FDUS 945-2

FINAL DRAFT UGANDA

STANDARD
First Edition
2012-mm-dd

Pre-insulated flexible pipe systems — Part 2: Non bonded

system with plastic service pipes, requirements and methods of
test

Reference number
FDUS 945-2: 2012

© UNBS 2012
FDUS 945-2: 2012

Compliance with this standard does not, of itself confer immunity from legal obligations

A Uganda Standard does not purport to include all necessary provisions of a contract. Users are
responsible for its correct application

© UNBS 2012

All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilised in any
form or by any means, electronic or mechanical, including photocopying and microfilm, without prior written
permission from UNBS.

Requests for permission to reproduce this document should be addressed to

The Executive Director

Uganda National Bureau of Standards
P.O. Box 6329
Kampala
Uganda
Tel: 256 414 505 995
Fax: 256 414 286 123
E-mail: unbs@infocom.co.ug

ii © UNBS 2012 – All rights reserved

 FDUS 945-2:2012

Contents Page

Foreword ............................................................................................................................................................ iv 

1  Scope ...................................................................................................................................................... 1 
2  Normative references ............................................................................................................................ 1 
3 Terms and definitions ..................................................................................................................................... 2 
4 Classification ................................................................................................................................................... 2 
4.1 Operating temperatures and service life.................................................................................................... 2 
4.2 Operating pressures .................................................................................................................................... 2 
4.3 General requirements .................................................................................................................................. 3 
4.4 Service pipes and fittings ............................................................................................................................ 3 
4.4.1 Quality ........................................................................................................................................................ 3 
4.4.2 Oxygen tightness ...................................................................................................................................... 3 
4.5 Sealing in linear direction ............................................................................................................................ 3 
4.6 Water vapour permeation ............................................................................................................................ 3 
5 Test procedures............................................................................................................................................... 3 
5.1 General .......................................................................................................................................................... 3 
5.2 Temperature cycle test ................................................................................................................................ 4 
Annex A (informative) Application of Miner's Rule......................................................................................... 5 
Annex B (normative) Specifications for crosslinking of pipes in service .................................................... 6 
B.1 Introduction .................................................................................................................................................. 6 
B.2 General .......................................................................................................................................................... 6 
B.3 Requirements ............................................................................................................................................... 6 
B.3.1 Pipe system ............................................................................................................................................... 6 
B.3.2 Determination of the ability to crosslink ................................................................................................ 7 
B.3.3 Service test ................................................................................................................................................ 7 
B.4 Marking ......................................................................................................................................................... 7 
B.5 Example ........................................................................................................................................................ 8 

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FDUS 945-2: 2012

Foreword

Uganda National Bureau of Standards (UNBS) is a parastatal under the Ministry of Tourism, Trade and
Industry established by the Act of Parliament of 1983, of the Laws of Uganda. UNBS is mandated to co-
ordinate the elaboration of standards and is
(a) a member of International Organisation for Standardisation (ISO) and

(b) a contact point for the WHO/FAO Codex Alimentarius Commission on Food Standards, and

(c) the National Enquiry Point on TBT/SPS Agreements of the World Trade Organisation (WTO).

The work of preparing Uganda Standards is carried out through Technical Committees. A Technical
Committee is established to deliberate on standards in a given field or area and consists of representatives of
consumers, traders, academicians, manufacturers, government and other stakeholders.
Draft Uganda Standards adopted by the Technical Committee are widely circulated to stakeholders and the
general public for comments. The committee reviews the comments before recommending the draft standards
for approval and declaration as Uganda Standards by the National Standards Council.
Committee membership

The following organizations were represented on the Building and civil engineering standards Technical
Committee (UNBS/TC 3), during the development of this standard:
• Department of Geological Mines and Surveys
• East African Distributors Ltd
• Institution of Surveyors of Uganda
• Kyambogo University
• Multiple Industries
• Uganda National Association of Building and Civil Engineering Contractors
• Uganda National Bureau of Standards
• Uganda National Plumbers Association

iv © UNBS 2012 – All rights reserved

FINAL DRAFT UGANDA STANDARD FDUS 945-2: 2012

Pre-insulated flexible pipe systems – Part 2: Non bonded

system with plastic service pipes, requirements and methods of
test

1 Scope
This Final Draft Uganda Standard specifies the requirements and methods of test for flexible, pre-insulated,
direct buried district heating pipes with plastic service pipes and no bonding between the layers of the pipes.

