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Euroheat & PowerRecommendation

for

Education, Training and Examination of Fitter and PE-welder
and

Certification of Fitter Companies

Approved by the Euroheat & Power Board Prepared by Task Force Transport & Distribution June 2010

Contents
1. 2. Annex A1 A 1.1 A 1.2 A 1.2.1 A 1.2.2 A 1.3 A 1.3.1 A 1.4 A2 A 2.1 A 2.2 A 2.2.1 A 2.2.2 A 2.2.3 A 2.2.4 A 2.2.5 A 2.2.6 A 2.2.7 A 2.3 A 2.3.1 A 2.3.2 A 2.3.3 A 2.3.4 A 2.3.5 A 2.3.6 A 2.3.7 A 2.4 A 2.4.1 A 2.4.2 A 2.4.3 A3 A 3.1 A 3.2 A 3.2.1 A 3.2.2 A 3.2.3 A 3.3 A 3.3.1 A 3.3.2 A 3.3.3 A 3.4 A 3.4.1 Introduction ....................................................................................................... 3 Recommendation EHP...................................................................................... 9 Qualification of fitters and PE welders as well as certification of fitter companies in different countries ....................................................................10 Finland ..............................................................................................................10 Qualification and certification scheme for companies and fitters........................ 10 Requirements for fitter certificate....................................................................... 10 Validity of the certificate .....................................................................................10 Training of fitters and PE welders.......................................................................11 Requirements for fitter company certificate ....................................................... 11 Validity of the certificate .....................................................................................12 On-site quality control........................................................................................ 12 Germany / Austria ............................................................................................12 Training of fitters and PE welders...................................................................... 12 Exam of fitters according to AGFW worksheet FW 603 ..................................... 13 Test Centre ........................................................................................................14 Admission to Exams...........................................................................................14 Theoretical Exam ...............................................................................................14 Practical Exam ...................................................................................................15 Overall Rating ....................................................................................................16 Period of validity and repetition of exam .............................................................17 Technical Rules..................................................................................................17 Exam of PE welders according to DVS 2212-4.................................................. 17 Test Centre ........................................................................................................17 Admission to Exam ............................................................................................17 Theoretical Exam ...............................................................................................18 Practical Exam ...................................................................................................18 Overall assessment............................................................................................19 Validity ...............................................................................................................20 Technical Rules..................................................................................................20 Certification of fitter companies ......................................................................... 20 Requirements for enterprises and content of examination..................................20 Review and Certification.....................................................................................22 Technical Rules..................................................................................................22 Sweden .............................................................................................................23 Area of validity for ficensing of fitters and authorisation of fitter companies ....... 23 Authorisation committee 23 Composition of the authorisation committee.......................................................23 Committee‘s decision method ............................................................................23 Business of the authorisation committee ............................................................23 Licensing of fitters ............................................................................................. 24 Requirements.....................................................................................................24 Charges for Iicensing .........................................................................................24 Obligations for suppliers of joint systems............................................................25 Authorisation of fitter companies ....................................................................... 25 Requirements.....................................................................................................27
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Steel valve assembly for steel service pipes........... gives instructions for the welding of medium pipes......................Fitting assemblies of steel service pipes.... Plastic jacket pipes are assembled onsite from pipes and fittings and other system components..Surveillance systems EN 448 EN 488 EN 489 EN 13941 EN 14419 EN 15698-1 District heating pipes ...Pipe assembly of steel service pipe...................... following Standard shall apply: EN 253 District heating pipes ........Preinsulated bonded twin pipe systems for directly buried hot water networks .....4.......Preinsulated bonded pipe systems for directly buried hot water networks ..... regarding the minimum inspection scope of pipes (EN 253) and fittings (EN 448)...... 28 1.Preinsulated bonded pipe systems for directly buried hot water networks ........ polyurethane thermal insulation and outer casing of polyethylene Based on EHP/001 Certification Guidelines for quality assessment of district heating pipes the production sites of manufacturers can be reviewed and certified.5 A 3...... Page 3 ....Preinsulated bonded pipe systems for directly buried hot water networks ..28 Identification and marking of joints ............ their static pipe design and the assembly.....Part 1: Twin pipe assembly of steel service pipe....Joint assembly for steel service pipes......... see Figure 1................ polyurethane thermal insulation and outer casing of polyethylene District heating pipes ..Preinsulated bonded pipe systems for directly buried hot water networks ........... provides information on the examination of the onsite produced and pipe joints and provides recommendations for the training of fitters........... constructed by using underground plastic jacket pipes.Preinsulated bonded pipe systems for directly buried hot water networks .................................................... polyurethane thermal insulation and outer casing of polyethylene Design and installation of preinsulated bonded pipe systems for district heating District heating pipes ..A 3.......6 Charges .................. polyurethane thermal insulation and outer casing of polyethylene District heating pipes ....... Note: EN 489 sets out requirements for pipe joints and type tests for joints... Note: For plastic jacket pipe-system components. Introduction The quality of the joint casing application is crucial for the useful life and efficiency of district heating networks..... polyurethane thermal insulation and outer casing of polyethylene District heating pipes ....... 28 Regulations ... Damage caused by improper construction lead to moisture in the insulation and on the long-term to corrosion of the steel pipes........2 A 3.......... A plastic jacket pipe connection is the establishment of the connection between the adjacent tubes and / or fittings.....

