BRL-K17401 Comments before.. Replaces BRL-K17401 d.d. 16 April Evaluation guideline

Transcription

1 Comments before.. Replaces d.d. 16 April 2004 Evaluation guideline For the Kiwa (technical approval-with-) product certificate for District heating: flexible piping systems with plastic medium pipe for transport of drinking water and warm tap water

2 Preface Kiwa This evaluation guideline has been prepared by the Kiwa Board of Experts CWK, in which the relevant parties in the field District heating: flexible piping systems with plastic medium pipe for transport of drinking water and warm tap water are represented. This Board of Experts also guides the performance of certification and updates this evaluation guideline in case necessary. Wherever the term Board of Experts is written in this evaluation guideline, the above- mentioned Board of Experts is meant. Kiwa shall use this evaluation guideline in conjunction with the Kiwa Regulations for Product Certification, in which the formal rules used by Kiwa in the event of certification are laid down. This evaluation guideline shall be renewed and appointed at least every 5 years by the above mentioned Board of Experts, the subsequent time not later than xxxxx (date 5 years after validation). Kiwa N.V. Sir W. Churchill-laan 273 P.O. Box 70 NL-2280 AB RIJSWIJK The Netherlands Tel Fax Kiwa N.V. All rights reserved. No part of this publication may be reproduced and/or published by means of printing, photocopying, microfilm or in any other manner whatsoever without the publisher s prior permission in writing. The use of this evaluation guideline for any purpose whatsoever shall only be allowed after the conclusion of a written agreement with Kiwa in which the right of use is arranged. Validation This evaluation guideline has been validated by the director of Kiwa per [dd month yyyy]. Kiwa Nederland B.V comments before

3 Contents 1 Introduction General Scope Terminology Acceptance of test reports provided by the supplier Certificate 7 2 Terminology General definitions Definitions: the construction Definitions: material characteristics Symbols 12 3 Quality system requirements General Manager of the quality system Internal quality control/quality plan Procedures and work instructions 13 4 Requirements and test methods for the piping system General Requirements to avoid deterioration of the quality of the drinking water Lifetime of the system Thermal insulation properties of piping package Requirements for the joints of the piping system Requirements for the piping package Installation instructions Protection of products during storage and transport 17 5 Requirements for the service pipe and test methods Long term strength Toxicological requirements Plastics barrier layer PE-X pipes PB pipes PE-RT II pipes 22 Kiwa Nederland B.V comments before

4 5.7 Multi layer pipes 24 6 Requirements for the fitting and test methods Requirements for the plastics fittings Requirements for metal fittings Toxicological requirements 26 7 Requirements for the insulation material and test methods Insulation material Functional requirements 27 8 Requirements for the outer casing and test methods Functional requirements Material Mechanical requirements of the PE or PP outer casing 29 9 Test methods Flexibility Axial shear strength (for bonded systems only) Linear water tightness (for bonded systems only) Sealing in linear direction (for non-bonded sytems only) Marking Outer casing Marking of the service pipe Fittings Summary of tests and inspections Test matrix Inspection of the quality system Agreements on the performance of certification General Certification staff Frequency of external inspections Interpretation of the requirements List of normative documents Public Law rules Standards / normative documents: 41 Kiwa Nederland B.V comments before

5 14 Annex 1: Model IQC scheme Annex 2: Certificate Annex 3: Measurement of linear thermal resistance and conductivity of the pipe General Apparatus Test sample Test conditions and procedures Measurement Thermal conductivity of the pipe system Declared linear thermal resistance and thermal conductivity Annex 4: Determination of the declared values of the radial thermal resistance conductivity of flexible pipe assembly Introduction Test specimens Determination of the declared values of the thermal resistance Annex 5: Determination of design values for the radial thermal resistance Annex 6: Calculation of the heat flow from the medium to the ambient(heat loss) General Radial thermal resistance of the surrounding soil Declared values of the radial thermal resistance of buried piping systems Annex 7: Compressive Creep General Principles of testing Test apparatus Test sample Test procedure Calculation and expression of results Annex 8: Products for transport of drinking water: guidance for prevention of contamination during transport and storage Importance of a hygienic operation Protection of the used products Requirements for the protection of products 59 Kiwa Nederland B.V comments before

6 21.4 How to protect: General How to protect: Pipes 60 Kiwa Nederland B.V comments before

7 1 Introduction 1.1 General This evaluation guideline contains all relevant requirements on the basis of which Kiwa handles an application and maintains a Kiwa product certificate for For the Kiwa (technical approval-with-) product certificate for: District heating: flexible piping systems with plastic medium pipe for transport of drinking water and warm tap water. This evaluation guideline replaces the evaluation guidelines (BRL): BRL K17401 part A dated 16 April 2004, District heating: flexible piping systems with plastic medium pipe for transport of warm drinking water.; Quality declarations issued on the basis of these evaluation guidelines maintain their validity. During the performance of the certification work, Kiwa is bound to the requirements as laid down in the chapter Agreements on the performance of certification. 1.2 Scope The products are intended to be used in piping systems for district heating at a design pressure (= maximum working pressure) of 1.0 MPa or 0.8 MPa under the conditions mentioned in table 1. Table 1 Classification system Temperature [ ºC] Lifetime Overall service coefficient T cold 20 0 years 1,25 T design years 1,5 T max 90 1 year 1,3 T malfunction hours 1,0 Remark: the mentioned temperature profile is in accordance with class DH1 Kiwa Nederland B.V comments before

8 1.3 Terminology In this Evaluation Guideline the following definitions shall apply: Board of Experts: the Board of Experts LSK ; Supplier: the party responsible for ensuring that the products continuously fulfil the requirements on which the certification is based; Note: the Supplier may also be the manufacturer of the certified product(s). IQC-scheme: a description of the quality inspections carried out by the supplier as part of his quality system. Diametral clearance: the difference between the mean inside diameter of the socket and the mean outside diameter of the spigot end. Cleaner: a fluid which aims at cleaning the surfaces to be bonded and making the surfaces lubricant free. 1.4 Acceptance of test reports provided by the supplier If the supplier submits reports from research bodies or laboratories to show that the requirements of the Evaluation Guideline are met, it will have to be shown that such reports were prepared by a body meeting the prevailing accreditation standard, i.e. NEN-EN-ISO/IEC for laboratories; NEN-EN-ISO/IEC for inspection bodies; NEN-EN for certification bodies certifying products; NEN-EN-ISO/IEC for certification bodies certifying systems; NEN-EN-ISO/IEC for certification bodies certifying persons. The body is deemed to meet these criteria if an accreditation certificate can be submitted which has been issued by Raad voor Accreditatie (Board of Accreditation) or an accreditation body with which Raad voor Accreditatie has concluded a mutual acceptance agreement. This accreditation should relate to the tests required for this Evaluation Guideline. If no accreditation certificate can be submitted, certification body itself shall verify whether the accreditation standard has been met or carry out the tests concerned itself, or have same them carried out. 1.5 Certificate Any quality certificate issued on the basis of this Evaluation Guideline is referred to as a KIWA product certificate. A model of the certificate to be issued on the basis of this Evaluation Guideline has been included as an Annex. Kiwa Nederland B.V comments before

9 2 Terminology 2.1 General definitions Supplier the party responsible for ensuring that the design of products continuously fulfils the requirements of this evaluation guideline. IQC-Scheme a description of the quality inspections carried out by the manufacturer as part of his quality system; Evaluation Guideline The agreements made within the Board of Experts with regard to the subjects of certification. Board of Experts The Board of Experts LSK. Heat distribution system Heat distribution is the collective use of heat for the purpose of heating houses, businesses and other buildings and the possible delivery of warm tap water to those houses, businesses and buildings. Flexible piping system A piping system in which possible bends in the pipe can be made without any mechanical means and in which the pipe is not deformed and the flow capacity is not reduced due to the possible bends. Remark: in case a minimum bending radius is required in the system, use can be made of mechanical means according to the installation instructions of the supplier. Lifetime The time during which the piping system has to function with a certain operating temperature. See table 1. Life expectancy The time during which the piping system has to function for the intended application. In this BRL the life expectancy is set to at least 30 years according to table 1. Operating temperature (T D) The temperature of the water in the piping system during operation, that occurs at least during a certain part of the lifetime of the piping system. See table 1. Maximum temperature (T max) The highest water temperature in the piping system during operation, that occurs during a certain part of the lifetime of the piping system (the highest occurring temperature during a short time). See table 1. Kiwa Nederland B.V comments before

10 Malfunction temperature (T mal) The highest water temperature in the piping system under abnormal circumstances. For example due to malfunctioning during a short period (maximum 100 hours per 30 years). See table 1. Temperature profile On the basis of the employed design pressure in relation with the maximum and peak temperature, the temperature profile according to table 1 may be used for a lifetime of 30 years. P LPL (or P D) Quantity with the dimension of pressure (for multi layer pipes), which represents the predicted mean pressure at a temperature T and a time t (97,5% value). Design pressure ( P D) The allowable pressure in the piping system that during continuous use during 30 years may occur. In this BRL design pressure is defined as the prevailing overpressure (so for example P D =10 bar overpressure means a design pressure of 11 bar absolute). Reference lines A generic description of the minimum long-term hydrostatic pressure to be expected from a particular composite pipe construction type. The reference lines are parallel to the plotted LTHS lines for a certain temperature and at least 97,5% of all individual experimental results shall lie on or above the reference lines. The procedure to find these lines is only valid for this Guideline. P LTHS Quantity with the dimension of pressure (for multilayer pipes), which represents the predicted mean pressure at a temperature T and a time t (50% value). P LPL The calculated value for the 97,5 % (one-sided) lower confidence limit of the predicted hydrostatic strength for a complete set of rapture data, using the SEM analyses model of ISO Definitions: the construction Piping system The total of pipes, (possibly) outer casing, fittings (and joint assemblies) and insulation material, but excluding distributors. Service pipe The medium carrying pipe, which is in contact with the warm water. Homogeneous service pipe Meant are the service pipes made of PE-X or PB or PE-RT type II and provided with an EVOH barrier layer. This barrier layer prevents or reduces the diffusion of oxygen through the pipe wall strongly. The barrier layer does not contribute to the mechanical strength of the pipe. multilayer M-pipe pipe comprised of polymeric stress-designed layers and one or more metallic stressdesigned layers. Kiwa Nederland B.V comments before

