BRITISH STANDARD District heating pipes — Pre-insulated flexible pipe systems Part 4: Bonded system with metal service pipes; requirements and test methods ICS 23.040.01 NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW BS EN 15632-4:2009 BS EN 15632-4:2009 National foreword This British Standard is the UK implementation of EN 15632-4:2009 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 This British Standard was published under the authority of the Standards Policy and Strategy Committee on 28 February 2009 © BSI 2009 ISBN 978 580 58239 Amendments/corrigenda issued since publication Date Comments BS EN 15632-4:2009 EUROPEAN STANDARD EN 15632-4 NORME EUROPÉENNE EUROPÄISCHE NORM January 2009 ICS 23.040.01 English Version District heating pipes - Pre-insulated flexible pipe systems - Part 4: Bonded system with metal service pipes; requirements and test methods Tuyaux de chauffage urbain - Systèmes de tuyaux flexibles préisolés - Partie 4: Système bloqué avec tube de service en métal - Prescriptions et méthodes d'essai Fernwärmerohre - Werkmäßig gedämmte flexible Rohrsysteme - Teil 4: Verbundmediumrohre aus Metall Anforderungen und Prüfungen This European Standard was approved by CEN on December 2008 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 worldwide for CEN national Members Ref No EN 15632-4:2009: E BS EN 15632-4:2009 EN 15632-4:2009 (E) Contents Page Foreword Introduction Scope Normative references Terms and definitions Operating conditions .6 5.1 5.2 5.3 5.4 5.5 5.6 Requirements General requirements Service pipes and fittings .6 Axial shear stress Linear water tightness Fittings Surveillance systems 6.1 6.2 6.2.1 6.2.2 6.3 6.4 Test procedures .7 General Axial shear stress General Test procedure .8 Cycle test Linear water tightness BS EN 15632-4:2009 EN 15632-4:2009 (E) Foreword This document (EN 15632-4:2009) 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 July 2009, and conflicting national standards shall be withdrawn at the latest by July 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 is one of a series of standards which form several parts of EN 15632, District heating pipes — Pre-insulated flexible pipe systems: Part 1: Classification, general requirements and test methods; m o c Part 2: Bonded system with plastic service pipes; requirements and test methods; w x Part 3: Non bonded system with plastic service pipes; requirements and test methods; f z b Part 4: Bonded system with metal service pipes; requirements and test methods w ww 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 网 享 分 标准 BS EN 15632-4:2009 EN 15632-4:2009 (E) Introduction Pre-insulated flexible bonded pipe systems with metallic service pipes are used in district and local heating networks This part of the series of standards for the various types of flexible pipe systems is intended to be used in connection with EN 15632-1 where the basic design criteria for flexible district heating pipes are specified m o c f z b 网 享 分 标准 w ww w x BS EN 15632-4:2009 EN 15632-4:2009 (E) Scope This European Standard provides requirements and test methods for flexible, pre-insulated, directly buried district heating pipe assemblies with metallic service pipes and bonding between the layers of the pipes and thermal insulation materials of polyurethane or polyisocyanurate foam, the casing pipes being made of polyethylene This European Standard is valid for maximum operating temperatures up to 140 °C and pressures up to 25 bar for a design lifetime of at least 30 years NOTE For higher temperatures or for the transport of other fluids, for example potable water, additional requirements and testing is needed Such requirements are not specified in this European Standard 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 m o c w x EN 1057, Copper and copper alloys — Seamless, round copper tubes for water and gas in sanitary and heating applications f z b EN 10088-2, Stainless steels — Part 2: Technical delivery conditions for sheet/plate and strip of corrosion resisting steels for general purposes w ww EN 10246-1, Non destructive testing of steel tubes — Part 1: Automatic electromagnetic testing of seamless and welded (except submerged arc welded) ferromagnetic steel tubes for verification of hydraulic leaktightness 网 享 分 EN 10305-1, Steel tubes for precision applications — Technical delivery conditions — Part 1: Seamless cold drawn tubes 标准 EN 10305-2, Steel tubes for precision applications — Technical delivery conditions — Part 2: Welded cold drawn tubes EN 12449, Copper and copper alloys — Seamless, round tubes for general purposes 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 15632-1:2009, District heating pipes – Pre-insulated flexible pipe systems – Part 1: Classification, general requirements and test methods Terms and definitions For the purposes of this document, the terms and definitions given in EN 15632-1:2009 shall apply BS EN 15632-4:2009 EN 15632-4:2009 (E) Operating conditions Pipe systems according to this European Standard shall have a lifetime of at least 30 years at a continuous operating temperature of 120 °C and a maximum operating temperature of 140°C Table —Operating pressures Service pipe Operating Pressure 16 bar X X X Copper Mild steel Corrugated stainless steel 5.1 25 bar X X Requirements General requirements In addition to the general requirements defined in EN 15632-1, the following product specific requirements apply 5.2 Service pipes and fittings w x The service pipes shall fulfil the requirements of diameter and wall thickness in Table f z b m o c Table — Nominal diameters and minimum wall