junction structures. The assembly of special moldings of coated pipes (segment bends.Figure 1: Example of a pipe connection between two plastic jacket pipes (Source: Canusa-CPS) The steel medium pipes are welded to each other or to the steel fittings. Page 4 . Their field of activity includes The installation of the monitoring and fault detection systems (if any) The sealing of the sleeve area or the connecting of the coated pipes. see Figure 2. Long-term statistics show that a large part of the damages can be traced back to poor performance qualities in the context of the joint casing application. The welding is performed by steel welders with a valid test certificate according to EN 287-1. Considerable expenditures are necessary to restore the required conditions of underground district heating pipes.) The insulation of the sleeve cavity. The supplementary insulation and sealing / connection of the PE casing pipe has to be performed by fitters and PE welders. The attachment of expansion cushion. Inadequate implementation qualities may require repair work or even cause an interruption in the heat supply. etc.

Another reason for the reduction of damages is today's safer and easier to handle PE.joint casing systems. in particular during construction.and PE-X.Figure 2: Breakdown of the causes of damage in Germany (Source: AGFW) Through improving the skills and knowledge of fitters and companies active in this field. Figure 3: Damage development of plastic jacket pipes without damages by third parties in Germany (Source: AGFW) Page 5 . were significantly reduced within the past decade in Germany. the damages of plastic jacket pipes. see Figure 3.

The instructions must contain the following sentence: "All wet foam must be to be removed from the pipe ends. must be part of the manufacturer's documentation and delivered together with the components of the casing pipe connection.Coordination of appointments with the construction . equipment and machinery effective quality control at the construction site . Cleaning Appropriate procedures for cleaning and drying must be defined for: o The entire section of a pipe connection between the pipes o The front of both welded together pipe components o The surface of the steel medium pipes o The surface of the insulation o The surface of the connection joint o The surface of the sheating o The sealing surfaces of the material used to coat the joint system pipe (connecting pipe sleeve and jacket pipe) o The wetting surfaces of the insulation of the sleeve cavity.is significantly influenced by the following factors: .Training and testing of fitters . tent) .and thus the damage caused by improper joint casing application .Use of joint systems and materials according to EN 489 . that are essential for the quality of the jacket pipe joints and for the reaching of the expected service life.Qualification of fitter companies functional organization adequate financial basis experienced and professionally qualified management personnel certified fitters and PE welders appropriate and serviceable tools.Workplaces and working conditions in the area of the joint casing according to the requirements of technical regulations Pipe trenches according to safety requirements with sufficient space Sufficient space around the tubes for the manufacture of the connecting and sealing of the jacket pipes Dry pipe trench (drainage) Protection against adverse weather conditions (umbrella. These have to mention at least the following topics: Working conditions The appropriate procedure for creating the best working conditions on the ground have to be established.The quality of pipe connections .Processing instructions of the joint manufacturer The processing instructions." Page 6 .

For the foaming at the construction site at least the following methods have to be described: o Measures to be taken. o temperatures. o assembly procedures to prevent gaps between the insulation of the jacket pipe joints and the pipe ends. For the installation of prefabricated insulation elements at least the following procedures have to be described: o storage procedures.Appropriate monitoring of the construction work according to technical specifications and by professional supervisors Construction site organization Construction timing specifications Excavation of the pipe trench (Sheeting. Scarping) Pipeline construction Joint casing application and fitters Page 7 .Adequate reimbursement for installation and assembly work . Type-specific methods for testing the tightness of the jacket pipe joints must be described. These measures shall at least include "welding procedures” and “welding preparation and orientation". at which the PUR heat insulation may be stored when the temperature is outside the range of 15 °C to 25 °C. suitable methods for connecting the monitoring system should be established before the start of the joint assembly. o measures to be taken to ensure that during the foaming of the joint the air can escape optimally and no excessive losses of the foam occur. if the surface temperatures is outside the range of 15 °C to 45 °C. Thermal insulation of the jacket pipe joint Appropriate procedures for the onsite foaming or for the installation of prefabricated insulation elements have to be described. .Monitoring In case monitoring system are installed in jacket pipe connection. in order to avoid damage of the insulation elements and to keep them dry. This determination shall comply with EN 14419 and include procedures for at least the following: o reviewing the measuring elements after delivery o assembling works in jacket pipe connections to ensure the functioning of the system o examination of the assembly quality of the monitoring system during the installation o examination after the completion of a measuring section Onsite steel welding Appropriate procedures for the welding of steel pipes have to be established. Joint Connection Appropriate instructions for handling and installation of the joint connection must be established.

