Installation of the joint . 9
4.1.3 Competence of the welder and fitter. 9
4.1.4 Expected thermal life and long term temperature resistance . 9
4.1.5 Steel service pipe weld . 9
4.1.6 Polyurethane rigid foam insulation (PUR) . 9
4.1.7 Joint casing . 9
4.2 Type test requirements . 10
4.2.1 Water tightness . 10
4.2.2 Soil stress test . 10
4.2.3 Polyurethane rigid foam insulation (PUR) properties . 10
4.2.4 Weld joint stress crack resistance . 10
4.3 Installation instructions . 11
4.3.1 General . 11
4.3.2 Work environment . 11
4.3.3 Cleaning . 11
4.3.4 Surveillance system . 11
4.3.5 Steel site weld . 11
4.3.6 Joint casing . 11
4.3.7 Joint insulation . 11
5 Methods for type tests . 12
5.1 Soil stress test . 12
5.2 Water impermeability test . 15
5.3 Weld joint stress crack resistance test . 15
5.4 Polyurethane rigid foam insulation (PUR) . 15
5.4.1 General . 15
5.4.2 Test specimens . 15
5.4.3 Sampling . 16
5.4.4 Ageing resistance . 16
5.4.5 Cell structure . 16
5.4.6 Foam density . 16
5.4.7 Water absorption at elevated temperature . 17
6 Marking . 17
6.1 General . 17
6.2 Joint casing . 17
6.3 Plugs . 17
6.4 Joint insulation system . 18
Annex A (normative)  Fusion welding of steel service pipes on site . 19
A.1 General . 19
A.2 Material . 19
A.3 Welding process . 19
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SIST EN 489:2009
EN 489:2009 (E)
A.4 Preparation for welding and lining up . 19
A.5 Qualification of welders . 19
A.6 Steel weld inspection . 20
A.6.1 General. 20
A.6.2 Leak-tightness test with air/gas . 20
A.6.3 Leak-tightness test with water . 20
A.6.4 Radiographic examination . 20
A.6.5 Ultrasonic examination . 20
Annex B (informative)  General guidelines for inspection of the joint on site . 21
Annex C (informative)  Qualification of fitters installing joints in preinsulated bonded pipe networks . 23
C.1 Knowledge and skills . 23
C.2 Background for training and testing . 23
C.3 Subjects for training and testing . 23
C.3.1 General. 23
C.3.2 Casing of polyethylene (PE) . 24
C.3.3 Surveillance . 25
C.3.4 PUR-foam system . 25
C.3.5 Joint types/jointing systems . 26
C.3.6 Installation of joints . 27
Bibliography . 31


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SIST EN 489:2009
EN 489:2009 (E)
Foreword
This document (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 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 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, Finland, 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.

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SIST EN 489:2009
EN 489:2009 (E)
Introduction
The first edition of EN 489 was 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 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 expected 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, 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, District 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;
 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 concluded 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 making 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.
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SIST EN 489:2009
EN 489:2009 (E)
The abovementioned items should be dealt with and the intention is to include the results in the next revision of this
European Standard.
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SIST EN 489:2009
EN 489:2009 (E)
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 specified 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 prefabricated 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 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 edition 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 test 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 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 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-welded 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 –
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)
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SIST EN 489:2009
EN 489:2009 (E)
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
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
1)
joint insulation manufactured by pouring the liquid polyurethane foam components into the joint volume at the
work site
3.5
prefabricated joint insulation
joint insulation manufactured by installing prefabricated elements of polyurethane foam in the joint volume prior to
2)
installation of the joint casing
3.6
steel weld
connection between the steel service pipes by welding
3.7
polyethylene weld
fusion jointing 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 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, 050715.
2) Ernst Kaufmann, 050715.
8