11 NOTE The wall thickness of the pipe consists of at least 60 % of polymeric material. multilayer P-pipe pipe comprised of more than one polymeric stress-designed layer NOTE Pipes consisting of one polymeric stress-designed layer and an outer polymeric layer which is not stress-designed are covered by the appropriate reference product. Outer casing A separate applied outer layer of the piping package, protecting the construction during installation and protecting the construction against external influences (after installation). Insulation layer The thermal insulation layer is meant to provide for the desired insulating characteristics of the piping package. Piping package The complete pipe existing of the service pipe, an insulation layer and (in general) an outer casing. Bonded piping package The different layers of the piping package are joined in such a way that under influence of expansion forces, no displacements at the interface of the mutual piping layers occur. Non-bonded piping package The different layers of the piping package can be mutually displaced under influence of expansion forces. Mechanical joint A connection between a pipe and a fitting, made by means of pressing a ring or case over the outside diameter of the pipe, with or without extra sealing elements and possibly making use of a supporting ring in the pipe, according NEN-EN-ISO Service pipe: Electro fusion joint A joint between a pipe and a fitting realised by melting together of the outer layer of the pipe and medium layer of the fitting. The melting of the material is realised by heat developed due to induction of an electrical resistance. The electrical resistance is composed of a metal thread that is embedded in the fitting. Pipe and fitting are first pushed together till the required installation position, before the material is melted. Service pipe: Socket fusion joint A joint between a pipe and a fitting realised by melting together of the outer layer of the pipe and medium layer of the fitting. The melting of the material is realised by a solid body with the appropriate temperature that is in contact with the material concerned during a certain amount of time: Socket shaped for the pipe and spigot-shaped for the fitting. The material is first melted, after which the pipe and fitting are pushed together till the required installation position is obtained. Kiwa Nederland B.V comments before

12 Service pipe: Butt fusion joint A joint between two pipes, made by heating the planed ends of the pipes by holding them against a flat heating plate until the material reaches fusion temperature. After quickly rmoving the heating plate, the two softened ends are pushed against one another. Mechanical outer casing joint The watertight joint between two outer casing parts by means of: - a contraction socket; - an electro fusion socket; - two (metallic) half plates. 2.3 Definitions: material characteristics S-serie A number without a dimension identifying the pipe according ISO 4065, where the S-series prescribes the pipe series for a certain design pressure SDR-value A number without dimension identifying the pipe according to ISO 4065, where the SDR-value describes a relation between the pipe and his wall thickness for a certain design pressure according to the following formula: ( 2σ + p) d n 2σ SDR = = = + 1 = 2. S + 1 e p p Hydrostatic tension σ Tension in the circumferential direction of the pipe wall caused by internal water pressure. This tension is deduced from the internal pressure according the following formula: ( d e ) p em σ = 20 e min min Where: σ = the tension in the circumference direction of the pipe wall in MPa; p = the internal pressure in bar; d em = the mean outside diameter of the pipe in mm; 1) e min = the minimum wall thickness of the pipe in mm. 1) 1) the stress bearing layers. E.g. in case of a homogeneous PEX pipe with EVOH barrier layer, only the PEX layer is e min and dem Calculated pipe value (Scalc) Value for a specific pipe calculated according to the following equation, rounded up to the nearest 0,1 mm: S calc d n e = 2 e n n In which: d n = the nominal outside diameter in millimeters; e n = the nominal wall thickness expressed in millimeters. Kiwa Nederland B.V comments before

13 Maximum calculated pipe value (Scalc,max) The maximum value of the calculated S value for a specific application class 2.4 Symbols D n Nominal outside diameter of the service pipe. d em Mean outside diameter of the service pipe. d n,m Nominal outside diameter of the outer casing. d i,m Internal diameter of the outer casing. e min Minimum wall thickness of the service pipe. e max Maximum wall thickness of the service pipe. Kiwa Nederland B.V comments before

14 3 Quality system requirements 3.1 General This chapter contains the requirements that have to be fulfilled by the manufacturer s quality system. 3.2 Manager of the quality system Within the manufacturer s organisational structure an employee must be appointed who is in charge of managing the quality system. 3.3 Internal quality control/quality plan As part of the quality system the manufacturer must implement an internal quality control schedule (IQC-scheme). In this IQC-scheme the following must be demonstrably recorded: which aspects are inspected by the manufacturer; according to which methods these inspections are carried out; how often these inspections are carried out; how the inspection results are registered and stored. This IQC-schedule shall be in the format as shown in the annex. The schedule must be detailed in such a way that it provides Kiwa sufficient confidence that requirements will be continuously fulfilled. 3.4 Procedures and work instructions The manufacturer must be able to submit: procedures for: o the handling of non-conforming products; o corrective actions in case non-conformities are found; o the handling of complaints regarding the products and / or services supplied; the work instructions and inspection sheets in use. Kiwa Nederland B.V comments before

15 4 Requirements and test methods for the piping system 4.1 General In this chapter the performance requirements imposed on the piping system are included, as well as the determination methods in order to be able to determine whether the requirements are fulfilled. 4.2 Requirements to avoid deterioration of the quality of the drinking water Products and materials, which (may) come into contact with drinking water or warm tap water, shall not release substances in quantities which can be harmful to the health of the consumer or negatively affect the quality of the drinking water. Therefore, the products or materials shall meet the toxicological, microbiological and organoleptic requirements as laid down in the valid Ministerial Regulation materials and chemicals drinking water and warm tap water supply (published in the Government Gazette). Consequently the procedure for obtaining a recognised quality declaration, as specified in the valid Regulation, has to be concluded with positive results. Products and materials with a quality declaration*, e.g. issued by a foreign certification institute, are allowed to be used in the Netherlands, provided that the Minister has declared this quality declaration equivalent to the quality declaration as meant in the Regulation. 4.3 Lifetime of the system The complete piping system must be designed for lifetime expectancy according to paragraph 1.2. Remark: with lifetime is meant the technical lifetime of the system during normal usage. The different life spans according to table 1 have to be totalled up in order to obtain the minimum lifetime of 30 years (class DH1). 4.4 Thermal insulation properties of piping package The manufacturer shall submit values for the heat loss of the piping package for all pipe dimensions in accordance with annex 6: Calculation of the heat flow from the medium to the ambient (heat loss), rounded to full 0,001 W/mK. NOTE Annex 3: Measurement of linear thermal resistance and conductivity of the pipe, specifies how to measure thermal properties, annex 4: Determination of the declared values of the radial thermal resistance conductivity of flexible pipe assembly, how to calculate declared values for thermal properties of all pipe dimensions, and annex 5: Determination of design values for the radial thermal resistance, how to (include) ageing effects. 4.5 Requirements for the joints of the piping system General The joints in the piping system have to be tested with regard to their proper functioning. In this chapter all joint tests required for the joint system are included. A quality declaration issued by an independent certification institute in another member state of the European Community than the Netherlands or another state party to the agreement to the European Economic Area, is equivalent to a recognised quality declaration, to the extent that, to the judgment of the Minister of the first mentioned quality declaration, is fulfilled the at least equivalent requirements as meant in the Regulation materials and chemicals drinking water- and warm tap water supply. Kiwa Nederland B.V comments before

16 The combination of a (possible) rubber seal, pipe, (possible) supporting insert and clamp construction in the fitting have to be tested with regard to the aspects as mentioned in table Rubber Rubber seals shall fulfill the requirements according to BRLK17105 for the herein described appropriate temperature class. The manufacturer has to declare to the approval body which type of rubber is applied, as well as the hardness and dimensions of the rubber seals Tightness and strength of the joints of the service pipe The fittings shall not deform during testing in accordance with table 2. After testing, the pipe ends shall show no severe damages. If not otherwise stated, the testing temperature is (23±2) C. Table 2 - Tightness and strength of the joints of the service pipe Aspect Requirement Test parameters Resistance to no n = 2000 cycli 4)6) thermal cycling leakage T max = 93 ± 2 C 1) T min = 23 ± 2 C 2) t cyclus= 30 min 3). P d (bar) One test piece Resistance to pull-out Leak tightness under vacuum Leak tightness under internal pressure and bending Resistance to internal hydrostatic pressure no leakage t = 60 ± 1 min. Three test pieces F = 1,5 * π/4 * D 2 n * P d (N) 0,05 bar t = 60 ± 1 min. Three test pieces P= -0,8 bar no t = 60 ± 1 min. leakage Three test pieces 7) Service pipe Type no leakage PE-X PB PE-RT type II Multi layer t = 1000 h T = 95 C Three test pieces Service pipe Type PE-X PB PE-RT type II Multi layer Test pressure P (bar) ,6 22,6 25,3 5) 27,5 30,1 33,7 5) Test pressure P (bar) ,3 8,7 7,5 5) 11,0 11,6 10,0 5) 34,4 37,6 42,2 5) 13,8 14,5 12,5 5) Test method NEN-EN NEN-EN 712 NEN-EN NEN-EN 713 NEN-EN- ISO 1167 Kiwa Nederland B.V comments before

17 1) Maximum test temperature of the water 2) Minimum test temperature of the water 3) for d 110mm t cyclus= t max + t min (= = 30 min) for d > 110mm t cyclus= t max + t min (= = 60 min) 4) for d 32mm counts n = 2000; for 40 d 110mm counts n = 1000; for d > 110mm counts n = 250 5) on basis of the regression curve and at least equal to the value of the service pipe material according to ISO ) if the service pipes are used in plastic piping systems for hot and cold water installations inside buildings, the number of cycles shall be n = ) only pipes < 63 mm General remark: These values are calculated like those in part 5 of the product standards using the design stress calculated for the DH1 temperature profile and the 1000 h/95 ºC values of table Requirements for the piping package Remark: For the most part the relevant requirements are taken over from NEN-EN Long term compression The long term compression of the piping package has to fulfil the requirements according table 3. Table 3 Requirements with regard to the long-term compression of the piping package Aspect Requirement Test parameters test method Ring stiffness 4 kn/m 2 Temperature compression velocity of compression 23 ± 2 C 3% 5 ± 1 mm/min. NEN-EN-ISO 9969 Creep ratio 5 Temperature 23 ± 2 C NEN-EN-ISO Compressive creep After testing in accordance with annex 7: Compressive creep, the decrease of the insulation thickness of the piping package may not be larger than 10% Flexibility The flexibility of the piping package shall be verified by the minimum bending radius. The minimum declared installation bending radius of the piping package shall not exceed 30 times the outer diameter of the casing. The producer shall declare the minimum installation bending radius for all dimensions produced. When bending to the minimum radius, the service pipe and the casing of the pipe assembly shall not break, and the ovality of the outer casing shall not exceed 30 % when tested according to 9.1. Cracks in the insulation material at the casing shall not exceed a width of 5 mm Axial shear strength (for bonded systems only) For bonded piping systems the axial shear strength between the service pipe and the insulation material shall be at least 0,09 MPa for polymer pipes and 0.12 MPa for multi layer pipes, when tested in accordance with 9.2. The test result shall be determined as an average of 5 measurements. Kiwa Nederland B.V comments before