that connect pre fabricated plastic jacket pipe components posses a valid qualification. such as technical colleges. Page 8 . suppliers or other competent organizations. to ensure that the connection of the jacket pipe has the same quality as the one of the type testing. as well as supervising personnel must possess theoretical knowledge and practical skills in relation to the following areas: . . According to EN 489 . insulation techniques and the installation of surveillance systems.the materials used.accident protection. . Annex C and reserve sufficient time for practical exercises with connection methods. in which their ability to conduct reproducible welds in the specified quality is confirmed. Training and inspection contents are indicated in EN 489.every single step in the processing of the application of the joint casing system must be according to the instructions of the manufacturer. The training programs should include the disciplines and subjects mentioned in EN 489:2003. . The required training programs may be carried out by manufacturers. . A qualification certificate is the prove of the received training and skills. The processing of jacked pipe joints under construction site conditions should be a part of the training.used joint system.In order to ensure the necessary high-quality joint casing application. .provisions for the processing and handling of materials.quality and error criteria.procedure of thermal insulation. . fitters have to have sufficient technical knowledge and manual skills regarding the utilized joint systems. . which confirms that they received an appropriate training for the utilized medium pipe connection and pipe system. . applicable safety precautions. . Annex C.installation of the monitoring system.PE-welder must possess a proof of a valid qualification. Fitters that connect prefabricated insulated jacket pipe systems.those persons.quality inspection and documentation.

Recommendation EHP The quality of the joint casing application depends largely on the skills.2. Instead of District Heating associations other bodies such as technical universities. The fitters and PE welders must repeatedly prove their knowledge and skills at appropriate intervals. The contractually agreed and technically specified . Fitter companies shall be certificated and authorized. EHP recommends: For assembly work of plastic jacket pipes only certified and therefore trained and tested fitters and PE welders are appointed.requirements regarding the quality of a construction can only be ensured by such professionals that . .master the necessary manual skills. The comparability of qualifications at European level is not possible.regular conduct joint casing application. The implementation is subject to the concerned interest groups or individual countries. Note: In Austria. Authorised companies shall equip each joint with a label containing the name of the company and a serial joint number. The valid qualification has to be confirmed at the construction site through a personalized certificate. Their training and certification should be organized and implement at the national level. In EN 489:2009. . knowledge and quality awareness of the fitters.have sufficient specialized knowledge. Fitter and PE welder shall be registered. the certification of fitters and PE welders is not further defined. Page 9 .in particular EN 489 . institutes etc. by which the fitter can be identified. Germany and Sweden the national District Heating association ensures the implementation and quality of the certification process (see also the examples in the following Annexes). Finland. can be in charge of certification. Another possibility is to base the certification process and education on the producer of the joint system.

Renewal by test installation is possible maximum two times.sirola@energia.2 Requirements for fitter certificate General requirements for a fitter certificate are: . a district heating company.: +358 9 5305 2303. after that a new 3-day course with exams is required.g. Welded casing joints are not covered as they mostly are company-specific and thus certification of fitters of welded joints should be borne by the producer. The certification process is regulated in a special document describing the requirements and the procedures of certification. Finnish Energy Industries recommends energy companies to use only certified companies and fitters for pipe installation in their projects. Page 10 . A 1. Finnish Energy Industries and Finnish Plastics Industries. Finnish Energy Industries keeps lists of certified companies and fitters updated on its web site.A 3-day course on joint installation and/or PE-welding with passed theoretical exams and practical tests .fi A 1. Tel. A1 Contact to: Finland Finnish Energy Industries PO Box 100 FI-00101 HELSINKI Veli-Pekka Sirola. or the verification / certification of fitter companies are regulated in the respective country.Licence for so called ”hot installations” (welding. More information on a particular approach can be obtained from the national District Heating associations. heat shrinking…) A 1. The goal of the scheme is to advance sound competition.Annex Qualification of fitters and PE welders as well as certification of fitter companies in different countries (informative) The following outlined procedures of individual countries show how training and the testing of fitters and PE-welders. The scheme is organised and operated in cooperation by two associations. The certificates can cover heat shrinkable joint installation and insulation or PEwelding of casings or both of them. If this is not the case. and this is nowadays common practise in Finland.1 Qualification and certification scheme for companies and fitters In Finland there is a national qualification scheme for fitter companies and fitters. the fitter shall make a test installation as condition for certificate renewal. Mailto: veli-pekka. There is a common Certification Board managing and operating the scheme. that the fitter has performed joint installations and/or PE-welding during the past year). Certification is naturally voluntary for companies and fitters.1 Validity of the certificate The certificate is valid for one year at a time. ensure the capacity of fitter companies and sufficient knowledge and skills of fitters and hence quality of joint installations. It is reissued annually by written evidence of fitter’s work experience during past year (evidence from e.2. flame cutting. The scheme that was started about 20 years ago covers certification of both fitter companies and fitters.

