SIST EN 489:2004

SLOVENSKI STANDARD
SIST EN 489:2004
01-oktober-2004
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SIST EN 489:2000
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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 - Werkmaßig gedämmte Verbundmantelrohrsysteme für direkt
erdverlegte Fernwärmenetze - Rohrverbindungen für Stahlmediumrohre mit Polyurethan-
Wärmedämmung und Außenmantel aus Polyethylen
Tuyaux de chauffage urbain - Systemes bloqués de tuyaux pré-isolés pour les réseaux
d'eau chaude enterrés directement - Assemblage pré-isolé pour tube de service en acier,
isolation thermique en polyuréthane et tube de protection en polyéthylene
Ta slovenski standard je istoveten z: EN 489:2003
ICS:
23.040.10 Železne in jeklene cevi Iron and steel pipes
91.140.65 Oprema za ogrevanje vode Water heating equipment
SIST EN 489:2004 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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SIST EN 489:2004

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SIST EN 489:2004
EUROPEAN STANDARD
EN 489
NORME EUROPÉENNE
EUROPÄISCHE NORM
February 2003
ICS 23.040.60 Supersedes EN 489:1994
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 - Werkmaßig gedämmte
pré-isolés pour les réseaux d'eau chaude enterrés Verbundmantelrohrsysteme für direkt erdverlegte
directement - Assemblage pré-isolé pour tube de service Fernwärmenetze - Rohrverbindungen für
en acier, isolation thermique en polyuréthane et tube de Stahlmediumrohre mit Polyurethan-Wärmedämmung und
protection en polyéthylène Außenmantel aus Polyethylen
This European Standard was approved by CEN on 28 November 2002.
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 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 Management Centre has the same status as the official
versions.
CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,
Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Slovak Republic, Spain, Sweden, Switzerland and
United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36  B-1050 Brussels
© 2003 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 489:2003 E
worldwide for CEN national Members.

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SIST EN 489:2004
EN 489:2003 (E)
Contents
page
Foreword.4
Introduction .5
1 Scope .6
2 Normative references .6
3 Terms and definitions.7
4 Requirements .7
4.1 General requirements.7
4.1.1 General requirements for the joint.7
4.1.2 Construction of the joint .7
4.1.3 Competence of the welder and fitter.8
4.1.4 Expected thermal life and long term temperature resistance.8
4.1.5 Steel service pipe weld.8
4.1.6 Polyurethane rigid foam insulation (PUR).8
4.1.7 Joint casing .8
4.2 Type test requirements .8
4.2.1 Soil stress test.8
4.2.2 Polyurethane rigid foam insulation (PUR) properties.9
4.3 Installation instructions .9
4.3.1 General.9
4.3.2 Work environment .9
4.3.3 Cleaning.9
4.3.4 Surveillance system .9
4.3.5 Steel site weld .9
4.3.6 Joint casing .9
4.3.7 Foaming .10
5 Methods for type tests.10
5.1 Soil stress test.10
5.1.1 General.10
5.1.2 Sand box.10
5.1.3 Sand .11
5.1.4 Test specimens .11
5.1.5 Sand box test.11
5.1.6 Water impermeability test .11
5.2 Polyurethane rigid foam insulation (PUR).12
5.2.1 General.12
5.2.2 Test specimens .12
5.2.3 Sampling.12
5.2.4 Ageing resistance .12
Annex A (normative)  Fusion welding of steel service pipes on site.13
A.1 Material.13
A.2 Welding process .13
A.3 Preparation for welding and lining up .13
A.4 Qualification of welders .13
A.5 Steel weld inspection .13
A.5.1 General.13
A.5.2 Leak-tightness test with air/gas .14
A.5.3 Leak-tightness test with water.14
A.5.4 Radiographic examination.14
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SIST EN 489:2004
EN 489:2003 (E)
A.5.5 Ultrasonic examination .14
Annex B (informative)  General guidelines for inspection of the joint on site.15
Annex C (informative)  Qualification of fitters installing joints in preinsulated bonded pipe networks .17
C.1 Purpose and scope.17
C.2 Background for training and testing.17
C.3 Subjects for training and testing.17
C.3.1 General.17
C.3.2 Casing of polyethylene (PE) .18
C.3.3 Surveillance.19
C.3.4 PUR-foam system .19
C.3.5 Joint types/jointing systems .20
C.3.6 Installation of joints.21
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SIST EN 489:2004
EN 489:2003 (E)
Foreword
This document (EN 489:2003) 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 August 2003, and conflicting national standards shall be withdrawn at the latest by
August 2003.