18 4.6.5 Linear water tightness (for bonded systems only) When tested in accordance with 9.3, the amount of water leaking through any of the pipe ends shall not exceed 100 g after 168 hours Sealing in linear direction (for non-bonded sytems only) The manufacturer of the system shall offer components to stop leakage in the linear direction at the end of each pipe section. These components shall be water tight when tested according to Water vapour permeation The pipe supplier shall give information about the risk of water accumulation in the insulation dependant on the service conditions. NOTE PEX, PE-RT type II and PB pipes are slightly open for diffusion of water from the media to the insulation. The rate of diffusion increases with the temperature. The casing is likewise open for diffusion from the insulation to the soil. The rate of this diffusion is depending upon the casing temperature and the water vapour partial pressure difference over the casing wall. For pipes installed under the ground water table there will always be a certain build up of water directly under the casing. Experience shows that this build up is limited and not detrimental to the function although a certain loss of insulation capacity may be expected Watertightness of Casing connections The water tightness off types of casing connections (main distribution system, house connections, etc.) shall be tested according to NEN-EN 489, point without sandbox. 4.7 Installation instructions The supplier shall provide installation instructions in the Dutch language. A reference to these instructions shall be made at or near the packaging. The instructions must contain specific information with regard to storage, safety, transport, processing temperature, construction of the joints and specific installation guidelines. 4.8 Protection of products during storage and transport The products shall be protected during storage and transport to prevent contamination of all product-parts intended to be in contact with the drinking water. See for information annex 8: products for transport of drinking water: guidance for prevention of contamination during transport and storage Kiwa Nederland B.V comments before

19 5 Requirements for the service pipe and test methods 5.1 Long term strength For the raw material to be used for the manufacturing of the pipes, the manufacturer shall submit pressure test data based on tests (in water or in air) of out of the raw material extruded pipes, in accordance with NEN-EN-ISO 1167, during at least hours and for the following temperatures: 20 C, C or 80 C, 95 C and 110 C. The data must be statistically processed and presented according NEN-EN-ISO The elaborated LPL curves must be equal or better than the curves of the relevant material according NEN-EN-ISO for PE-X, NEN-EN-ISO for PB, NEN-EN ISO for PE-RT Type II and NEN-EN-ISO for multi layer. 5.2 Toxicological requirements See point Plastics barrier layer General The barrier layer shall fulfil the following preconditions: Information concerning the thickness of the layer and its tolerances, as well as the type and the supplier of the plastics barrier layer, shall be a part of the certification agreement as to be concluded with the certification body. 5.4 PE-X pipes Remark: For the most part the relevant requirements are taken from NEN-EN-ISO Classification On the basis of the S-value, it is determined at which pressure which wall thickness is suitable for class DH1, see table 4. Table 4 S-value and application Class S-value (P D = 8 bar) S-value (P D = 10 bar) DH1 4,0 3,2 Kiwa Nederland B.V comments before

20 5.4.2 Dimensions The dimensions of the pipes are given in table 5. For the determination of the dimensions, the method according NEN-EN-ISO 3126 has to be followed. Table 5 - Dimensions of PE-X pipes (in mm). d n d em Out of roundness Min. Max. P = 8 bar Wall thickness SDR 9 SDR 7.4 S = 4 P = 10 bar S = 3.2 e min e max e min e max 12 12,0 12,3 0,3 1,4 1,7 1,7 2, ,0 16,3 0,4 1,8 2,1 2,2 2, ,0 18,3 0,5 2,0 2,4 2,4 2, ,0 20,3 0,5 2,3 2,7 2,8 3, ,0 22,3 0,5 2,5 3,0 2,9 3, ,0 25,3 0,6 2,8 3,2 3,5 4, ,0 28,3 0,6 3,2 3,7 3,9 4, ,0 32,3 0,8 3,6 4,1 4,4 5, ,0 40,4 1,0 4,5 5,1 5,5 6, ,0 50,5 1,2 5,6 6,3 6,9 7, ,0 63,6 1,4 7,1 8,0 8,6 9, ,0 75,7 1,4 8,4 9,4 10,3 11, ,0 90,9 1,4 10,1 11,3 12,3 13, ,1 111,0 1,6 12,3 13,7 15,1 16, ,0 126,2 1,6 14,0 15,4 17,1 19, ,0 141,3 1,6 15,7 17,4 19,2 21, ,0 161,5 1,8 17,9 19,8 21,9 24, ,0 191,5 1,8 20,0 22,1 24,6 27, ,0 201,5 2,0 22,4 24,8 27,4 30, ,0 226,5 2,0 25,0 27,6 30,8 33, ,0 251,5 2,0 27,9 30,9 34,2 37,6 Kiwa Nederland B.V comments before

21 5.4.3 Physical and mechanical properties of PE-X pipes Table 6 Requirements for PE-X pipes Aspect Requirement Test parameter Dimensions According Dimensions table 5 Appearance Smooth Soundness without any flaws Test method NEN-EN-ISO 3126 Visual inspection Extent PE- Peroxide 70 % NEN-EN 579 NEN-EN 579 of cross linking 1) Xa PEsystem Silane system 65 % NEN-EN 579 Xb PE- Radiation 60 % NEN-EN 579 Xc System PE- Xd AZO-system 60 % NEN-EN 579 Resistance to internal pressure 1 h 4) 20 C 12 2) NEN-EN-ISO h 4) 95 C 4,8 2) 22 h 4) 95 C 4,7 2) 165 h 4) 95 C 4,6 2) 1000 h 4) 95 C 4,4 2) Thermal stability h 4) 110 C 2,4 2) NEN-EN-ISO 1167 Longitudinal reversion 3 % 3) Change of length NEN-EN-ISO NEN-EN-ISO 2505 method B 1) The maximum allowed percentage of cross linking of the system must be stated by the manufacturer. The percentage measured during the determination according the above mentioned method, shall be in between both values. 2) σ (N/mm 2 ) 3) After the test, the test pieces may not show any cracks, blisters or cavities. 4) Minimum required test time 5.5 PB pipes Remark: For the most part the relevant requirements are taken over from NEN-EN-ISO Classification On the basis of the S-value, it is determined at which pressure which wall thickness is suitable for class DH1, see table 7. Table 7 S-value and application Class S-value (P D = 8 bar) S-value (P D = 10 bar) DH1 5,2 4,1 Kiwa Nederland B.V comments before

22 5.5.2 Dimensions The dimensions of the pipes are given in table 8. For the determination of the dimensions, the method according NEN-EN-ISO 3126 has to be followed. Table 8 - Dimensions of PB pipes (in mm) d n d em Max. Out of round ness Wall thickness SDR11 SDR 9 P = 8 bar S= 5 P = 10 bar S= 4 Min. Max. e min e max e min e max 12 12,0 12,3 0,3 1,3 1,6 1,4 1, ,0 16,3 0,4 1,5 1,8 1,8 2, ,0 18,3 0,5 1,7 2,0 2,0 2, ,0 20,3 0,5 1,9 2,2 2,3 2, ,0 22,3 0,5 2,0 2,3 2,4 2, ,0 25,3 0,6 2,3 2,7 2,8 3, ,0 28,3 0,6 2,6 3,0 3,1 3, ,0 32,3 0,8 2,9 3,3 3,6 4, ,0 40,4 1,0 3,7 4,2 4,5 5, ,0 50,5 1,2 4,6 5,2 5,6 6, ,0 63,6 1,4 5,8 6,5 7,1 8, ,0 75,7 1,4 6,8 7,6 8,4 9, ,0 90,9 1,4 8,2 9,2 10,1 11, ,0 111,0 1,6 10,0 11,1 12,3 13, ,0 126,2 1,6 11,4 12,7 14,0 15, ,0 141,3 1,6 12,7 14,1 15,7 17, ,0 161,5 1,8 14,6 16,2 17,9 19, ,0 191,5 1,8 16,4 19,2 20,1 22, ,0 201,5 2,0 19,2 20,2 22,4 24, ,0 226,5 2,0 20,5 22,7 25,2 27, ,0 251,5 2,0 22,7 25,1 27,9 30,7 Kiwa Nederland B.V comments before

23 5.5.3 Physical and mechanical properties of PB pipes Table 9 - Requirements for PB pipes Aspect Requirement Test parameter Dimensions According Dimensions table 8 Appearance Smooth Soundness without any flaws Resistance to internal pressure 1 h 20 15,5 2 C ) 22 h 95 C 6,5 2) 165 h 95 C 6,2 2) 1000 h 95 C 6,0 2) Thermal stability h 110 C MFR Value may vary max. 30% of nominal value 2 % 1) T = 190 C Test methods NEN-EN-ISO 3126 Visual inspection NEN-EN-ISO ,2 2) NEN-EN-ISO 1167 mass = 5 kg Longitudinal Change of reversion length NEN-EN-ISO ) After the test, the test pieces may not show any cracks, blisters or cavities. 2) σ (N/mm 2 ). NEN-EN-ISO 1133 NEN-EN-ISO 2505 method B 5.6 PE-RT II pipes Remark: For the most part the relevant requirements are taken over from NEN-EN-ISO Classification On the basis of the S-value, it is determined at which pressure which wall thickness is suitable for class DH1, see table 10. Table 10 S-value and application Class S-value (P D = 8 bar) S-value (P D = 10 bar) DH1 3,5 2, Dimensions The dimensions of the pipes are given in table 11. For the determination of the dimensions, the method according NEN-EN-ISO 3126 has to be followed. Kiwa Nederland B.V comments before