t-pieces. as surveillance systems are not commonly used in Finland) .work safety in joint installations .welding machines and devices .welding preparations . either covering both joint installation and PE-welding or one of them.practical training (pipes.filler materials . A 1. properties and identification .joint technologies . at certain intervals.surveillance systems and alarm wire joints (just a lecture.The company has sufficient technical and economical capacities Page 11 .supervision.3 Requirements for fitter company certificate General requirements for a fitter company certificate are: . not included in exams.inspection and evaluation of practical test installation .plastic materials. These courses are obligatory for fitters wishing to receive a fitter certificate.welding methods .practical training .2.theoretical and practical exams Contents of the course on PE-welding of casings: .materials . tests and inspections of joint installations .The company is registered in Register of Companies .2 Training of fitters and PE welders There is a 3-day course on heat shrinkable joint installation and insulation and a separate 3day course on PE-welding of casings with theoretical exams and practical tests.g. Contents of the course on joint installation: .installation of joints . This makes it easier to manage the system and ensures that the contents and implementation of the education and training and exams is the same for all. The education and training is carried out by one education and training centre for the whole country.There are no additional requirements for repetition of the course and exams e.g.general about DH pipes and networks .theoretical exam and practical tests Joint producers should evaluate if additional training and/or additional certification by the producer for their specific joint systems is needed (e. repairs) . bends. A 1.welding parameters and controls . when new joint systems are put on the market).

not just one. A 1.The company employs a full-time foreman/leading fitter responsible for the installation work quality with at least one year experience as a foreman or three years as a fitter and a passed 3-day course on joint installation . Tel. Kälte und KWK e.withdraval of certificate of fitter or fitter and company.reneval of the 3-day course with exam and test . as well as the contents of the AGFW worksheet FW 401 should be the subject of the training.limitation of the scope of certificate . The content specified in EN 489. A2 Contact to: Germany / Austria AGFW | Der Energieeffizienzverband für Wärme. take care and control that all fitters carrying out joint installation or PEwelding in their projects are certified. A 1. Part of on-site control is making sure that all fitters carrying out jointing of pipes are certified.technical colleges The training at technical colleges for fitter and PE welder lasts five days.The company has a valid liability insurance All fitters of a company should be certified.4 On-site quality control Certification of fitter companies and fitters ensures the necessary preconditions and qualifications for a good quality joint installation are there.: +49 69 6304-346.1 Training of fitters and PE welders The training is carried out by .besier@agfw. It is reissued annually by written evidence that the requirements described above are still fulfilled.de A 2. It is also recommended for DH companies to take care that fitters of every joint in the field will be documented and marked on the joint.remark . V. It includes the exam for fitter according to AGFW worksheet FW 603 and the exam for PE welders according to DVS Directive 2212-4. On-site control is linked to the certification so that significant and repeated defects in installation quality communicated to the Certification Board may lead to: . Mailto: r. see Figure 4 and Figure 5.1 Validity of the certificate The certificate is valid for one year at a time.. It is up to the district heating company to require.The company employs at least one permanent fitter with a fitter certificate . Page 12 . On-site control is responsibility of DH companies.3.public notice (to be communicated to DH companies) . Stresemannallee 28 D-60596 Frankfurt/Main Rolf Besier. The training must provide sufficient time for practical exercises.companies that provide joint casing application services . but does not mean that on-site quality control is not needed anymore.

Preparation for joint casing application .Guideline DVS 2284 sets the contents and scope of the training for PE-welder.Processing of permanent sealings of the entire joint system (PE-shrink sleeve with hotmelt adhesive and PE-X-Shrink bands).Assembly and testing of the monitoring and error tracking system.Testing of the joint system for leakages prior to the insulation by means of air pressure.Preparation of the joint system for processing and sealing. . Contents of the exam are . Page 13 . It is divided into 14 lessons of specific theory and professional practice with 22 teaching units. see Figure 6.2 Exam of fitters according to AGFW worksheet FW 603 The AGFW worksheet FW 603 specifies the technical and practical exam of fitters. . Figure 4: Specialized Training (Source: SKZ) Figure 5: Exercises for testing the manual skills fitters according to AGFW worksheet FW 603 (Source: SKZ) Figure 6: Exercises for testing the manual skills of PE welders according to DVS 2212-4 (Source: SKZ) A 2. It is the basis for the initial exam and the repeated tests. .

