BRITISH STANDARD BS EN 12162 2001 Liquid pumps — Safety requirements — Procedure for hydrostatic testing ICS 23 080 NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW +A1 2009 Nati[.]
BRITISH STANDARD Liquid pumps — Safety requirements — Procedure for hydrostatic testing ICS 23.080 NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW BS EN 12162:2001 +A1:2009 BS EN 12162:2001+A1:2009 National foreword This British Standard is the UK implementation of EN 12162:2001+A1:2009 It supersedes BS EN 12162:2001 which is withdrawn The start and finish of text introduced or altered by amendment is indicated in the text by tags Tags indicating changes to CEN text carry the number of the CEN amendment For example, text altered by CEN amendment A1 is indicated by !" The UK participation in its preparation was entrusted to Technical Committee MCE/6, Pumps and pump testing 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 This British Standard was published under the authority of the Standards Committee and comes into effect on 15 May 2001 © BSI 2009 ISBN 978 580 62246 Amendments/corrigenda issued since publication Date Comments 31 July 2009 Implementation of CEN amendment A1:2009 EUROPEAN STANDARD EN 12162:2001+A1 NORME EUROPÉENNE EUROPÄISCHE NORM May 2009 ICS 23.080 Supersedes EN 12162:2001 English Version Liquid pumps - Safety requirements - Procedure for hydrostatic testing Pompes pour liquides - Exigences de sécurité - Procédure d'essai hydrostatique Flüssigkeitspumpen - Sicherheitstechnische Anforderungen - Prozessverfahren für hydrostatische Druckprüfung This European Standard was approved by CEN on 18 January 2001 and includes Amendment approved by CEN on 19 April 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 respons bility 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 worldwide for CEN national Members Ref No EN 12162:2001+A1:2009: E BS EN 12162:2001+A1:2009 EN 12162:2001+A1:2009 (E) Contents Foreword Introduction Scope Normative references Terms and definitions General Timing of the test 6 Preparation for testing 7 Test equipment Test liquid Test pressure 10 Test procedure 11 Acceptance criteria 12 Repairs 13 Test Records Annex A (informative) Random sample schedule 11 Annex ZA (informative) !Relationship between this European Standard and the Essential Requirements of EU Directive 98/37/CE" " 13 Annex ZB (informative) !Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC" " 14 Bibliography 15 BS EN 12162:2001+A1:2009 EN 12162:2001+A1:2009 (E) Foreword This document (EN 12162:2001+A1:2009) has been prepared by Technical Committee CEN /TC 197, "Pumps", the secretariat of which is held by AFNOR 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 November 2009, and conflicting national standards shall be withdrawn at the latest by December 2009 This document includes Amendment 1, approved by CEN on 2009-04-19 This document supersedes EN 12162:2001 The start and finish of text introduced or altered by amendment is indicated in the text by tags !" This European Standard has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive(s) !For relationship with EU Directive(s), see informative Annexes ZA and ZB, which are integral parts of this document." Annex A is informative 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 United Kingdom BS EN 12162:2001+A1:2009 EN 12162:2001+A1:2009 (E) Introduction CEN have prepared a series of related machinery safety standards, some of which are to be harmonised European Standards, in order to implement the essential requirements for health and safety set down in the Supply of Machinery (Safety) Directive This European Standard is one of this series and provides the procedure to be used for a specific verification requirement of EN 809 The subject of this European Standard is the proving of the integrity of pump parts intended to withstand internal pressure It refers, therefore, to the in-process testing of pump parts so that each item may be considered to have been examined This European standard is a type C standard as stated in EN 1070 BS EN 12162:2001+A1:2009 EN 12162:2001+A1:2009 (E) Scope This standard specifies the hydrostatic test procedure to be applied to pressure containing parts of all types of liquid pumps including any auxiliary equipment making up a pump unit as described in the scope of EN 809:1998, except : domestic water pumps within the scope of EN 60335-2-41:1996 or EN 60335-2-51:1997 ; domestic circulation pumps within the scope of EN 1151:1999 ; !deleted text" !fire-fighting pumps with primers within the scope of EN 1028-1:2002+A1:2008 and EN 10282:2002+A1:2008;" pump parts with a maximum allowable working pressure below 0.1 bar Requirements are included for applying a hydrostatic test at different pressures to separate zones within a pump which are subject to different allowable maximum working pressures This standard is for pumps and pump units which are placed upon the market after the publication date of the standard 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 809:1998, Pumps and pump units for liquids - Common safety requirements !EN 1028-1:2002+A1:2008, Fire fighting pumps - Fire fighting centrifugal pumps with primer - Part : Classification - General and safety requirements" !EN 1028-2:2002+A1:2008, Fire fighting pumps - Fire fighting centrifugal pumps with primer - Part : Verification of general and safety requirements" EN 1151:1999, Rotodynamic pumps - Circulation pumps having an electrical effect not exceeding 200 W for heating installations and domestic hot