24 Table 11 - Dimensions of PE-RT II Type pipes (in mm) d n d em Max. Out of round ness Wall thickness SDR 7,4 SDR 6 P = 8 bar S= 3,2 P = 10 bar S= 2,5 Min. Max. e min e max e min e max 12 12,0 12,3 0,3 1,7 1,7 2,0 2, ,0 14,3 0,4 1,9 2,2 2,2 2, ,0 16,3 0,4 2,2 2,6 2,7 3, ,0 20,3 0,5 2,8 3,2 3,4 3, ,0 25,3 0,6 3,5 4,0 4,2 4, ,0 32,3 0,8 4,4 5,0 5,4 6, ,0 40,4 1,0 5,5 6,2 6,7 7, ,0 50,5 1,2 6,9 7,7 8,3 9, ,0 63,6 1,4 8,6 9,6 10,5 11, ,0 75,7 1,4 10,3 11,5 12,5 13, ,0 90,9 1,4 12,3 13,6 15,0 16, ,0 111,0 1,6 15,1 16,8 18,3 20, ,0 126,2 1,6 17,1 19,0 20,8 23, ,0 141,3 1,6 19,2 21,3 23,3 25, ,0 161,5 1,8 21,9 24,2 26,6 29, ,0 191,5 1,8 25,7 28,4 31,7 35, ,0 201,5 2,0 27,0 29,9 33,3 36, ,0 226,5 2,0 30,4 33,6 37,5 41, ,0 251,5 2,0 33,8 37,3 41,7 46,0 Kiwa Nederland B.V comments before

25 5.6.3 Physical and mechanical properties of PE-RT Type II pipes Table 12 Requirements for PE-RT Type II pipes Aspect Requirement Test parameter Test method Appearance Smooth without any flaws Soundness Visual inspection Material IQC 1) IQC 1) IQC 1) Dimensions of different layers IQC 1) IQC 1) IQC 1) MFR (PE-RT) 30% difference with respect to granulated material Mass 5 kg Temperature 190 C Test period 10 min ISO 1133 Resistance to internal Testing time (hour) T ( C) σ (MPa) ISO pressure complete pipe 2) ,8 series , , ,6 Thermal stability (PE-RT) Test time (hour) T ( C) σ (MPa) ISO ,2 series Influence of heating of complete pipe 2 % Change in length at 110 C ISO hour en 8 mm 2 hour 8 mm < en 16 mm 4 hour en > 16 mm Melting temperature adhesive 120 C DSC method ISO ) IQC is laid down as part of the certification agreement, after approval of the certification body. 2) For initial evaluation and yearly inspection the 1000 hours test at 95 Cis carried out. The other testing times can be applied during production control. 5.7 Multi layer pipes The multi layer pipes have to fulfil the requirements of NEN-EN-ISO Long term characteristics The long term pressure strength of the multi layer pipes shall be determined in accordance with NEN-EN-ISO Dimensions The pipe manufacturer shall give detailed information related to the geometrical characteristics, including the wall thickness with tolerances of each layer of the component in a technical file. All relevant dimensions shall be designed according to the requirements of NEN-EN-ISO Kiwa Nederland B.V comments before

26 6 Requirements for the fitting and test methods 6.1 Requirements for the plastics fittings Loaded parts Remark: with "loaded parts" is meant: by internal hydraulic pressure loaded parts. Table 13 Requirements for plastics fittings Aspect Requirement Test parameter Test method Material According IQC 1) Accordng IQC 1) According IQC 1) Long-term strength design stress (σ D) according to the relevant product standard at Resistance to internal hydraulic pressure 2) - at 20 ºC ISO 1167-series with the help of ISO 9080 Class DH1 - at 60 or 80 ºC - at 95 ºC - at 110 ºC Dimensions Specification manufacturer Dimensions ISO 3126 Degree of cross linking (PE-X fittings) Melt flow index (PB fittings) PE-Xa 70% PE-Xb 65% PE-Xc 60% PE-Xd 60% 0,3 g/10 min difference with respect to granulated material Extent of cross linking EN 579 Mass 5 kg Temperature 190 C Test period 10 min EN-ISO Appearance Smooth without any flaws Soundness Visual inspection Thermal stability 3) Test time > hours Resistance to internal hydraulic pressure 2) ISO 1167-series Behaviour at heating Damages around injection point 30 % of wall thickness No holes, bubbles or cracks At 110 C Stress is accordance with the long term strength data In consultation with manufacturer EN-ISO 580 1) IQC: is laid down as part of the certification agreement, after approval of the certification body 2) test on injection moulded, cylindrical test specimens Plastic fittings molded with the identical polymer grade as used for the pipe can refer to the thermal stability test of the pipe material. Fitting material different from the pipe material must perform the thermo stability test of h at 110 C.The hydrostatic tests have to be performed for both variants according to the standard the material belongs to. 3) results to be processed together with results long-term strength" Unloaded parts The requirements applying for plastics (other than according 6.1.1), that are used for the not by internal hydraulic pressure loaded parts of the fittings, are determined separately. Hereby, the manufacturer has to submit the required information to the certification body. Kiwa Nederland B.V comments before

27 6.2 Requirements for metal fittings Table 14 Requirements for metal fittings Aspect Requirement Test parameter Test method Material composition NEN-EN Information manufacturer Dimensions NEN-EN Minimum thickness NEN-EN-ISO 3126 Construction NEN-EN Construction drawings NEN-EN-ISO 3126 Strength fitting body: Resistance to internal hydraulic NEN-EN paragraph 5.1 NEN-EN-ISO 1167 pressure Resistance to stress corrosion No cracks 9,5 > ph > 10 NEN-ISO 6957 Remark: for metal fittings, not manufactured from copper, divergent parameters count which are determined with approval and in consultation with the testing body 6.3 Toxicological requirements See point 4.2. Kiwa Nederland B.V comments before

28 7 Requirements for the insulation material and test methods 7.1 Insulation material Insulation material which fulfils the requirements of NEN-EN 14303, NEN-EN 14304, NEN-EN 14305, NEN-EN 14306, NEN-EN 14307, NEN-EN 14308, NEN-EN 14309, NEN-EN 14313, NEN- EN and CUAP with ETA request No 12.01/02 are applicable for insulation material in flexible district heating systems. 7.2 Functional requirements The materials shall meet the requirements of table 15. When the functional requirements are fulfilled according to another material, then in any case the following requirements apply: Sufficient dimensional stability and uniform dimensions of the cell structure; Closed cell %; For polyolefin: a proved life time according to 5.1; The requirements to be applied are, in this case, determined and evaluated in consultation with the certification body. Table 15 Mechanical requirements for the insulation material. Aspect Requirement Test parameter Test method Material composition According IQC 1) According IQC 1) According IQC 1) Water Option A Option A EN 489 absorption 10% T=100 ± 2 C paragraph Test pieces 3 Option B Option A % T=80 ± 2 C Other According relevant standard materials Water vapour permeation 2) According IQC 1) According IQC 1) According IQC 1) Cell structure Distribution Uniform dimensions According IQC 1) According IQC 1) Cell dimension According IQC 1) According IQC 1) According IQC 1) Closed cell % According IQC 1) According IQC 1) According IQC 1) Thermal characteristics According IQC 1) Test pieces 2 NEN-EN-ISO ) IQC: is laid down as part of the certification agreement, after approval of the testing body. 2) The pipe supplier shall give information about the risk of water accumulation in the insulation dependent on the service conditions. Kiwa Nederland B.V comments before

29 8 Requirements for the outer casing and test methods 8.1 Functional requirements This chapter concerns flexible, corrugated and non-corrugated outer casings of polyolefin s (PE, PP), where the functional requirements for the outer casing are translated to specific material requirements for the outer casing. In case the functional requirements are fulfilled according to another construction, then in any case the following requirements apply: Sufficient dimensional stability and smoothness; Resistance to impact, see table 14; Resistance to traffic load, see table 3; The requirements to be applied are, in this case, determined and evaluated in consultation with the certification body. 8.2 Material Reprocessable material Only clean reprocessable material of the manufacturer s own production of pipes may be used as rework material. Reprocessable material obtained from external sources and recyclable material shall not be used Material requirements The PE or PP raw material has to fulfil the requirements from table 16. Table 16 PE and PP material requirements for the granulated material Aspect Requirement Test parameter Test method Material composition According IQC 1) According IQC 1) Acc. IQC 1) Carbon black content PE 2 2,5% mass According ISO 6964: 1986 ISO 6964 OIT 2) (oxidative induct. time) Melt flow rate (MFR) PE 20 minutes Test temperature 210 C 0,2 to 1,4 g/10 min. PP < 0,5 g/10 min. Weight Test Temperature Weight Test Temperature PE PP 5 Kg 190 C 2,16 Kg 230 C EN 728 NEN- EN-ISO 1133 Conditi on T NEN- EN-ISO 1133 Conditi on M 1) IQC: is laid down as part of the certification agreement, after approval of the testing body 2) is applicable in case the outer casing can be welded Kiwa Nederland B.V comments before

30 8.3 Mechanical requirements of the PE or PP outer casing Unless otherwise stated, a test temperature of 23 ± 2 C applies. Table 17 mechanical requirements for the PE or PP outer casing Aspect Appearance Dimensions Mass per length Longitudina l reversion UVresistance 3) Creep ratio 2) Ring stiffness 2) Resistance to impact 5) Oxidative induction time (OIT) Melt flow rate (MFR) Stress crack resistance 6)7) Requirem ent Test parameter Test method Sound, no According Visual inspection holes or IQC 1) blisters According IQC 1) According IQC 1) 3% No cracks bumps or delamination See footnote 3) According IQC 1) Weight/m ± 1,0g NEN-EN-ISO 3126 Weighing wall thickness 30 min PE PP 8 mm wall thickness 8mm 60 min Method B NEN-EN- ISO C Method B NEN-EN-ISO C Light energy 3,5 GJ/m 2 NEN-EN-ISO 16871: Test pieces 3 NEN-EN-ISO KN/m 2 TIR 10% No failure Compression velocity Test pieces Test temperature Type of striker Falling weight d = 90 mm d = 110 mm d = 125 mm d = 140 mm d = 160 mm d = 190 mm d = 200 mm d = 250 mm 20 minutes Test temperature Test pieces PE ± 20 % 8) PP ± 30 % 8) No failure Weight Test Temperature Weight Test Temperature Failure time Temperature σ 2 ± 0,4 mm/min 3 0 C d 90 0,8 kg 1,0 kg 1,25 kg 1,6 kg 1,6 kg 2,0 kg 2,0 kg 2,5 kg PE PP 210 C 1 Fall heigh t: 1,2 m 1,6 m 2,0 m 1,8 m 2,0 m 1,8 m 2,0 m 2,0 m 5 Kg 190 C 2,16 Kg 230 C >100 hrs 80 C 4,0 N/mm 2 NEN-EN-ISO 9969 NEN-EN 744 EN 728 NEN-EN-ISO 1133 Condition T NEN-EN-ISO 1133 Condition M NEN-ISO Kiwa Nederland B.V comments before