This document will supersede EN 489:1994.
Annex A is normative. Annexes B and C are informative.
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland,
France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal,
Slovakia, Spain, Sweden, Switzerland and the United Kingdom.
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SIST EN 489:2004
EN 489:2003 (E)
Introduction
The first edition of EN 489 was approved in 1994. The main areas of the revision are the following:
 the title has been amended by ”District heating pipes”;
 the term ”underground” has been changed to ”directly buried”;
 definitions for ”polyethylene weld” and ”double sealing” have been added;
 the requirements for the qualification of work force have been changed and annex C has been added;
 requirements concerning double sealing have been added;
 the water content of the sand used in the sand box has been limited to maximum 0,5 % (mass fraction).
 the former annex C “Assumptions made to establish functional requirements of joints” and all references to it
have been deleted and substituted by a reference to EN 13941.
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 253:2003, annex B.
The other standards from TC 107 are:
EN 253:2003, 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 448:2003, 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.
NOTE The following draft in connection with the above mentioned is under development:
prEN 14419, 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;
 establishment of normative references for PE welding;
 further preparation of annex C aiming at making this annex normative.
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SIST EN 489:2004
EN 489:2003 (E)
The above mentioned items should be dealt with and the intention is to include the results in the next revision of
this standard.
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.
The 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.
This standard specifies methods for type tests of complete joints and PUR-foam for joints under laboratory
conditions. The type tests apply only to straight casing joints which are not-welded.
The requirements of this standard can also be applied to casing pipe weldings/connections of on site made fittings.
The requirements of this standard are aiming at obtaining a technical life of the joints of at least 30 years.
2 Normative references
This European Standard incorporates by dated or undated reference, provisions from other publications. These
normative references are cited at the appropriate places in the text, and the publications are listed hereafter. For
dated references, subsequent amendments to or revisions of any of these publications apply to this European
Standard only when incorporated in it by amendment or revision. For undated references the latest edition of the
publication referred to applies (including amendments).
EN 253:2003, 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, Approval testing of welders – Fusion welding – Part 1: Steels.
EN 288-1:1992, Specification and qualification of welding procedures for metallic materials – Part 1: General rules
for fusion welding.
EN 444, Non-destructive testing – General principles for radiographic examination of metallic materials by X- and
gamma-rays.
EN 583-1, Non-destructive testing – Ultrasonic examination – Part 1: General principles.
EN 1435, Non-destructive examination of welds – Radiographic examination of welded joints.
EN 1712, Non-destructive examination of welds – Ultrasonic examination of welded joints – Acceptance levels.
EN 1714, Non-destructive examination of welds – Ultrasonic examination of welded joints.
EN 13941, Design and installation of preinsulated bonded pipe systems for district heating.
EN 25817:1992, Arc-welded joints in steel materials – Guidance on quality levels for imperfections
(ISO 5817:1992).
ISO 6520, Welding and allied processes – Classification of geometric imperfections in metallic materials.
ISO 9692, Metal-arc welding with covered electrode, gas-shielded metal-arc welding and gas welding – Joint
preparations for steel.
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SIST EN 489:2004
EN 489:2003 (E)
3 Terms and definitions
For the purposes of this European Standard, the terms and definitions given in EN 253:2003 together with 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
steel weld
connection between the steel service pipes by welding
3.4
polyethylene weld
molecular jointing of polyethylene to polyethylene under influence of heat, pressure and time
3.5
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
3.6
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:
 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 Construction of the joint
Each individual step in the construction 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.
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SIST EN 489:2004
EN 489:2003 (E)
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 perform
reproductive 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 4.5.4 of
EN 253:2003.
4.1.5 Steel service pipe weld
The steel service pipe weld shall:
 be tight when tested in accordance with A.5;
 have mechanical properties equivalent to those of the service pipe.
4.1.6 Polyurethane rigid foam insulation (PUR)
The foaming of a joint shall be carried out in a confined space.
The PUR foam shall completely fill the joint.
The requirements for the rigid PUR foam insulation shall be in accordance with 4.4.2, 4.4.3, 4.4.4 and 4.4.5 of
EN 253:2003.
4.1.7 Joint casing
The joint casing shall be tight against external water pressure.
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.
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 Soil stress test
No water ingress shall be detected after the soil stress test in accordance with 5.1.