water installations - Requirements, testing, marking EN 12723:2000, Liquid pumps - General terms for pumps and installations - Definitions, quantities, letter symbols and units !deleted text" EN 60335-2-41:1996, Safety of household and similar electrical appliances - Part 2: Particular requirements for electric pumps for liquids having a temperature not exceeding 35 °C EN 60335-2-51: 1997, Safety of household and similar electrical appliances - Part 2: Particular requirements for stationary circulation pumps of heating and service water installations BS EN 12162:2001+A1:2009 EN 12162:2001+A1:2009 (E) Terms and definitions For the purposes of this standard, EN 12723:2000 and the following definition apply: "Item" or "items to be tested" any part, component, sub-assembly, pump or pump units which is to be the subject of hydrostatic pressure test1) General 4.1 All pressure containing items shall be hydrostatically pressure tested The purpose of this hydrostatic test is to demonstrate the absence of leakage through pressure containing walls of any item under test and from the joints formed by an assembly of items under test, by imposing a defined pressure in excess of the allowable working pressure for which the item is supplied 4.2 This test procedure shall be applied to a sampling programme only where the manufacturer can show the validity of the sampling programme and that it is appropriate for the application An example of a sampling programme is given in annex A 4.3 Pumps with double volutes, multiple stages, and otherwise with internal separating walls and to be tested segmentally shall have a hydrostatic pressure applied to each segment related to the operating conditions in the segment when the pump is working at its allowable working pressure 4.4 Pressure containing chambers which function independently shall be tested separately without pressure being applied to any adjacent chamber 4.5 To avoid excessive loads on crank-shafts in multiplex reciprocating pump assemblies those elements in the suction stage of the cycle shall be supported or disconnected from the crank-shaft Timing of the test The manufacturer shall allow sufficient time during manufacture for the test and examination of all items within the scope of this standard The test may be carried out on an individual item or on a sub-assembly as a group of items Normally, the hydrostatic test is carried out : after completion of machining ; prior to the application of coatings, insulation, and overlays, (protection of raw parts against rust shall not be considered as a coating) ; following non-destructive testing, or after special leak tests below a gauge pressure of 0,5 bar on reciprocating positive displacement pumps, at the start of the performance test of the fully assembled pump 1) A rotating mechanical seal assembled into a pump or into a separate sub-assembly, together with an end plate to connect the stationary elements of the seal to the stationary parts of the pump, will not be considered as an item to be tested but may be subjected to the test pressure BS EN 12162:2001+A1:2009 EN 12162:2001+A1:2009 (E) Preparation for testing 6.1 Items to be subjected to test shall be free from grease, oil and other contaminants, and any cleaner used shall be compatible with the materials of manufacture of the pump, its auxiliaries, and its intended use 6.2 The items to be tested are to be assembled for the test and all openings are to be blanked-off by appropriate means which may include blind flanges, plugs, closures and tension rings Care shall be taken in selecting the closure arrangements not to impose forces capable of distorting the items under test nor of otherwise obscuring any leak Through bolting shall not be used unless it is part of the construction of the item being tested 6.3 The item to be tested and the gauge lines are to be vented and filled completely with the test liquid 6.4 Wherever feasible the mating parts and fasteners used in any assembly shall be those to be used in the delivered pump, otherwise reasons for deviating from this requirement shall be recorded Test equipment 7.1 The test equipment shall comprise a device for generating the test pressure using a test liquid defined in clause 8.1, the item to be tested prepared in accordance with clause 6, and a pressure indicating device NOTE The device generating the test pressure may be the pump under test 7.2 The hydrostatic test shall be carried out with calibrated pressure gauges The pressure indicating device selected shall be accurate to within ± 1,5 % of the reading at the test pressure The reference point for the pressure shall be the lowest point of the item to be tested The applied test pressure shall be uniformly distributed within the item being tested Test liquid 8.1 The hydrostatic test is normally to be carried out using clean water at ambient temperature, with the addition of corrosion preventative and organic growth inhibitors where necessary If the properties of the material imposes a limit on the test temperature which affects the test procedure this is to be noted on the test record 8.2 An alternative liquid shall be used where clean water is not appropriate for the application The liquid used and the reason for its selection shall be recorded Where residual chloride deposition is not acceptable for the application, the chloride content of the test liquid shall not exceed 50 ppm (0,005 %) Test pressure 9.1 The hydrostatic test pressure relates to the allowable working pressure at ambient temperature of the items to be