This standard is valid for maximum operating temperatures of 95 °C and maximum operating pressures up to
10 bar for a design lifetime of at least 30 years.

This standard does not cover surveillance systems.

NOTE For higher temperatures or for the transport of other fluids, for example potable water, additional requirements
and testing may be needed. Such requirements are not specified in this standard.

2 Normative references
The following referenced documents are indispensible for the application of this standard. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.

ISO 9080, Plastics piping and ducting systems — Determination of the long-term hydrostatic strength of
thermoplastics materials in pipe form by extrapolation

ISO 10147, Pipes and fittings made of crosslinked polyethylene (PE-X) — Estimation of the degree of
crosslinking by determination of the gel content

ISO 10508; Plastics piping systems for hot and cold water installations — Guidance for classification and
design

ISO 13760, Plastics pipes for the conveyance of fluids under pressure — Miner's rule — Calculation method
for cumulative damage

ISO 15875-1, Plastics piping systems for hot and cold water installations — Crosslinked polyethylene (PEX)
— Part 1: General

ISO 15875-2, Plastics piping systems for hot and cold water installations — Crosslinked polyethylene (PE-X)
— Part 2: Pipes

ISO 15875-3, Plastics piping systems for hot and cold water installations — Crosslinked polyethylene (PEX)
— Part 3: Fittings

ISO 15875-5, Plastics piping systems for hot and cold water installations — Crosslinked polyethylene (PE-X)
— Part 5: Fitness for purpose of the system

ISO 15876-1, Plastics piping systems for hot and cold water installations — Polybutylene (PB) — Part 1:
General

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FDUS 945-2: 2012

ISO 15876-2, Plastics piping systems for hot and cold water installations — Polybutylene (PB) — Part 2:
Pipes

ISO 15876-3, Plastics piping systems for hot and cold water installations — Polybutylene (PB) — Part 3:
Fittings

ISO 15876-5, Plastics piping systems for hot and cold water installations — Polybutylene (PB) — Part 5:
Fitness for purpose of the system

ISO 17455, Plastics piping systems — Multilayer pipes — Determination of the oxygen permeability of the
barrier pipe

ISO 21003:1: Multilayer piping systems for hot and cold water installations inside buildings — Part 1: General

ISO 21003-2, Multilayer piping systems for hot and cold water installations inside buildings — Part 2: Pipes

3 Terms and definitions

For the purposes of this standard, the terms and definitions given in FDUS 945-1:2011 apply.

4 Classification

4.1 Operating temperatures and service life

Pipe systems according to this standard are designed for a service life of at least 30 years when operated at
the following temperature profile:

29 years at 80 °C + 1 year at 90 °C + 100 h at 95 °C.

Other temperature/time profiles can be applied in accordance with ISO 13760 (Miner's Rule). Further
information is given in ISO 10508 and ISO 21003-2.

The maximum operating temperature shall not exceed 95 °C.

4.2 Operating pressures

Pipe systems according to this standard are designed for continuous operating pressures of 6 bar, 8 bar or 10
bar. Table 1 defines maximum SDR ratios of the service pipe required to withstand the operating pressures.

Table 1 — SDR ratios required for different operating pressures

Service pipe Operating pressure

6 bar 8 bar 10 bar

PE-X SDR 11 SDR 9 SDR 7.4

PB SDR 13.6 SDR 11 SDR 9
Multilayer pipes Wall thicknesses shall be calculated according
to the methods defined in ISO 21003-2

The SDR ratios in Table 1 are based on the regression curves of ISO 15875 series and ISO 15876 series.

Higher SDR ratios may be applied, if they are based on regression curves developed in accordance with EN
ISO 9080.

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 FDUS 945-2: 2012

5 Requirements

5.1 General

In addition to the general requirements defined in ISO 21003-2, the product specific requirements in 5.2 – 5.4
shall apply.

5.2 Service pipes and fittings

5.2.1 Quality

Plastics service pipes and fittings shall comply with:

• ISO 15875-1, ISO 15875-2, ISO 15875-3 and ISO 15875-5 for pipes made of cross linked
polyethylene (PE-X, for PE-Xb see also Annex B),

• ISO 15876-1, ISO 15876-2, ISO 15876-3 and ISO 15876-5 for pipes made of polybutylene (PB), and

• for multi-layer pipes, ISO 21003-2.