31 1) IQC: is laid down as part of the certification agreement, after approval of the testing body 2) Only applicable in case the insulation material does not contribute to the stiffness of the piping package 3) Only applicable in case the carbon black content 2% mass weight and/or for pipes different from black coloured. After UV exposure the resistance to impact test of this table shall still be fulfilled. 4) Comparison of the elongation at break before and after UV exposition 5) Only applicable for outer casings provided with an after extrusion applied profile 6) LDPE materials shall not exceed a failure rate F20 when tested in accordance with procedure B of NEN-EN-IEC for 1000hrs 7) Only applies for non corrugated outer casings 8) % of the value stated by the supplier of the raw material Kiwa Nederland B.V comments before

32 9 Test methods 9.1 Flexibility The pipe assembly shall be conditioned for 24 hours at the minimum temperature according to the manufacturers installation instructions. Afterwards the pipe assembly shall be fixed onto a bending rig according to Figure 9-1 within ten minutes. After 30 minutes the ovality shall be measured at the positions shown in Figure 9-1. Figure 9-1 Flexibility test Key 1 pipe assembly 2 bending rig 3 straps or clamps 4 measuring point for ovality After measuring the ovality the outer casing shall be opened in the axial direction and visual inspection of the insulation material of the whole bend section shall be carried out. Kiwa Nederland B.V comments before

33 9.2 Axial shear strength (for bonded systems only) The axial shear strength between the service pipe and the insulation material shall be tested as shown in Figure 9-2. The test specimen shall have a length which equals the outer diameter of the casing ± 5 %, the ends shall be cut at a right angle with a tolerance of 5. The piston shall be made from metal and shall have an outer diameter which equals the outer diameter of the service pipe with a tolerance of 1 mm. The support 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. Figure 9-2 Shear strength test apparatus Legend 1 test specimen 2 piston for load impact F 3 support The piston and the support are to be moved towards each other with a tensile testing machine at a constant speed of 5 mm/min and the displacement and the force is to be recorded. The shear strength τ ax is to be calculated as follows: τ ax = F max / L x D n x π where F max L D n = maximal recorded force in Pa = length of the specimen in mm = outer diameter of the service pipe mm 9.3 Linear water tightness (for bonded systems only) On a 4 m long sample of the pipe, taken from a pipe in the delivery condition the casing shall be removed 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. Kiwa Nederland B.V comments before

34 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 weighed. 9.4 Sealing in linear direction (for non-bonded sytems only) Test joints 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 colored. Kiwa Nederland B.V comments before

35 10 Marking 10.1 Outer casing After contracting the certification agreement, the outer casing shall be provided, at intervals of not more than 2m, with the following clearly legible and indelible markings: Kiwa (or Kiwa word mark); Kiwa watermark: - depending on the type of service pipe: PE/X or "PE-X/Al"; PB, PE-RT, PE-RT/AL ; design pressure: 8 or 10 bar; the nominal outside diameter(s) of the service pipe(s) in mm; the nominal outside diameter of the outer casing in mm; the production code; the system name; DH1 or district heating or stadsverwarming Marking of the service pipe After conclusion of the certification agreement, the medium-pipes shall be provided, at intervals of not more than 2 m, with the following clearly legible and indelible markings: Kiwa (or Kiwa word mark); Kiwa watermark: service pipe material dependent on the type of plastics used: PE-X, PB, PE-X/Al, PE-RT, PE-RT/Al; the nominal outside diameter and the nominal wall thickness in mm; design pressure: 8 of 10 bar; class DH1; the production code Fittings After conclusion of the certification agreement, the fittings shall be provided with the following clearly legible and indelible markings on the packaging: Kiwa (or Kiwa word mark); Kiwa watermark: Supplier s name or registered trademark or logo; The outside diameter in mm of the accompanying pipe; For plastics fittings: the material indication of the material from the fitting body according NEN-EN-ISO Kiwa Nederland B.V comments before

36 11 Summary of tests and inspections This chapter contains a summary of tests and inspections to be carried out during: Pre-certification tests: the investigation necessary in order to determine whether all requirements of the evaluation guideline are fulfilled, Inspection visit: the surveillance inspections carried out after issue of the certificate in order to determine whether the certified products continuously fulfil the requirements of this evaluation guideline. The inspections are carried out according to the frequency indicated. Inspection of the quality system: inspection with regard to the correct implementation of the IQC-scheme and procedures Test matrix The table below contains a summary of the tests and inspections to be carried out in the event of certification. Description of requirement Tests within the scope of Article BRL Precertification tests Supervision by CI after granting of the certificate 1) Inspection visit 2) Frequency (per year) System requirements Toxicological requirements 4.2 X X 1 x year Installation instructions 4.7 X X 3) 1 x year Rubber seals X X 3) 1 x year Service pipe joint requirements Resistance to thermal cycling X Resistance to pull-out X Resistance to pressure cycling X Leak tightness under vacuum X Leak tightness under internal pressure and X bending Resistance to internal hydrostatic pressure X X 1 x 2 year Piping package requirements Thermal insulation properties 4.4 X X 3) 1 x year Ring stiffness X X 1 x 2 year Creep ratio X X 1 x 2 year Compressive creep X X 1 x 2 year Flexibility X X 3) 1 x year Axial shear strength (for bonded systems only) X X 3) 1 x year Linear water tightness (for bonded systems only) X X 3) 1 x year Sealing in linear direction (for non-bonded systems X X 3) 1 x year only) Water vapour permeation X X 3) 1 x year Service pipe requirements Long term strength 5.1 X X 3) Toxicological requirements 5.2 X X 1 x year Dimensions 5.4.2, 5.5.2, X X 1 x year 5.6.2, Appearance 5.4.3, 5.5.3, X X 1 x year Extent of cross linking (only PE-X of PE-X/Al) X X 1 x year Kiwa Nederland B.V comments before

37 Resistance to internal hydrostatic pressure 5.4.3, 5.5.3, X X 1 x year Thermal stability 5.4.3, 5.5.3, X MFR X X 1 x year Longitudinal reversion 5.4.3, X X 1 x year Influence of heating the complete pipe X X 1 x year Fitting requirements Dimensions X X 1 x year Appearance X X 1 x year Long term strength fitting body X X 3) Behaviour after heating X X 1 x year Thermal stability X Metal fitting requirements 6.2 X X 1 x year Toxicological requirments 6.3 X X 3) 1 x year Insulation material requirements Water absorption 7.2 X X 3) 1 x year Water vapour permeation 7.2 X X 3) 1 x year Cell structure distribution 7.2 X X 3) 1 x year Cell dimension 7.2 X X 3) 1 x year Closed cell 7.2 X X 3) 1 x year Thermal characteristics 7.2 X X 3) 1 x year Outer casing requirements Material composition X X 1 x year Carbon black content X X 1 x year OIT X X 1 x year MFR X X 1 x year Dimensions 8.3 X X 1 x year Appearance 8.3 X X 1 x year Longitudinal reversion 8.3 X X 1 x year UV-resistance 8.3 X Creep ratio 8.3 X X 1 x year Ring stiffness 8.3 X X 1 x year Resistance to impact 8.3 X X 1 x year OIT 8.3 X X 1 x year MFR 8.3 X X 1 x year Stress crack resistance 8.3 X Marking Outer casing 10.1 X X 3) 1 x year Service pipe 10.2 X X3) 1 x year fitting 10.3 X X 3) 1 x year 1) In case the product or production process changes significantly, it must be determined whether the performance requirements are still met. All product properties that can be determined within the visiting time (maximum 1 day) are determined by the inspector or by the supplier in the presence of the inspector. In case this is not possible, an agreement will be made between the certification body and the supplier about how the inspection will take place. 2) This aspect is compared with the for this aspect ascertained acceptance parameters on the basis of the IQC inspection (indirect by means of direct related parameters). Kiwa Nederland B.V comments before

38 11.2 Inspection of the quality system During the inspection visits the Kiwa inspector checks the internal quality system by verifying the IQC-scheme. Kiwa Nederland B.V comments before

39 12 Agreements on the performance of certification 12.1 General This chapter contains the agreements made within the Central Board of Experts on the implementation of the certification by Kiwa Certification staff The staff involved in the certification process is sub-divided into: Certification engineers: in charge of carrying out the pre-certification tests and assessing the reports of the inspectors; Inspectors: in charge of carrying out external inspections at the supplier s works; Decision-makers: in charge of taking decisions in connection with the precertification tests performed, continuing the certification in connection with the inspections performed and taking decisions with regard to corrective actions Qualification requirements Distinguished are: Qualification requirements for executive staff of a CI that fulfil the requirements of EN 45011; Qualification requirements for executive staff of a CI that are in addition set up by the Board of Experts for the subject of this evaluation guideline. Kiwa Nederland B.V comments before

40 Qualification requirements for executive staff of a CI that fulfill the requirements of EN The qualification of the executive staff of a CI shall fulfil the requirements of chapter 5 of EN The way how qualification of the staff is performed shall be described in the quality manual of the CI. EN Education General Education Specific Experience General Experience Specific Auditor pre-certification tests and evaluation of production location Relevant technical thinking and working level comparing to Bachelor Internal training in certification and Kiwa policies Training in audit skills Specific courses and training (knowledge and skills), or relevant experience 1 year of relevant working experience with a minimum of 4 pre-certification tests of which: 1 complete pre-certification test independently, under supervision Detailed knowledge of guideline and 4 tests relating to the specific guideline or to guidelines which are related to each other. Inspector factory, field & project visits and followup inspections Technical thinking and working level at vocational education (intermediate level) Internal training in certification and Kiwa policies Training in audit skills Specific courses and training (knowledge and skills), or relevant experience 1 year of relevant working experience with a minimum of 4 pre-certification tests of which 1 under supervision Detailed knowledge of guideline and 4 tests relating to the specific guideline or to guidelines which are related to each other. Person deciding on granting of certificate and certificate extension Thinking and working at Bachelor level Internal training in certification and Kiwa policies Training in audit skills not applicable 4 years of working experience, with a minimum of 1 year of experience with certification Basic knowledge of the guideline on main lines Qualification requirements for executive staff of a CI that are in addition set up by the Board of Experts for the subject of this evaluation guideline No additional requirements are set up by the Board of Experts Qualification Certification staff shall be demonstrably qualified by examining education and experience on the basis of the above mentioned requirements. In case qualification takes place on the basis of other requirements, then this shall be laid down in writing. The authority to qualify rests at: Decision-maker: qualification of auditors and inspectors; Management of the certification body: qualification of the decision-maker. Kiwa Nederland B.V comments before