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SIST EN 489:2004
EN 489:2003 (E)
4.2.2 Polyurethane rigid foam insulation (PUR) properties
The polyurethane rigid foam insulation (PUR) for joint assemblies shall meet the requirements of 4.4, 4.5.4 and
4.5.5 of EN 253:2003.
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 a surveillance system is installed proper procedures for connecting the surveillance system shall be
specified. This specification shall, as a minimum, include:
 general handling instructions to avoid damaging the system;
 procedures for positioning and connecting adjacent pipes to ensure the function of the system;
 procedures and test methods to check the function of the surveillance system during construction.
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 and lining up" in accordance with annex A.
4.3.6 Joint casing
Proper handling and installation procedures for the joint casing shall be specified.
Type specific test procedures for leak-tightness of installed joints shall be described.
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SIST EN 489:2004
EN 489:2003 (E)
4.3.7 Foaming
Proper procedures for the foaming shall be described. The following procedures shall, as a minimum, be described:
 the precautions to be taken if surface temperatures are outside the range of 15 °C to 45 °C;
 the temperature at which PUR components may be stored if outside the range of 15 °C to 25 °C;
 the precautions to be taken to optimize venting of the joint and to prevent excessive foam losses.
5 Methods for type tests
5.1 Soil stress test
5.1.1 General
The soil stress test shall be carried out as follows.
5.1.2 Sand box
A box with minimum dimensions as shown in Figure 1 shall be used. The box shall be provided with a rigid
compression plate that covers the entire box.
Dimensions in millimetres
Key
1  Sand
2  Joint
Figure 1 — Minimum dimensions of sand box
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SIST EN 489:2004
EN 489:2003 (E)
5.1.3 Sand
Natural sand in air-dried condition with a moisture content of maximum 0,5 % (mass fraction), at room temperature
with a grain distribution as shown in Figure 2 shall be used.
Key
1  Grain size, mm
2  Accumulated weight, %
Figure 2 — Standard sand quality
5.1.4 Test specimens
Three test specimens of minimum length 2,5 m shall be used. Each test specimen shall comprise a joint made by
welding together two prefabricated pipe ends.
Two test specimens shall be made of pipes with casing diameter 160 mm and one specimen shall be made of pipe
with casing diameter 250 mm. The test can also be applied on other casing diameters.
5.1.5 Sand box test
The following test parameters shall be used:
 service pipe temperature of (120 – 2) °C maintained for 24 h before the testing;
2
 simulated sand overfill of 1 m (18 kN/m effective vertical soils stress);
 displacement of 75 mm;
 forward speed of 10 mm/min;
 backward speed of 50 mm/min;
 100 cycles, where a cycle is defined as one forward and one backward movement without pause.
5.1.6 Water impermeability test
Following the test in 5.1.5, each joint shall be immersed in a water tank at 30 °C and pressurized externally with a
constant pressure of 30 kPa for a period of 24 h.
To facilitate assessment of water ingress, the liquid can be coloured.
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SIST EN 489:2004
EN 489:2003 (E)
5.2 Polyurethane rigid foam insulation (PUR)
5.2.1 General
The type tests for polyurethane rigid foam insulation (PUR) for joints shall be carried out in accordance with 5.3 of
EN 253:2003, with the exceptions given in 5.2.2 to 5.2.4.
5.2.2 Test specimens
The test specimens shall comprise two joint casings having a diameter of at least 160 mm.
Only PE-joint casings shall be used to construct the joint test specimens.
If the joints are made on one pipe, the minimum space between the joints shall be 400 mm (see Figure 3). The
cutout in the joint area shall be minimum 600 mm.
Dimensions in millimetres
Figure 3 — Specimens for testing ageing resistance of joint foam
5.2.3 Sampling
PUR test specimens shall only be taken from the foam after the sample has been stored at room temperature for at
least 72 h.
Cutting of test specimens from the foam to determine foam density, cell structure, compressive strength and water
absorption shall be done in accordance with 5.1.1.4 and 5.1.1.5 of EN 253:2003.
5.2.4 Ageing resistance
Two joints shall be positioned in accordance with Figure 3.
The test shall be done in accordance with 5.4.4 of EN 253:2003 with the exception that test specimens shall be
taken from the foam in the joints.
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SIST EN 489:2004
EN 489:2003 (E)
Annex A
(normative)
Fusion welding of steel service pipes on site
This annex specifies requirements and test methods for the joint between two adjacent steel service pipes by
means of fusion welding.
A.1 Material
The mechanical properties of the weld shall correspond to those of the pipe material.
A.2 Welding process
Welding processes shall be suitable for
...