Deviating from these standards, temperature cycle tests on pipe systems and fittings shall be carried out with
test cycle numbers specified in 6.2.

5.2.2 Oxygen tightness

The oxygen diffusion of service pipes shall not exceed 3.6 mg/m²d at 80°C when tested in accordance with
ISO 17455.

NOTE The value of 3.6 mg/m2d is state of the art at general heating applications. A maximum diffusion rate of 0.8
mg/m d is recommended for district heating purposes.
2

5.3 Sealing in linear direction

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 tightness test of
ISO 9080 (without the box load test).

5.4 Water vapour permeation

The pipe supplier shall give information about the risk of the water accumulation in the insulation dependent
on the service conditions.

NOTE PE-X and PB pipes are slightly open for diffusion of water from the media to the insulation. The rate of
diffusion is increasing 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.

6 Test procedures

6.1 General
Unless stated otherwise, all tests are to be carried out:

a) no sooner than 72 h after production;

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FDUS 945-2: 2012

b) at room temperature; and

c) on samples taken from coiled pipes.

6.2 Temperature cycle test

The minimum test cycles and the cycle times for service pipe system tests are given in Table 2.

Table 2 — Test cycles

Service pipe outer diameter d2, Test cycles Cycle times,

mm min

d2 ≤ 32 2 000 30

40 mm ≤ d2 ≤ 110 1 000 30
d2 > 110 250 60

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 FDUS 945-2: 2012

Annex A
(informative)

Application of Miner's Rule

For plastic service pipes the lifetime is influenced by the temperature profile. For this European Standard a
calculatory temperature profile has been used. The lifetime is calculated by applying Miner's Rule. For other
temperature profiles new calculations have to be made.

District Heating systems are usually operated at various flow temperatures according to the necessary heat
load. When the actual temperature profile is deviating from the standard profile, the system supplier should
provide calculations applying Miner's Rule based on the information given in Table A.1.

Table A.1 — Examples for applying Miner's Rule

Operating temperature, Example 1 Example 2 Example 3

°C Operating time per year, Operating time per year, Operating time per year,
h h h

95 3.3 0 0
90 292 50 50
85 0 100 1 000
80 8 468 200 3 450
75 0 2 000 1 000
70 0 2 410 0
65 0 4 000 0
60 0 0 0
total 8 763.3 8 760 5 500

The total operation time should comply with the annual operation time (max. 8 760 hours). For systems
operating only for the heating period, the annual operation time might be below 8 760 hours.

Example 1 is taken from the temperature profile in FDUS 945-1 which means a total life time of 30 years and
100 h.

When calculated in accordance with Miner's rule Example 2 gives an estimated life time of more than 50 years
for a service pipe and Example 3 an estimated life time of more than 40 years.

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FDUS 945-2: 2012

Annex B
(normative)

Specifications for crosslinking of pipes in service

B.1 Introduction
The PE-X service pipe material may be crosslinked by any process (peroxide, silane, electron beam and azo)
which changes the chemical structure in such a way that the polymer chains are connected with each other to
a three-dimensional net by chemical bonds (commonly termed cross linking). Cross linking is carried out
during or after the manufacture of the pipe (see ISO 15875-2:2003, 4.1).

Silane cross linked polyethylene (PE-Xb) pipes are not fully crosslinked when being extruded. Crosslinking
occurs in contact with water, at a rate dependent on time and temperature.

The crosslinking of pipes in contact with water can either be carried out as a part of the production process or
allowed to occur during the commissioning and the first short period of service.

The purpose of this annex is to specify the requirements and test procedures of the pipe systems cross linked
during service to ensure that they comply with the specifications of Clause 4.

Pipes that are covered by this annex are curing so rapidly, that under ambient conditions they are curing partly
during storage. They are therefore like all fully crosslinked PE-X pipes unsuited for butt-welding.

Since not sufficient experience with electrofusion fittings is available, this annex does not cover pipe systems
with electrofusion fittings.