41 12.3 Frequency of external inspections The Certification Institute shall execute inspections at the supplier to check the fulfilling of all obligations. The Board of Experts decides about the inspection frequency. For this Guideline this is fixed on 4 inspections per year. A decrease with a maximum of 2 inspections is possible, when: When there is confidence for the aspects below: - the quality of production equipment (hysteresis, tolerances); - production is automated with continuously monitoring; - staff and personnel is fully qualified; - the experience of the production location with the certified products to maintain a contentious quality level and -the production location where the certified products are produced, is ISO 9001 certified by an accredited certification institute; Inspections will in any case cover the following: The IQCS of the supplier and the results of the quality controls; The required marking of the certified products; Are the required procedures followed. Al data of the inspection will be (tracibel) fixed in a report Interpretation of the requirements In needed, the Board of Experts can fix the requirements in this Guideline.in a separate document. Kiwa Nederland B.V comments before

42 13 List of normative documents 13.1 Public Law rules Staatscourant van 29 juni 2011, nr BJZ Regeling materialen en chemicaliën leidingwatervoorziening 13.2 Standards / normative documents: Number Title BRL17105 Vulcanized rubber pipe joint seals for drinking water pipes DIN 4726 Warm water floor heating systems and radiator pipe connecting - Piping of plastic materials ISO 760 Determination of water - Karl Fischer method ISO 4065 Thermoplastic pipes - Universal wall thickness table. ISO 6964 Polyolefin pipes and fittings; Determination of carbon black content by calcination and pyrolysis; Test method and basic specification ISO 9001 Quality management systems. Requirements ISO/TR Determination of the thermal stability of polyethylene (PE) for use in gas pipes and fittings ISO Plastics. Differential scanning calorimetry (DSC). Determination of oxidation induction time NEN-ISO 6957 Cupper alloys ammonia test for stress corrosian resistance NEN-ISO Plastics - Determination of environmental stress cracking (ESC) of polyethylene - Full-notch creep test (FNCT) NEN-EN 579 Plastics piping systems. Crosslinked polyethylene (PE-X) pipes. Determination of degree of crosslinking by solvent extraction NEN-EN 489 Pre-insulated bonded pipe systems for underground hot water networks. Joint assembly for steel service pipes, polyurethane thermal insulation and outer casing of polyethylene NEN-EN 712 Thermoplastics piping systems. End-load bearing mechanical joints between pressure pipes and fittings. Test method for resistance to pull-out under constant longitudinal force NEN-EN 713 Plastics piping systems. Mechanical joints between fittings and Polyolefin pressure pipes. Test method for leak tightness under internal pressure of assemblies subjected to bending NEN-EN 728 Plastics piping and ducting systems Polyolefin pipes and fittings Determination of oxidation induction time. NEN-EN 744 Plastics piping and ducting systems - Thermoplastics pipes - Test method for resistance to external blows by the round-the-clock method NEN-EN Copper and copper alloys. Plumbing fittings. Fittings with compression ends for use with plastics pipes NEN-EN 1605 Thermal insulating products for building applications - Determination of deformation under specified compressive load and temperature conditions NEN-EN 1606 Thermal insulating products for building applications - Determination of compressive creep NEN-EN Plastics piping systems. Thermoplastics pipes and fittings for hot and cold water. Test method for the resistance of mounted assemblies to temperature cycling NEN-EN Plastic piping systems. Systems for hot and cold water. Test method for leak tightness under vacuum NEN-EN Plastics piping systems - Thermoplastics pipes and associated fittings Kiwa Nederland B.V comments before

43 for hot and cold water - Test method for resistance of joints to pressure cycling NEN-EN Thermal performance of building materials and products - Determination of thermal resistance by means of guarded hot plate and heat flow meter methods - Products of high and medium thermal resistance NEN-EN Design and installation of pre-insulated bonded pipe systems for district heating NEN-EN Thermal insulation products for building equipment and industrial installations - Factory made mineral wool (MW) products - Specification NEN-EN Thermal insulation products for building equipment and industrial installations - Factory made flexible elastomeric foam (FEF) products - Specification NEN-EN Thermal insulation products for building equipment and industrial installations - Factory made cellular glass (CG) products - Specification NEN-EN Thermal insulation products for building equipment and industrial installations - Factory made calcium silicate (CS) products - Specification NEN-EN Thermal insulation products for building equipment and industrial installations - Factory made extruded polystyrene foam (XPS) products - Specification NEN-EN Thermal insulation products for building equipment and industrial installations - Factory made rigid polyurethane foam (PUR) and polyisocyanurate foam (PIR) products - Specification NEN-EN Thermal insulation products for building equipment and industrial installations - Factory made products of expanded polystyrene (EPS) - Specification NEN-EN Thermal insulation products for building equipment and industrial installations - Factory made polyethylene foam (PEF) products - Specification NEN-EN Thermal insulation products for building equipment and industrial installations - Factory made phenolic foam (PF) products - Specification NEN-EN General requirements for bodies operating product certification systems NEN-EN District heating pipes. Pre-insulated flexible pipe systems. Bonded plastic service pipes. Requirements and test methods NEN-EN-ISO 580 Plastics piping and ducting systems - Injection-moulded thermoplastics fittings - Methods for visually assessing the effects of heating NEN-EN-ISO Plastics - Symbols and abbreviated terms - Part 1: Basic polymers and their special characteristics NEN-EN-ISO 1133 Determination of the melt mass flow rate (MFR) and the melt volume (MVR) of thermoplastics NEN-EN-ISO 1167 hermoplastics pipes, fittings and assemblies for the conveyance of fluids - Determination of the resistance to internal pressure NEN-EN-ISO 2505 Thermoplastics pipes - Longitudinal reversion - Test methods and parameters NEN-EN-ISO 3126 Plastics piping systems - Plastics components - Determination of dimensions NEN-EN-ISO 6708 Pipework components -- Definition and selection of DN (nominal size) NEN-EN-ISO 8497 Thermal insulation. Determination of steady-state thermal transmission properties of thermal insulation for circular pipes NEN-EN-ISO 9080 Plastics piping and ducting systems - Determination of long term hydrostatic strength of thermoplastics materials in pipe form by standard Extrapolation method. NEN-EN-ISO 9967 Thermoplastics pipes. Determination of creep ratio Kiwa Nederland B.V comments before

44 NEN-EN-ISO 9969 Thermoplastics pipes. Determination of ring stiffness NEN-EN-ISO Plastics piping systems for hot and cold water installations Crosslinked polyethylene (PE-X) NEN-EN-ISO Plastics piping systems for hot and cold water installations Polybutylene (PB) NEN-EN-ISO Plastics piping and ducting systems - Plastics pipes and fittings - Method for exposure to direct (natural) weathering NEN-EN-ISO Multilayer piping systems for hot and cold water installations inside buildings NEN-EN-ISO Thermal insulation products for building equipment and industrial installations Determination of design thermal conductivity NEN-EN-ISO/IEC General criteria for the operation of various types of bodies performing inspection NEN-EN-ISO/IEC Conformity assessment - Requirements for bodies providing audit and certification of management systems NEN-EN-ISO/IEC Conformity assessment - General requirements for bodies operating certification of persons NEN-EN-ISO/IEC General requirements for the competence of testing and calibration laboratories NEN-EN-IEC Insulating and sheathing materials of electric and optical cables - Common test methods - Part 4-1: Methods specific to polyethylene and polypropylene compounds - Resistance to environmental stress cracking - Measurement of the melt flow index - Carbon black and/or mineral filler content measurement in polyethylene by direct combustion - Measurement of carbon black content by thermogravimetric analysis (TGA) - Assessment of carbon black dispersion in polyethylene using a microscope NEN-EN District heating pipes:pre-insulated flexible pipe systems NEN-EN-ISO Plastics piping systems for hot and cold water installations - Polyethylene of raised temperature resistance (PE-RT) - Part 1: general NEN-EN-ISO Plastics piping systems for hot and cold water installations - Polyethylene of raised temperature resistance (PE-RT) Part2: pipes NEN-EN-ISO Plastics piping systems for hot and cold water installations - Polyethylene of raised temperature resistance (PE-RT) - Part 3: fittings NEN-EN-ISO Plastics piping systems for hot and cold water installations - Polyethylene of raised temperature resistance (PE-RT) - Part 5: Fitness for purpose of the system Kiwa Nederland B.V comments before

45 14 Annex 1: Model IQC scheme Inspection subjects Raw materials or materials supplied: - recipe sheets - incoming goods inspection raw materials Production process, production equipment, plant: - procedures - working instructions - equipment - release of product Inspection aspects - Recipe according annex product agreement - melt flow rate - moisture content thermal stability (PE) - tuning parameters - maintenance aspects - dimensions - soundness Inspection method Comparison supplied certificate with agreement - ISO ISO ISO TR adjustments machine - maintenance scheme - measuring - visual evaluation Inspection frequency Each delivery Each delivery - continuously - continuously - start up new product Inspection registration Entry control document - "digital" - work sheet - inspection document Finished-products - soundness - dimensions - resistance internal pressure - visually - measuring - ISO continuously - each 3 hours - per day per product per machine End control documents Measuring and testing equipment - measuring equipment - proper functioning - during usage - continuously - end control document - calibration Logistics - internal transport - storage - Preservation - accuracy within the range of measurement - circumstances in practise - records of nonconformities - comparison with procedure - 1 x year - calibration document - continuously - keep logistical procedures up to date - packaging - identification - comparison with order - visual inspection Kiwa Nederland B.V comments before