thickness w ww Outside diameter d2 , minimum inside diameter d1, and Nominal diameter minimum wall thickness s mm Copper Mild steel Corrugated stainless steel s d2 s d1 s mm mm mm mm mm 1,0 - - 14 0,2 18 1,0 20 2,0 18 0,2 22 1,0 25 2,0 22 0,2 25 28 1,2 28 2,0 30 0,3 32 35 1,5 - - 39 0,4 40 42 1,5 - - 48 0,5 50 54 1,5 - - 60 0,5 65 - - - - 75 0,6 80 - - - - 98 0,8 100 - - - - 127 0,9 125 - - - - 147 1,0 150 - - - - 197 1,2 DN 12 16 20 d2 网 享 分 mm 标准 15 EN 10088-2 shall be applied for pipes made of corrugated stainless steel Material: 1.4301 or 1.4404 For copper pipes EN 12449 shall be applied The material shall be Cu-DHP-CW024A-H40, and for the tolerances EN 1057 shall be applied BS EN 15632-4:2009 EN 15632-4:2009 (E) For seamless steel pipes EN 10305-1 shall be applied The material shall be E215+N For welded steel pipes EN 10305-2 shall be applied The material shall be E215+N Welded pipes shall be tightness tested according to EN 10246-1 Deviating from these standards, service pipes and fittings shall be designed and tested for the operating cycles specified in 6.3 5.3 Axial shear stress The axial shear strength between the service pipe and the insulation shall be at least 0,12 MPa when tested according to 6.2 at ambient temperature The axial shear strength between the service pipe and the insulation shall be at least 0,08 MPa when tested according to 6.2 at maximum operating temperature This requirement is only applicable for smooth wall service pipes and not relevant for corrugated stainless steel pipes 5.4 Linear water tightness m o c When tested in accordance with 6.4, the amount of water leaking through any of the pipe ends shall not exceed 100 g after 168 hours 5.5 Fittings f z b w x When tested in accordance with 6.3 there shall be no leakage 5.6 Surveillance systems w ww If measuring systems are installed, all relevant requirements of EN 14419 shall be fulfilled before and after the flexibility test according to EN 15632-1:2009, 6.1, and the linear water tightness test according to 6.4 of this document shall be performed with the measuring elements installed 网 享 分 标准 Test procedures 6.1 General Unless stated otherwise, all tests are to be carried out: no sooner than 72 hours after production, at room temperature, on samples taken from coiled pipes 6.2 6.2.1 Axial shear stress General The shear stress of a soft steel or copper smooth walled pipe assembly shall be determined on at least test specimens at each temperature There shall be no visual air gap between service pipe and insulation on a corrugated stainless pipe assembly (For corrugated stainless steel pipe assembly an axial shear test cannot be carried out) BS EN 15632-4:2009 EN 15632-4:2009 (E) 6.2.2 Test procedure The axial shear stress between the service pipe and the insulation shall be tested as shown in Figure 1, where (1) is the test specimen, (2) a cylindrical piston pressing onto the service pipe and a support (3) with a cylindrical opening The test specimen (1) shall have a length which equals the outer diameter of the casing ± %, the ends shall be cut at right angle The piston (2) shall be made from metal and shall have an outer diameter which equals the outer diameter of the service pipe with a tolerance of up to −01 mm The support (3) shall be made of metal, the diameter of the circular central opening shall equal the mean of the inner and outer diameter of the insulation m o c f z b 网 享 分 w ww 标准 Key test specimen piston for force F support Figure — Shear stress test apparatus w x BS EN 15632-4:2009 EN 15632-4:2009 (E) The piston (2) and the support (3) are to be moved towards each other with a tensile testing machine at a constant speed of mm per minute and the movement and the force is to be recorded The shear stress τax is to be calculated as follows: τax = F/(L· d2 ·π) in N/m where F L d2 6.3 is the recorded force is the length of the test is the outer diameter of the service pipe in N in m in m Cycle test A straight sample of service pipe shall be fitted with a connector at one side and a T-piece or a reducer at the other side The length of the sample shall be at least times the outer diameter of the pipe This sample shall be tested at alternating strain and alternating operating pressure according to Table at the continuous operating temperature of the pipe system The test cycles for service pipes are given in Table m o c Table — Pressure testing of fittings Material Mild steel Alternating strain mm/m to 1,2 Copper to 1,7 Corrugated stainless steel to 1,7 Alternating pressure bar to 25 f z b w x Butt weld Butt welded T-piece or reducer Soldered connector or press coupling Soldered T-piece or reducer or press T-piece or reducer System specific connector System specific T-piece w ww to 16 to 25 网 享 分 Connection of the fitting Table — Test cycles for service pipes 标准 Service pipe nominal diameter DN DN ≤ 50 mm DN > 50 mm Test cycles 2500 500 Cycle times min The test cycle numbers are derived from EN 13941 6.4 Linear water tightness On a m long sample of the pipe, taken from a pipe in the delivery condition the casing shall be removed on 0,1 m at 2,0 m distance from one pipe end A suitable water container shall be sealed to the casing at both sides of the exposed insulation and be filled with water with a pressure of 0,05 bar at room temperature The sample shall be placed horizontally In both ends of the sample a suitable container shall be mounted to collect water leaking from the pipe end After 168 h, the water collected from the pipe ends shall be weighted BS EN 15632-4:2009 BSI - British Standards 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