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SIST EN 489:2009
EN 489:2009 (E)
 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 double 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 supplier's installation instructions in 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 ability to reproduce
welding of the quality specified.
Recommended subjects for training are given in Annex C.
4.1.4 Expected thermal life and long term temperature resistance
The requirements for expected life and long term temperature resistance shall be in accordance with 5.4.4 of
EN 253:2009.
4.1.5 Steel service pipe weld
The steel service pipe weld shall:
 be tight when tested in accordance with A.6;
 have mechanical properties equivalent to those of the service pipe.
4.1.6 Polyurethane rigid foam insulation (PUR)
The foaming of a joint on site shall be carried out in a confined space.
The insulation shall completely fill the joint.
The requirements for the rigid PUR foam insulation shall be in accordance with 4.2.3.2, 4.2.3.3, 4.2.3.4 and with
EN 253:2009, 4.4.3 for the compressive strength.
4.1.7 Joint casing
The joint casing shall be tight against external water pressure.
Casings for welded joints shall fulfil Clause 4.3.1 of EN 253:2009.
All joints shall be subject to a leak-test. If this is not possible, a type specific procedure of 100 % visual test in
combination with a destructive spot test scheme shall be described in the manufacturer's documentation.
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SIST EN 489:2009
EN 489:2009 (E)
NOTE Leakage testing of joints should be carried out with air or another suitable gas. The test pressure of 20 kPa should
be applied at a temperature of ≤ 40 °C for a minimum of 2 min. The leak-tightness should be checked by means of a suitable
indicator liquid or a leakage detector. The indicator liquid should be detrimental neither to the casing and joint material, nor to
the environment.
Proper handling and installation procedures and type specific test procedures for the verification of leak-tightness of
installed joint casings shall be described in the manufacturer's documentation.
4.2 Type test requirements
4.2.1 Water tightness
No water ingress shall be detected after the water impermeability test in accordance with 5.2.
Both welded and non-welded joints shall be tested.
4.2.2 Soil stress test
Non-welded joints shall pass the soil stress test in accordance with 5.1 before the water impermeability test in
accordance with 5.2 is carried out.
4.2.3 Polyurethane rigid foam insulation (PUR) properties
4.2.3.1 General
3)
The polyurethane rigid foam insulation (PUR) material for joint assemblies shall, when tested as a pipe assembly ,
meet the requirements of EN 253 regarding voids and bubbles, compressive strength, long term temperature
resistance and thermal conductivity in addition to 4.2.3.2, 4.2.3.3 and 4.2.3.4.
When tested according to 5.4.4 the joint insulation shall not shrink more than 2 mm in the axial or the radial
direction.
4.2.3.2 Cell structure
The average size of the cells in a radial direction shall be less than 0,5 mm, determined in accordance with 5.4.5.1.
The closed cell content determined in accordance with 5.4.5.2 shall be not less than 88 %.
4.2.3.3 Foam density
3
The density of the foam at any position shall be not less than 60 kg/m when measured in accordance with 5.4.6.
3
No specimen may have a density below 60 kg/m .
4.2.3.4 Water absorption at elevated temperature
When tested in accordance with 5.4.7, the water absorption after 90 min of immersion in boiling water shall not
exceed 10 % of the original volume.
4.2.4 Weld joint stress crack resistance
When tested in accordance with 5.3 the time until failure shall be at least 300 hours.

3) Ernst Kaufmann, 050715.
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SIST EN 489:2009
EN 489:2009 (E)
4.3 Installation instructions
4.3.1 General
Installation instructions, crucial for the quality of the installed joint and for achieving the expected life, shall be a part
of the manufacturer's documentation and shall be supplied together with the component parts.
The installation instructions shall, as a minimum, deal with the topics mentioned in 4.3.2 to 4.3.7.
4.3.2 Work environment
Proper procedures to obtain optimum work conditions on site shall be specified.
4.3.3 Cleaning
Proper procedures for the cleaning and drying shall be specified for:
 steel pipe surfaces;
 insulation surfaces;
 joint casing surfaces;
 casing surfaces.
The sentence ”Any wet foam shall be removed from the pipe ends" shall be included in the instructions.
4.3.4 Surveillance system
When measuring elements for a surveillance system is installed in the joint, proper procedures for connecting the
surveillance system shall be specified before the assembly takes place. This specification shall comply with EN
14419 and include procedures for:
 check of measuring elements upon receipt of pipe elements;
 assembly work in joints to ensure the function of the system;
 assembly check of the surveillance system during construction;
 test after finishing a measuring section.
4.3.5 Steel site weld
Proper procedures for the steel weld shall be described. This description shall, as a minimum, include the parts
"Welding process" and "Preparation for welding
...