46 15 Annex 2: Certificate Number Replaces Issued Dated technical approval-with-product certificate District heating: flexible piping systems with plastic medium pipe for transport of drinking water and warm tap water Based on pre-certification tests as well as periodic inspections by Kiwa, the products referred to in this certificate and marked with the Kiwa-mark as indicated under marking, manufactured by Supplier may, on delivery, be relied upon to comply with the Kiwa evaluation guideline District heating: flexible piping systems with plastic medium pipe for transport of warm drinking water. Kiwa Nederland B.V. ing. B. Meekma Kiwa Kiwa Nederland B.V. Sir W. Churchill-laan 273 P.O. Box AB Rijswijk The Netherlands Telephone Telefax Internet This certificate is issued in accordance with the Kiwa-regulations for Product Certification and consists of pages. Publication of the certificate is allowed. Company Kiwa Nederland B.V comments before

47 Kiwa technical approval-with-product certificate KXXXXX/0X Naam product PRODUCT SPECIFICATION Product specification The products mentioned below belong to this certificate Product name Toxicological requirements Approval: This product is approved on the basis of the requirements set in the "Regeling materialen en chemicaliën leidingwatervoorziening" ( Regulation Materials and Chemicals for Drinking Water Supplies ; published in the Staatscourant). ATA criteria: The ATA product certification is based on two main criteria. It should permanently comply with: The product recipe approved during the assessment procedure. The recipe is laid down in the for confidentiality reasons undisclosed appendix 1A to the certification agreement Kxxx. This recipe is not to be changed without prior approval by Kiwa according to the Kiwa-ATA-approval procedure; Specific ATA-product requirements, laid down in appendix 1A to the certification agreement Kxxx. For confidentiality reasons this appendix 1A is not public. Marking De products shall be marked with the Kiwa -mark (KIWA) and the Kiwa -Watermark The minimum required marking on the products (outer casing) shall be: Manufacturer s or suppliers name and trade mark or identification mark of the adhesive; Application area: district heating Batch number The realization of the marks is as follows: clearly and indelible at Location Application and use RECOMMENDATIONS FOR CUSTOMERS Check at the time of delivery whether: the producer has delivered in accordance with the agreement; the mark and the marking method are correct; the products show no visible defects as a result of transport etc. If you should reject a product on the basis of the above, please contact: Company and, if necessary, Kiwa Nederland B.V. Consult the producer's processing guidelines for the proper storage and transport methods. Kiwa Nederland B.V comments before

48 16 Annex 3: Measurement of linear thermal resistance and conductivity of the pipe 16.1 General This Annex describes benchmarks and procedures for measuring the linear thermal resistance of flexible pipe systems in accordance with EN ISO Apparatus For testing purposes heated test pipes (compensation heating) and test pipes with calibrated or calculated pipe ends according to EN ISO 8497 shall be used Test sample The test sample is of the same length as the test pipe, including compensation heating if being used. The sample shall be conditioned for one week at room temperature conditions. Pipe systems with cell gases in the insulation material other than air shall be tested not earlier than six weeks after production Test conditions and procedures The thermal parameters shall be measured in accordance with EN ISO 8497 under the following conditions: 1) ambient air temperature at 23 C ± 2 C; 2) for the determination of a thermal conductivity at 50 C a minimum of three measurements are necessary, the spacing of which shall be 10 ± 2 K and the temperature range shall include 50 C; 3) the measured values are to be related to the arithmetic average value of the temperature ϑ1 at the inner diameter of the service pipe d1 and ϑ4, at the outer diameter of the casing d4 (see Figure A.1); 4) for pipe systems with metal service pipes the temperature value ϑ1 of the service pipe can be taken as for the temperature value ϑ2 measured at the outer diameter d2 of the service pipe; 5) for pipe systems with plastic service pipes the temperature value ϑ1 of the service pipe shall be measured directly at the inner side of the service pipe; 6) the temperature ϑ4 is the temperature directly at the outside of the casing pipe; 7) for pipe systems with corrugated casing pipes the temperature ϑ4 is the average value of the temperature measured at the highest and lowest point of the wave (see Figure 16.2). For pipe systems with corrugated medium or casing pipes an average value for the maximum and minimum diameter has to be taken for the thermal calculation purposes (see Figure 16.2). The sensors have to be fixed firmly at the surface of the medium and casing pipes in order to ensure proper thermal contact Measurement Linear thermal resistance of the piping system The average temperature for single pipes shall be calculated in accordance with equation (16.1). Kiwa Nederland B.V comments before

49 ϑ av = ϑ 1 + ϑ 2 (16.1) 4 in C The average temperature for twin pipes shall be calculated in accordance with equation (16.2). ϑ av = 1 2 ( ϑ + ϑ ) 1, f (16.2) 2 1, r + ϑ 4 in C The radial thermal resistance R of the piping system at any average temperature ϑav can be calculated with the measured value of the radial heat flow rate q and the length L of the tested pipe and the temperatures measured at the relevant surfaces d1 and d4 with equation (16.3) for single pipe systems and equation (16.4) for twin pipe systems. L = ( ϑ ϑ ) 1 4 R, ϑ av (16.3) q in (m K)/W R TPS, ϑav 1 L = 2 (16.4) ( ϑ1, f + ϑ1, r ) ( q + q ) f r + ϑ 4 in (m K)/W 16.6 Thermal conductivity of the pipe system The thermal conductivity of a single piping system at any average temperature ϑav shall be calculated from d ln q d λsps, ϑav = L( ϑ ϑ ) 2π in W/(m K) (16.6) The thermal conductivity of a twin pipe system at any average temperature ϑav shall be calculated from λ TPS, ϑav = 1 L 2 (16.7) ln ( q f + qr ) d 2π ( ϑ + ϑ ) + ϑ 1, f 1, r 4 d 4 1 in W/(m K) 16.7 Declared linear thermal resistance and thermal conductivity The relation of the thermal values and the average temperatures can be obtained by an analysis (regression curve) of the minimum of 3 temperature measuring points at various average temperatures. For other temperatures than those which have been measured the thermal resistance and conductivity shall be obtained from this regression curve. The declared values for the linear thermal resistance of the piping system Rdecl and of the linear thermal conductivity λdecl shall be calculated for an average temperature of 50 C. Kiwa Nederland B.V comments before

50 Figure 16.1: diameter designations Figure 16.2: diameters of corrugated pipe Kiwa Nederland B.V comments before

51 17 Annex 4: Determination of the declared values of the radial thermal resistance conductivity of flexible pipe assembly 17.1 Introduction The manufacturer of the flexible district heating pipes is responsible for providing the declared values and respective traceable information about the radial thermal resistance of the pipe assembly. Information about the long term performance of the thermal resistance is given in annex Test specimens The piping system shall be tested at least for one of the two the smallest and one of the two largest nominal dimensions of the production variety of the piping system according to annex 3. Additionally the value for the heat conductivity λi of the insulation shall be determined according to NEN-EN from a test sample taken from the same batch Determination of the declared values of the thermal resistance All calculations shall be based on average temperatures of 50 C. Any differences between calculated thermal resistance of a pipe assembly based on declared thermal resistance values of the pipe components and the measured test results according to annex 3 are to be expressed by a corrective factor fcor: where R λi λs λc dx f cor = λ I R 1 2πλ S d 2 1 ln d1 2πλ 1 d 3 ln 2π d 2 d ln d is the value of the linear thermal resistance determined acc. to annex 3 in m K/W is the thermal conductivity the insulation material acc. to NEN-EN12667 in (m K)/W is the thermal conductivity of the service pipe in W/(m K) is the thermal conductivity of the outer casing in W/(m K) is the diameter according to figure 16.1 and 16.2 in m C 4 3 (17.1) For nominal dimensions, for which no radial thermal resistance has been determined, the respective corrective factor ƒcor shall be interpolated or extrapolated from corrective factors determined using equation Kiwa Nederland B.V comments before

52 The declared value of the radial thermal resistance Rdecl at average temperature ϑav = 50 C for each nominal dimension shall be calculated with equation R decl ϑav = 1 λ S ln d d f λ cor I 2π ln d d λ C ln d d 4 3 in m.k/w (17.2) and the declared value of the thermal conductivity with λ decl 1 d 2 f cor ln + ln λs d 1 λi = ϑav 2π d d λ C ln d d 4 3 in W/(m.K) (17.3) In case no values for the radial thermal conductivities are given by the manufacturer, the following values shall be taken: Mild steel (C-steel): 50 W/(m K) Stainless steel (CrNi steel): 15 W/(m K) Copper: 384 W/(mK) Polyethylene (PE, PE-X): 0,4 W/(m K) Kiwa Nederland B.V comments before

53 18 Annex 5: Determination of design values for the radial thermal resistance The design value for the radial thermal resistance R should be calculated in accordance with documents of EN ISO taking into account the conditions relevant to the expected life time. R design = 1 d 2 ln λ d S (19.1) 1 + f λ cor design 2π d ln d λ S d ln d 4 3 in (m K)/W with λ design = λ decl (19.2) F m F a in W/(m K) where λdesign is the calculated value of the thermal conductivity of the insulation material in W/(m K); fc is the correction factor for existing open splits, thermal bridges or change of the factor for shape caused by influence of laying in the ground and the relevant factors set up by EN ISO Fm for the influence of moisture; Fa for the influence of ageing. NOTE In case Fm or Fa are not known the following values should be taken: Fm = 1 for metal service pipe; = 1,1 for plastic service pipes if no other information is available and if not laid in ground water and the operating temperature is not higher than 80 C up to 85 C; Fa = 1 for insulation material with air as cell gas only Fa = 1 for diffusion tight encapsulation of the insulation Fa = 1,25 for insulation materials with other cell gases unless other values are supported by test results. Kiwa Nederland B.V comments before

54 19 Annex 6: Calculation of the heat flow from the medium to the ambient(heat loss) 19.1 General This annex provides methods and recommended bench marks for the calculation of the heat flow of the heat medium for single piping systems in the earth without a heat influence between the flow and return pipes and for a twin pipe system Single pipe system (SPS) The longitudinal heat flow density for a buried single piping system to the ambient condition is given by the following conditions: Flow pipe: Return pipe: q q q q SPS f SPS f SPS r SPS r = = = = U SPS ( ϑ f ϑamb ) f ( ϑ ϑ ) R s f + R amb SPS f U SPS ( ϑr ϑamb ) r ( ϑ ϑ ) R r + R amb in W/m (19.1) in W/m (19.2) in W/m (19.3) s SPS r in W/m (19.4) where: U is the coefficient of the heat loss; ϑf, ϑr and ϑamb are the flow, return and ambient temperatures; Rs is the linear thermal resistance of the soil The longitudinal heat flow density for buried flow and return single pipe systems to the ambient condition without a heat interaction between flow and return pipes is given as follows. q = q + q SPS f + r SPS f SPSr in W/m (19.5) When the flow and return pipes are laid near together the longitudinal density of heat loss of the flow or return pipe can influence the longitidunal density of heat loss of the return and flow pipe, so that the total longitudinal density of heat loss of a pair of pipes can be reduced (see NEN-EN 13941) Twin pipe system (TPS) The longitudinal heat flow density for twin pipe systems shall be calculated with the equations 19.6 and 19.7: ϑ + ϑ f r q TPS = U ϑ S TPS 2 in W/m (19.6) q TPS ϑ f + ϑr ϑ = 2 R + R S TPS S in W/m (19.7) Kiwa Nederland B.V comments before