tested Where the items to be tested are to be offered for general application the test pressure shall relate to their maximum allowable working pressure 9.2 The hydrostatic test pressure shall be calculated from the formula: Ptest = K × K × Pallw where p test is the hydrostatic test pressure ; p allw is the allowable working pressure at operating temperature ; K1 is a factor whose value shall be determined by the pump specification, but shall not be less than 1,3 ; BS EN 12162:2001+A1:2009 EN 12162:2001+A1:2009 (E) is a factor whose value shall be determined by the material strength K2 = allowable stress at ambient temperature allowable stress at operating temperature 10 Test procedure 10.1 At the start of the hydrostatic pressure test the external walls of the item to be tested shall be dry 10.2 Prior to applying the test pressure the arrangements used to seal the chambers to be pressurised shall be inspected for proper bolting and enclosure 10.3 The hydrostatic pressure shall be steadily increased in a controlled manner until the test pressure is achieved The test pressure shall be held essentially constant for the full duration of the test period Throughout this procedure continuous observation shall be maintained to detect any leakage 10.4 The test pressure shall be maintained for a sufficient time to allow the item being tested to be completely inspected This will normally be not less than 60 s Longer periods will be necessary for large, heavy castings, and for those made from forgings or welded construction These longer periods shall be determined by the pump specification or as otherwise set out in table below Table - Longer test periods Items to be tested Test duration in Rotodynamic pumps pumps rated above 25 bar 30 pumps rated above 10 bar and not above 25 bar 10 pumps rated up to 10 bar Rotary positive displacement pumps 10 Reciprocating positive displacement pumps 10 Cooling passages Cooling jackets for bearings, shaft seals, pedestals oil coolers, shaft seal coolers and cooling coils 10 Heating jackets 10.5 If the item to be tested is a completely assembled pump or pump unit, checks shall be made to ensure that excessive stresses are not created on the shaft seal or on the rod seal and the results of the checks recorded 10.6 At the end of the test duration the sudden release of the test liquid shall be avoided 10.7 If necessary, the tested item shall be completely drained of test liquid and thoroughly washed and carefully dried When using oil as the test liquid, drying is not usually required BS EN 12162:2001+A1:2009 EN 12162:2001+A1:2009 (E) When residual chloride deposition is not acceptable, washing shall be by de-ionised or distilled water and evaporative drying should be avoided Any other special cleaning requirements applied to the item being tested shall be examined for additional hazards and appropriate measures taken to reduce them The results of the examination shall be recorded 11 Acceptance criteria 11.1 The integrity of the item under test is to be regarded as satisfactory if during the test period there are no visible signs of leakage 11.2 Leakage through shaft or rod packing, through temporary gaskets or through internal test partitions required for segmental hydrostatic testing, is acceptable 12 Repairs If the acceptance criteria stated in clause 11 are not met the cause shall be identified and the manufacturer shall either safely dispose of the item tested or apply suitable corrections After correction, the hydrostatic test shall be repeated The methods of correction and any changes to the design shall be recorded 13 Test Records 13.1 The manufacturer shall keep a record of the test and its results The record shall contain: identification of the item tested ; details of the test including the liquid used, the test pressure, and the test result ; any corrective actions applied including changes to the design ; other information required by this standard to be recorded 13.2 Test certificate If required by the purchaser a test certificate may be made available The test certificate shall certify that the hydrostatic test was carried out in accordance with this Standard, and that the test item met the acceptance criteria Where a sampling programme is used the certificate shall include a reference to the quality grade of the test lot Annex A gives an example of random sample schedule 13.3 Test report If required by the purchaser, the manufacturer/supplier may supply a report of the hydrostatic test, which shall indicate at least the following information: identification of the pump ; type and characterising data (eg dimensions) of the item tested ; list of any modifications made to the design ; applicable test-, quality-, supply-standard ; type of test liquid ; test pressure ; test duration ; BS EN 12162:2001+A1:2009 EN 12162:2001+A1:2009 (E) result of the test ; date when the test was carried out ; signature of the inspector or test controller Each item subject to a test report shall be marked uniquely for identification In the case of a witnessed test, the acceptance of an item or its release for further manufacturing steps shall be confirmed by the signature of the purchaser's representative 10 BS EN 12162:2001+A1:2009 EN 12162:2001+A1:2009 (E) Annex A (informative) Random sample schedule This annex provides an example of a statistically based sampling programme for the selection and assessment of test items for series or mass-produced pumps, as allowed in clause It is based upon ISO 2859-1 The programme relates the size of the test