A 2. Note: In the practical exam only one joint system can be examined.1 Test Centre The exam may only provided by manufacturers and technical schools. This has to be provided by the fitter to be tested. When successfully passing a test on the sample. gloves. . work pants. In case of defects they may not be used. If the exam is in a direct connection to an educational program.Requirements for joint casing application Page 14 . recognized by the AGFW worksheet FW-604.2.2. This approach aims to ensure that the fitters and their companies are equipped with appropriately.2.Insulation of sleeve cavity with polyurethane foam. It includes amongst other safety goggles.3 Theoretical Exam In the theoretical exam of joint casing application the necessary expertise in the practical work rules and safety measures have to be demonstrated. carried out by the fitter that is tested. it can be assumed that the fitter is also able to work with other professional systems.Occupational Safety Securing the work area Personal protection equipment Execution of pipe trenches Storage. -jacket and -helmet. the technical equipment of the test center may also be used.Sealing of the foaming holes with PEwelding plugs (procedure heated plate welding) . if through their training and previous work it can be expected that they have sufficient technical knowledge and skills in order to pass the exam. This is usually the case if a person has at least one year experience as assistant fitter and sufficient knowledge of the materials and processes on the basis of the relevant technical regulations. one member of the examination board must be an examiners appointed by AGFW. non-destructive testing of the quality of the joint casing applicatio .Final. transport and processing of chemicals and flammable / explosive substances equipment and tools etc. . the exam is not only a purely personal examination but also in some sense a procedural examination.2 Admission to Exams Persons may participate at the initial tests. A 2. The practical test may only be performed using the necessary personal protection equipment. Through the composition of the examination board it has to be ensured that all the content of the exam are covered. Note: As the exam has to be carried out by the fitters with their own equipment and machinery. Subjects of the theoretical exam are: . These must be in a technically flawless security condition. A 2. The practical work has to be certified by the companies. safety shoes. Repeated tests have in any case be carried out with the equipment of the respective fitter. If the exam is performed by manufacturers. The practical exam has to be performed by the fitter with its own tools. The exam has to take place in front of examination board. the test center can request an approval test. In case of doubt.. equipment and machinery.

The position of the test sample has to be unchanged during the exam. Page 15 .Sleeve cavity insulation with polyurethane foam .Assembly and testing of the plastic jacket pipes-monitoring and fault detection systems . The theoretical exam is considered passed if at least 75% of possible points are achieved.Testing of the tightness of the joint system before insulation through air pressure . A 2.Sealing the foaming holes with welding plugs .Preparation of a polyurethane foam sample .Preparation of the sealing surfaces .4 Subjects are: .Preparation of joint casing application .Assembly and testing of the plastic jacket pipes-monitoring and fault detection systems .Sealing the foaming holes with welding plugs . The weighting factors 1-3 take into account the practical importance of the joint casing application. There are 30 weighted questions.Testing of the tightness of the joint system before insulation .Preparation of a polyurethane foam sample . It is mandatory to pass the theoretical exam before the practical exam.2.Preparation of joint casing application .Preparation of the sealing surfaces . The level of support from the floor to the bottom of the medium pipe must not exceed 20 cm. The repetition of the exam on the same day is not allowed.Testing by the fitter The exam is carried out within 45 minutes by a written multiple-choice test.Processing and sealing of joint systems with permanently melt adhesives . Practical Exam In the practical exam the fitters have to demonstrate their manual skills.Testing by the fitter The test sample shown in Figure 7 has to be attached during the exam on the floor in a similar way as at the construction site.Sleeve cavity insulation with polyurethane foam .Processing and sealing of joint systems with permanently melt adhesives .Conditions of work and surrounding Applied systems and products Used tools and equipment .

The ID must be readable under construction site conditions during the period of validity. undergo a visual inspection and mechanical-technological tests. A failed test can be repeated. A 2.5 Overall Rating To pass the exam as a fitter both the theoretical exam and the practical exam have to be successfully passed. The repeated exam should be accompanied by adequate practical and theoretical training. The practical test is passed if the requirements on the test sample and the taken sample in the visual assessment and the mechanical-technological tests are met. see Figure 8. The repetition of the practical exam on the same day is not allowed. Figure 8: ID of fitters according to AGFW-Worksheet FW 603 (Source: SKZ) Page 16 . To demonstrate the successfully passed exam the fitters receive of an exam certificate and an ID. This ID mentions the name of the fitter and validity of the qualifications specified.2.Figure 7: Test sample for exam according to AGFW worksheet FW 603 The individual work steps and the final test sample as well as the sample taken from the test sample by the examiners.

The guideline DVS 2212-4 is the basis for the initial exam and repetition of the exam on the correct and professional execution of PE welding procedures such as hot gas string bead welding and hot gas extrusion welding at construction sites on plastic jacket pipes.3 Exam of PE welders according to DVS 2212-4 In addition to the exam as a fitter according to AGFW worksheet FW 603. acknowledgment from inspection stations to the examination from fitters of work sheet FW 603 . This provides the permission for welding with the procedures hot gas string bead welding and hot gas extrusion welding. This is usually the case when one of the following conditions is met: Page 17 . the trainer and evaluator may be no identical for any candidates.2007 . For these techniques complementary trainings or exams have to be carried out by the manufacturer. The test center must have the necessary facilities to carry out the tests. edition 12. examination of fitters . A 2. The repetition of the exam is always necessary if the fitter has interrupted his activity for longer than 6 months.2007 Joint casing application on preinsulated bonded pipes and flexible pipes.Rules of procedure for acknowledgment of inspection stations according to work sheet FW 604.2007 A 2. edition 12. edition 12.Conditions for recognition of testing centers according to FW 604.Rules of procedures for examination of fitters work sheet according to FW 603. and the assessment of joint mechanics after FW 603. A 2.Qualification criteria for recognition as an examiner AGFW FW-603 and as examiners AGFW FW 604.3.2.2007 .2 Admission to Exam Only welder who passed the exam on plastic welding according to guideline DVS 2212-1.A 2. edition 12.6 Period of validity and repetition of exam The validity of the exam is two years.2007 Joint casing on preinsulated bonded pipes and flexible pipes. A 2.7 Technical Rules .AGFW worksheet FW 603. an exam as a PE welder according to DVS 2212-4 has to be passed if PE-welded joints have to be applied on the jacket tubes. The directive does not apply to other PE-welding techniques such as heated plate welding or sleeve welding with incorporated electric heating elements. edition 12.1 Test Centre The exam is carried out in a test center and supervised by an examiner for plastic welders. edition 12. If the exam takes place at the end of a preparatory course for the exam for example according to DVS 2284.3. subgroup I-5 and II-1 may participate in the exam and only if from their training and previous work it can be expected that they posses sufficient technical knowledge and skills to pass the exam.AGFW worksheet FW 604.2007 .2. The repletion of the exam may be integrated in an additional training session.