55 19.2 Radial thermal resistance of the surrounding soil R 1 4Z c s = ln 2 πλ s d 4 in (m K)/W (19.8) where Zc is a corrected value for the soil coverage, Z Z c = Z + R λ 0 s in m (19.9) = is the soil coverage above the center line of the pipe d4 Z = + 2 λs R0 H H in m (19.10) = the thermal conductivity of the soil in W/(m.K) = the thermal transmittance factor of earth surface to ambient air in (m 2.K)/W = soil covering in m 19.3 Declared values of the radial thermal resistance of buried piping systems If the manufacturer declares general values for the radial thermal resistance (or conductivity) of buried pipes, the respective calculation shall be based on: λs R0 H = 1.0 W/(m K) = 0,0685 m 2 K/W = 0,8 m (other values may be given additionally) Kiwa Nederland B.V comments before

56 20 Annex 7: Compressive Creep 20.1 General The test procedure for the compressive creep at elevated temperatures of the insulation material shall be carried out in a similar way to EN 1606 (respectively EN 1605). In addition to these tests the following changes/additions in testing are standardised in order to reflect the special situation of insulation procedures for flexible pipe systems. NOTE Table 20-1 and the test are based on the "Findley equation" (see EN 1606). The traceability of the logarithmic coherence and the adequate verification of the test should be shown by calculation (with the squared factor for accuracy of determination larger than 0,9) Principles of testing The compressive creep of samples under pressure is tested by measuring the increase of deformation of a test sample under a constant pressure load and defined conditions respectively temperature, humidity and time Test apparatus Plate for heating purposes (for heating up one side of the test samples forming part of the pressure apparatus): The heated plate shall provide an equally distributed temperature at the surface of the heating plate and produce a heat flow vertical to the plate. The temperature shall be measured with an accuracy of +/- 0,5 K. Pressure apparatus: Consists of two horizontal plates with one being able to tilt in the plane in order to apply an even compressive load on the entire surface of the sample in a vertical direction. It must be assured that the plates are able to withstand the test loads without deformation, so that the load during the test can vary by not more than +/- 5 %. Measuring equipment: Instrument for measuring the distance between both plates, i.e. the deformation of the sample measured to within 0,01 mm. The apparatus is shown in Figure Kiwa Nederland B.V comments before

57 Figure 20-1 Test apparatus 20.4 Test sample The dimensions of the sample should be related to the minimum thickness of the insulation used in the type of the district heating pipe assembly tested, the maximum temperature of the heat medium used, and at or near to the maximum diameter produced. The form of the samples should be rectangular or cylindrical with these dimensions of the base: 50 mm up to 100 mm or an equivalent diameter. The length should be equal to or greater than the thickness. The samples are preferably taken from the insulation material of the pipe assembly. In case the samples will get too small using this procedure they also can be taken from a square formed of the material having the same consistency and properties. Alternatively the Kiwa Nederland B.V comments before

58 samples can be assembled from more than one layer. This comparative sample must be taken from the same production machine used for manufacture of the insulation material normally. The specification values, especially density and cell-structure must be comparable with the insulation material used for pipe assembly production. Minimum number of test samples is three for each test condition. Preparation of the samples: The samples must be taken from the insulation in such a way that the direction of the test load is equal to the direction in which the load lasts on the pipe assemblies installed. The samples shall be conditioned for a minimum of 6 h at 23 C ± 3 C and at a relative humidity of 50 % ± 5 % Test procedure Length and width of the sample are measured in accordance with EN to an accuracy of at least 0,5 %. With this data the initial area of the cross section of the sample can be calculated for determination of the maximum load. The preliminary load of the test sample shall be less than 10 % of the lowest amount of load chosen for thetest. The thickness must be measured with an accuracy of 0, 1 mm. The test samples shall have an additional side insulation (see Figure 20-1) during the test. However it must give free movement to the test sample itself. During the test phase the first thermal test should last for two hours on the heated plate in order to compensate effects of expansion due to gas production of the sample and first appearance of additional cross linking processes. Therefore the sample has to be put on the heating plate under the test load and heated up to the test temperature. The first test value is taken after two hours. This is declared then as the zero-value of the test series. The relevant test methods shall be selected for the product to be tested in accordance with Table The tests are done in two test sequences, A and B in parallel Calculation and expression of results The area related load Pweight resulting from load on the cross section of the test specimen of the insulation material shall be calculated as follows: Pweight = Fweight /A where in Pa Pweight is the area related load on the cross section of the test specimen of the insulation material, Fweight=M G; where in N M is the mass of the pipe inclusively the water inside in kg, A is the projected area of the service pipe (length width) in m 2 The area related load Pexp on the insulation resulting from heat expansion of the service pipe is calculated as follows: Pexp = 2 Fexp /( r d2 ) in Pa where Fexp is the force resulting from heat extension in N, r is the bending radius in the axis of the pipe in m, d2 is the diameter of the service pipe. The test load Ptest shall be the maximum value of Pweight and Pexp. NOTE The stability of dimensions of the insulation can be negatively influenced in the vertical direction by the mass of the service pipe filled with water and in the horizontal direction by the extension forces caused by heating up. Kiwa Nederland B.V comments before

59 It is sufficient to test the stability of dimensions for each pipe assembly in accordance with the maximum value of the forces appearing because in the first approach these forces act independently from each other. The test shall always be done with the largest dimension of the pipe assembly and with the smallest thickness of insulation. In case of corrugated service pipes (compensation for the thermal related change of the length by the corrugated contour) and in case of plastic service pipes (axial stresses relax under operating temperatures relatively fast) the area related force Pweight has to be used for the calculation. The testing temperatures and testing times are selected in accordance with table Table 20-1 in relation to each system. The test results as a percentage (compression Σ) shall be documented for each test and each test piece shall be rounded to three digits in percent: Σ = (s - sstb)/s 100; where Σ is the compression in % s is the thickness of the test piece before applying the load in mm, sstb is the thickness of the test piece after load testing and temperature testing in mm. Table 20-1 Test conditions for testing stability of dimensions nr System Test load Pa 1 Metal service pipe 2 Plastic service pipe Ptest Ptest Test A Test A continuous operating temperature continuous operating temperature minus 2K Test B Testing Test time h temperature C 1000 maximal operating temperature 1000 continuous operating temperature minus 2K Testing time h If the test is carried out under cover gas conditions the test apparatus shall comply to Figure 20-1.b) and the pressure of the cover gas shall be 5 mbar ± 3 mbar above ambient pressure. Kiwa Nederland B.V comments before

60 21 Annex 8: Products for transport of drinking water: guidance for prevention of contamination during transport and storage 21.1 Importance of a hygienic operation A hygienic operation is since decades an important issue for the transport and distribution of drinking water in the Netherlands. The impact of pollution can have big consequences for the water distribution 1) (normally chlorine is not used) and need substantial efforts to clean the system. All ready in the 1983 published guideline for installation of PVC-U piping systems, this is described with chapter 4.2: Opslag van de Richtlijnen voor de aanleg van hoofdleidingen van ongeplastificeerd polyvinylchloride (PVC) voor het transport van drinkwater Also the aspect hygiene is mentioned in the Dutch Hygiënecode Drinkwater; Opslag, transport en distributie, 2010, including manuals for installers. As result of the Hygienic code a wide range of courses for parties involved (installers, personnel of water companies, etc.) can be followed. Last but not least the Hygiëne code is also mentioned in the drinking water law of 1 July 2011 and is therefore part of the Dutch law Protection of the used products In the Hygiënecode Drinkwater; Opslag, transport en distributie is the aspect how to work hygienically extensively described. Here actions for all used parts as pipes, fittings and valves in the complete system, from construction until operation are described. The primary task in this case is prevention. Secondary is also important the preparation of the main for the actual drinking water transport. For all products coming from the production location, until installation in the drinking water system the same preventive measurements shall be taken 2), to prevent pollution. Therefore manufacturers shall have a procedure how to prevent pollution of certified (drinking water) products during production, transport and storage Requirements for the protection of products For all preventive (protective) actions taken to protect the products against pollution it is important that the protection will last for the complete process of storage, transport and again storage. remark : 1) mostly this is a microbiological contamination coming from the surrounding area on macroand micro scale (like dust, but also ficalien and dead beasts. 2) protection is the combination of packaging and closing the pipe/fitting ends. Kiwa Nederland B.V comments before

61 21.4 How to protect: General The used packaging depends on the product itself (shape, dimensions, etc.) Some packaging solutions are mentioned below: A plastic bag (in a box) for small fittings (couplings, rings, rubber seals); Protection fil with inserted bubbles in combination with tape for big(ger) fittings; The combination of bags of GRP material or crimp-foil and the use of a box for smaller part; End-caps of stern material of plastics bags for the pipe mouth (where the complete pipe package is wrapped in foil) How to protect: Pipes In 2007 representatives of the manufacturers and the water companies organized in the commission Onderhandelings Commissie Kunststoffen (OCK) have started a project to improve the packaging quality. As result of this a guidance is made to use packaging products as shown with the pictures below. The end cap is unmovable fixed in the pipe by using flaps in a labyrinth structure to let in air but prevent pollution. The end cap is developed for a 110 mm PVC pipe but can also be developed for other diameters (50, 63, 75, 90, 160, 200 and 250 mm), and for all used pipe materials. For the protection of the pipe mouth for 315, 400, 500 and 630 mm PVC pipes a GRP foil with tape can be used (see the pictures below). For smaller diameters this solution is not recommended. KWR Water cycle Research Institute, Martin Meerkerk (in name of the Dutch water companies) Nieuwegein, December 2011 In the last picture the banding is replaced by tape. Kiwa Nederland B.V comments before