lot to the size of the production lot or batch being considered and relates the permitted incidence of defects to a quality grade Defects are defined as deviations from permitted tolerances but not sufficiently so as to permit the delivery of unsafe products A.1 Selection of quality grade The selection of the appropriate quality grade is made on the basis of the assessed risks of hazards to safety which relate to the integrity of the pressure retaining walls and joints Quality Grade may be considered adequate for pumps handling noxious but non-toxic or flammable liquids and is likely to be selected for pumps supplied for most industrial uses Similarly, Quality Grade may be considered adequate for a pump which is intended for decorative water display The Acceptable Quality Limit is defined as the average incidence of defects in a batch The sampling numbers in Table A.1 give a 95 % probability that the sample represents the entire batch But it is not certainty, and there remains a calculable possibility that the batch may have a higher defect rate than the AQL Values of these probabilities against actual defect rates can be found from ISO 2859-1 A.2 Formation of a test-lot A production lot or batch from which the samples are to be chosen for testing shall comprise only such items which have been manufactured under the same processes and to the same state of manufacture A sample of one or more items must be taken at random from the lot, without regard to their quality The random sample must be representative of the entire lot It must be selected in such a way that each item or unit is given the same probability of being chosen The number chosen shall conform to Table A.1 below, and will form the test lot A.3 Acceptance and rejection The acceptance or rejection of a production lot or batch shall be made on the basis of the number of defective items found in the test lot as set out in Table A.1 below Each defective item recognised in the test shall be discarded This is independent of the decision regarding whether the lot is or is not accepted Discarded items can be repaired or otherwise corrected and then shall be retested prior to being accepted A.4 Symbols N the number of units making up the production lot, batch or group which are to be assessed for acceptance ; n the number of units selected from the production lot or batch which make up the test lot and are tested ; c the maximum number of defective units permitted in a test lot to permit acceptance of the production lot or batch 11 BS EN 12162:2001+A1:2009 EN 12162:2001+A1:2009 (E) Table A.1 - Quality grade Quality Grade Acceptable Quality Limit 0,1 % 1,0 % 2,5 % N c n c n c to N N 5*) to 15 N N 16 to 25 N 13 26 to 50 N 13 51 to 90 N 13 20 91 to 150 125a 13 20 151 to 280 125 50 32 281 to 500 125 50 50 501 to 1200 125 80 80 1200 to 10000 125 150 150 10 a 12 n Test lot is the number shown or N whichever is the lesser BS EN 12162:2001+A1:2009 EN 12162:2001+A1:2009 (E) Annex ZA (informative) !Relationship between this European Standard and the Essential Requirements of EU Directive 98/37/CE This European Standard has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association to provide a means of conforming to Essential Requirements of the New Approach Directive Machinery 98/37/EC, amended by 98/79/EC Once this standard is cited in the Official Journal of the European Communities under that Directive and has been implemented as a national standard in at least one Member State, compliance with the normative clauses of this standard, except clauses 13.2 and 13.3, confers, within the limits of the scope of this standard, a presumption of conformity with the Essential Requirements 1.3.2 and 1.5.13 of that Directive and associated EFTA regulations WARNING — Other requirements and other EU Directives may be applicable to the product(s) falling within the scope of this standard." 13 BS EN 12162:2001+A1:2009 EN 12162:2001+A1:2009 (E) Annex ZB (informative) !Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC This European Standard has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association to provide a means of conforming to Essential Requirements of the New Approach Directive 2006/42/EC on machinery Once this standard is cited in the Official Journal of the European Communities under that Directive and has been implemented as a national standard in at least one Member State, compliance with the normative clauses of this standard, except clauses 13.2 and 13.3, confers, within the limits of the scope of this standard, a presumption of conformity with the Essential Requirements 1.3.2 and 1.5.13 of that Directive and associated EFTA regulations WARNING — Other requirements and other EU Directives may be applicable to the product(s) falling within the scope of this standard." 14 BS EN 12162:2001+A1:2009 EN 12162:2001+A1:2009 (E) Bibliography [1] ISO 2859-1:1989, Sampling procedures and tables for inspection by attributes – Part 1: Sampling plans indexed by acceptable quality level (AQL) for lot-by-lot inspection 15 BS EN 12162:2001 +A1:2009 BSI - British Standards Institution BSI is the independent national body responsible for preparing British Standards It presents the UK view on standards in Europe and at the international level It is incorporated by Royal Charter Revisions British Standards are updated by amendment or revision Users of British Standards should make sure that they possess the latest amendments or editions It is the constant aim of BSI to 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