The theoretical exam shall be considered passed if at least 66% of possible points are achieved. execution qualities Welding parameters Weld preperation Implementation of welding procedures Welding Minutes Occupational safety A written multiple-choice serves as the basis.. Page 18 . as well as according to DVS 2212-4 may be held consecutively.3 Theoretical Exam In the theoretical exam the welder has to demonstrate that he possesses the required working knowledge and understanding of safety measures for an accident-free and professional work.3. The exams according to DVS 2212-1. skilled worker or journeyman in a relevant profession) and successful participation in a basic course on the processing of semi-finished products made of thermoplastics the course to prepare for the exam as plastic welder according to DVS 2284. the test center can perform an approval test. A 2. As part of the initial exam at least 30 questions. The test includes the following subjects: .Technical training (e. in the context of a repeated exam at least 15 questions have to be answered. skilled worker or journeyman in a relevant profession).Thermoplastics Denomination Strength characteristics Influence of temperature Quality and condition of the semi finished product as well as welding consumables .4 Practical Exam In the practical exam. e.. equipment. i. . the exam for both may be held on one day. The training and practical work have to be demonstrate by certificates. the PE welder has to prepare a test sample and provide for each weld seam a welding protocol.. sufficient experience in the processing of semi-finished products made of thermoplastic materials with the welding procedures hot gas string bead welding and hot gas welding by extrusion of filler material and successful participation in the course of preparation for the welding test in accordance with DVS 2284 .3. In this case. subgroup I-5 and II-1. In case of doubt. g.At least one year experience as a plastic welder and a satisfactory knowledge of the materials and processes involved. A 2.Technical training (e. g. the theoretical l exam has to be passed just once.Welding Specificities of the procedures hot gas string bead welding and hot gas welding by extrusion of filler material on plastic jacket pipes Requirements for basic and welding consumables.

Figure 10: ID of PE welder according to DVS 2212-4 (Source: SKZ) Page 19 . The height of the free supports affixed on the steel medium pipe may at most be 200 mm. The repeated exam should be accompanied by adequate practical and theoretical training. see Figure 10. or those of the test center. the test sample has to be fixed in a similar location. as on the construction site. A failed test can be repeated. from the floor to the under edge of the steel medium pipe.The equipment to be used and machinery must be in a technically flawless security condition. Figure 9: Test sample for the exam as PE welders according to guideline DVS 2212-4 The test sample has to be inspected visually during and after manufacturing. The branch pipe has to lean 45 ° from the vertical.5 Overall assessment To pass the exam as a PE welder both the theoretical exam and the practical exam have to be successfully passed. samples for further tests including visual quality of the weld and for subsequent mechanicaltechnological tests have to be taken. This ID mentions the name of the fitter and validity of the qualifications specified.3. During the weld preparation and the welding process. To demonstrate the successfully passed exam the fitters receive of an exam certificate and an ID. above the floor. The welder can decide whether to use his own tools and machines (or from his employers). The ID must be readable under construction site conditions during the period of validity. Thereafter. A 2.

through a working sample the manual skill and quality are demonstrated. Therefore one for the PE welders produced weld . PE welders .4. edition 9. The validity of the welder exam may be prolonged by a test centre for two years. edition 9.A 2.6 Validity The welder must annually repeat the exam. A three-year practice of joint casing application and experience in the management of corresponding constructions have to be demonstrated. can demonstrate .3. The requirements and the procedure of the certification process are regulated in the AGFW worksheet FW 605.7 Technical Rules DVS 2212-1 Exam of PE welders. if at the expiry of the ID. o the leading fitter of the construction site The leading fitter of the construction site has to proof his qualification according to FW 603 and DVS 2212-4 o employees of individual sites and branch offices or business offices. preparation for the welding test in accordance with guideline DVS 2212-4 Certification of fitter companies A 2.possibly out of a difficult working position must be checked at a unforeseen time. This applies for the following employees: o The responsible professional o The quality officer The responsible professional and the quality officer must be employed by the company.4 Regulations claim that joint casing application has to be performed by qualified companies. A 2. This also applies to the assembly of plastic jacket pipes.2004 Exam of PE welders.plastic jacket pipes. A 2. welding of plastic jacket pipes – pipes and pipe parts DVS 2284.2004 DVS-course.3. which are commercially related to the execution of published services and can demonstrate their qualification. Qualified companies are those. They have to prove knowledge of joint casing application with the peculiarities that arise from the processing of materials and work techniques.1 Requirements for enterprises and content of examination Formal Requirements Control of documents Organization The management of the company must ensure that the responsibilities and authority within the organization are established and publicized. Page 20 . The contracting authority must ensure . test group I and II DVS 2212-4. A retest is always due necessary if the welder has interrupted his work for longer than six months.that only suitably qualified companies and institutes perform these activities. where appropriate.and.