B.2 General
The degree of crosslinking shall meet the minimum requirement of 65 % specified in ISO 15875-1. The time
needed for reaching this crosslinking level is dependent upon the formulation of the material, the dimensions
of the pipe and the temperature of the water.

A pipe system fulfilling the requirements of B.3 may be installed directly and put into operation at the working
temperatures and pressures given in Clause 4.

The recommendations of the piping system producer shall be followed.

B.3 Requirements

B.3.1 Pipe system

The pipe and fitting system shall be specified by the producer and only such fittings which have been tested
together with the pipes in accordance with the service test specified in B.3.3 shall be used with the pipes in
the system.

Pipe systems shall comply with the thermo cycling test specified in ISO 21003-2, 6.2 and the pullout-test
according to of ISO 15875-5, 4.4 without prior conditioning.

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 FDUS 945-2: 2012

B.3.2 Determination of the ability to crosslink

A test piece of 2 mm thickness taken from the pipe or from the pipe or the fitting shall be conditioned in hot
water at 95 ° C for 24 h.

The degree of crosslinking of the conditioned sample when tested in accordance with ISO 10147 shall be ≥ 65
%.

The degree of crosslinking test shall be a quality control test.

B.3.3 Service test

The pre-insulated pipe systems shall meet requirements at both temperatures specified in Table B.1,
minimum 24 h and maximum seven days after production of the service pipe, when stored at 23 °C ± 3 °C and
an air humidity of 50 % ± 10 %:

a) a test piece of a minimum 1 m length shall be fitted with a connection fitting at both ends in
accordance with the supplier’s instructions. The fittings to be used for the test shall be those
belonging to the commercial system;

b) the test pieces shall be placed in air at room temperature and filled with water at room temperature,
and subject to internal pressure for thirty minutes at 1.3 times the pressures given in Table B.1; and

c) the pressure shall then be set and the temperature shall be increased to the values given in Table
B.1 and held constant for the periods of time given in Table B.1. The water circulation shall be
adequate to maintain the specified temperature accuracy in the entire test sample.

Table B.1 — Pipe testing for various SDR values

SDR value Test pressure, Testing time at (50 ± 1) °C, Testing time at (95 ± 1) °C,
bar h h

SDR 11 6 3 000 1 000

SDR 9 8 4 000 1 000
SDR 7.4 10 8 760 1 000

If it can be shown that a crosslinking degree of 65 % is reached earlier than the times stated in Table B.1, the
test may be interrupted when 65 % is reached.

After the tests according to Table B.1:

a) there shall be no visible failures or leakages; and

b) the pipes shall comply with ISO 15875-1.

The service test shall be a type test.

B.4 Marking
The marking of the service pipe shall include minimum information concerning material or material code
according to the relevant standard for crosslinkable PE-Xb pipes.

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 FDUS 945-2: 2012

B.5 Example
The common operating temperatures are 70 °C or 80 °C and common pipe dimensions are diameters 32 and
63 with SDR 11. Larger dimensions are available (for example, 110 SDR 11).

Considering these parameters and a typical PE-Xb material on the market, the necessary time to achieve 65
% of crosslinking in operation is given in Table B.2.

Table B.2 — Testing of pipe diameters

Diameter, SDR value Test temperature, Testing time at 80 °C, Test temperature, Testing time at 70
°C,
mm °C h °C
h
32 11 16 32
63 11 80 45 70 90
110 11 105 210

Pipes can be operated at the maximum service pressure during crosslinking.

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 FDUS 928-2: 2012

Certification marking

Products that conform to Uganda standards may be marked with Uganda National Bureau of Standards
(UNBS) Certification Mark shown in the figure below.

The use of the UNBS Certification Mark is governed by the Standards Act, and the Regulations made
thereunder. This mark can be used only by those licensed under the certification mark scheme operated by
the Uganda National Bureau of Standards and in conjunction with the relevant Uganda Standard. The
presence of this mark on a product or in relation to a product is an assurance that the goods comply with the
requirements of that standard under a system of supervision, control and testing in accordance with the
certification mark scheme of the Uganda National Bureau of Standards. UNBS marked products are
continually checked by UNBS for conformity to that standard.

Further particulars of the terms and conditions of licensing may be obtained from the Director, Uganda
National Bureau of Standards.

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FDUS 945-2: 2012

ICS 23.040.20

Price based on nn pages

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