.Implementation of the joint casing application It must be ensured that the materials and auxiliary materials required for the joint casing application are properly transported.. o provide prove for the proper disposal of waste or residual materials . as well as the test results. If different sleeve materials or systems are processed. Page 21 . etc. the weather and construction site condition and the extent and nature of the tests. The company has to set measurements how to deal with the results of the quality checks. the company has to ensure that confusion is avoided. machinery or test equipment are used. for which only special tools. equipment. qualifications. . The current processing instruction for the respective sleeve systems and materials used on the construction site must be available at all times. For example how necessary improvement or corrective action can be quickly implemented. Additional supporting joint casing application staff and / or personnel undergoing training may only work under the constant supervision and instruction of the leading fitter of the construction site. o ensure the validity of certificates. o appoint for each construction site a leading fitter of the construction site and qualified personnel in sufficient number. The qualification for the processing of producer-specific sleeve systems with the appropriate equipment and machinery has to be demonstrated by an additional proof of the manufacturer (procedure for sleeve welding with incorporated electric heating elements). including references.Equipment For executing their work.at least twice a year. The company has to o cover the need for necessary training and instruction of the professionals.professionals that conduct activities affecting the quality of the product must have the ability and experience to be able to carry out their tasks. identifying the construction site. The documentation of the tests must be clear and comprehensible.Evidence of activity and references The company or the responsible person has to submit evidence of past lessons learned and executed work.Quality Assurance The quality officers of the company has to test the fitters at the construction sites in regular intervals . The quality officer has to check through visual tests the condition of the technical equipment. . o ensure the compliance with the requirements if using external professionals and / or subcontractors. based on appropriate education and training. stored and processed according to the manufacturer. The onsite responsible fitters have to demonstrate their qualification with exams in accordance with valid FW 603 and possibly DVS 2212-4. companies need to use the required equipment in operational condition in sufficient quantities. The equipment shall meet the relevant safety requirements in accordance with the rules and regulations regarding work safety and health standards and correspond to the "state of the technical rules".

It must be ensured that these are not older than one year.2003 Comparative overview of existing management systems and qualifications Page 22 .2003 Qualification requirements for AGFW.L1. A 2.Business rules to AGFW/FVGW-worksheet FW 605.Application forms for certification according to AGFW/FVGW-worksheet FW 605 for companies which carry out joint casing application . Edition 9.2003 . Edition 9.L4. receive a certificate and can use the certification for promotion on the company vehicles.4. Edition 9. Figure 11: Model of certificate according to AGFW worksheet FW 605 for joint casing application Figure 12: Advertising of a qualified fitter company on a company vehicles A 2.3 Technical Rules .2 Review and Certification The inspections and certifications are carried out by certification bodies accredited according to EN ISO / IEC 17021.2003 Joint casing application on preinsulated bounded pipes on flexible pipes.2003 Principles of cooperation between AGFW / FVGW and certification bodies FW605.2003 .4. The companies that have been successfully tested. Edition 9. Edition 9.L3.AGFW-Worksheet FW 605. requirements for companies which carry out joint casing application . see Figure 11 and Figure 12. in their scope the certification process has to be implemented according to AGFW worksheet FW 605.Guidelines to AGFW/FVGW-worksheet FW 605 FW605. Edition 9.Reports of independent. external audit bodies on the implementation quality have to be submitted upon request of the customer.und FVGW-Experts FW 605 FW605.

Appellants must lodge their records of appeal within three weeks of the service of the decision The Technical Council must have obtained the committee‘s report before the decision. Likewise.2006 Conformity assessment – Requirements for bodies providing audit and certification of management systems A3 Contact to: Sweden Svenska Fjärrvärmeföreningen Olaf Palmes gata 31 101 53 Stockholm Ture Nordenswan Tel. In cases such as e.nordenswan@svenskfjarrvarme. alarms and insulation in connection with the laying of district heating pipes. The committee must record an up-todate list of its members.1 Authorisation committee Composition of the authorisation committee Members of the committee are to be appointed by Svensk Fjärrvärme (Swedish District Heating Association) and manufacturing company each with one member and a third appointed jointly by the first two.2 A 3. A 3.2.EN ISO/IEC 17021.2 Committee‘s decision method The committee decisions regarding licensing and authorisation are to be notified in writing. the committee must give the party the opportunity to plead its case before the decision. Secretary and convener appointed by Svensk Fjärrvärme. The committee‘s ordinances may only be changed through a decision by the superordinate Svensk Fjärrvärme‘s Technical Council. The committee have a quorum when at least half of the members are present. the revocation of licensing or authorisation or the delivery of warnings.: +46 (8) 6772718 Mailto: ture.2.1 Area of validity for ficensing of fitters and authorisation of fitter companies Regulations for licensing and authorisation embraces the assembly of joint systems ..se A 3. Neither may information that comes to light during the processing of cases by the committee be disclosed to outsiders.sealed joints. the committee can be disbanded through decisions made in the same way as applies for amendments to the ordinances. Cases against the committee‘s decision are appealed to Svensk Fjärrvärme´s Technical Council.g. A 3. Authorisation and licensing is awarded after application and approved examination of companies and fitters.3 Business of the authorisation committee The authorisation committee has the task. Refusals must be motivated. after examination according to the ordinances and regulations for authorisation and licensing. to issue licences and authorisation to fitters and Page 23 . Committee minutes and other documents are not to be made available to parties other than those working on the committee. Edition 12. Minutes are to be kept of committee meetings. which is enclosed with the ordinances. A 3. Members are appointed for a term of office comprising three calendar years. Licensed fitters and authorised companies are registered on Svensk Fjärrvärme‘s website.2.

The same applies if it comes to the attention of the committee that the fitter does not follow applicable laws. Licence applications are made in writing to the Authorisation committee at Svensk Fjärrvärme. Licences can be revoked or limited by the committee if the conditions of licensing no longer exist. The authorisation committee must keep a list of licensed fitters and authorised companies. A 3. A certificate of an approved theory examination and of practical training carried out at an authorised company in accordance with the requirements established by the Authorisation committee are to be enclosed with the application. The parties concerned are obligated to provide the committee with the details and documents that the committee may find necessary for checks or an objective examination of submitted complaints. However the fitter has the right to receive reasonable time to redress these matters.3 Licensing of fitters Licences for assembling the joint system are issued to fitters that have completed examination and who conform to the committee‘s requirements. Holds a doctor‘s certificate according to AFS 2005:18 ‘Thermosetting plastic“. inform where the list of authorised companies and licenses fitters arc available. Holds approved application documents 2. Authorisation and licenses can be revoked by the committee if any of the conditions for authorisation or licensing are no longer fulfilled.2 Charges for Iicensing The charge for licenses is SEK 300. A 3. for practical experience1 and specifically executed joint work on site 5. standards and directives. A 3. in an appropriate manner. The committee must examine submitted complaints. certificate of completed courses in “Hot Work“.1 Requirements As conditions for licensing it applies that the fitter: 1.companies. However the authorised company has the right to receive reasonable time to redress these matters. standards and directives. Holds a certificate from the inspector. VUC‘s ‘Basic course in safety on the road“ as well as training in the risks and safety actions when working with thermosetting plastic according to AFS 2005:18 “Thermosetting plastic“. The authorisation committee can appoint inspectors with the task of examining that the company and fitters uphold established quality requirements.3. Holds a certificate from a joint supplier of authorisation in the joint type in question and specific execution 4. The committee has the task to ensure that the ordinances do not restrict competition. Is trained and examined in theory according to the Casing Joint Technology 3. The committee decides on any amendments. The committee must. The same applies if the company does not observe the laws.3. 1 Guideline value: 500 executed joints under the supervision of a Iicensed fitter Page 24 . appointed by the supplier.

However. Training updates must take place at least every second year. etc that the company does not follow applicable laws. the company has the right to receive reasonable time to redress these matters. company or authorized signatory or other circumstances of significance these must be reported immediately and without request to the committee. The supplier must also ensure that the fitter is checked by independent inspectors at least every second year.3. The same applies if it comes to the attention of the committee via inspections. Authorisation and licensing can be revoked.A 3. Authorised companies and licensed fitters are registered on Svensk Fjärrvärme‘s website. Page 25 . The application is made using the application form issued by the authorisation coinmittee. A 3.3 Obligations for suppliers of joint systems Suppliers of joint systems are responsible for documented assembly instructions and the training of fitters.1 no longer exist. Authorised companies receive a certificate issued by the authorisation committee. This also applies to such circumstances that can affect the company‘s ability to satisfactorily fulfill its duties or if the company ceases with joint assembly. see Figure 13 and Figure 14. Should the authorisation cease to apply the certificate must be returned without delay to the authorisation committee. standards and directives. In the event of changes regarding the authorised company‘s fitters. The authorised company is responsible to the client that the requirements demanded here are satisfied.4.4 Authorisation of fitter companies The authorisation application is made in writing to the authorisation committee at Svensk Fjärrvärme. This can occur if demands as set out in A 3.

Figure 13: Authorisation application Figure 14: Personal details Page 26 .

Is responsible that assembly work is carried out by licensed fitters 7. Gives inspectors the possibility to make inspections and rectify any shortcomings 8. inspection of machine functions. Figure 15: Annual report 2 Quality system is defined as the measures the company documents in work descriptions and which are routinely performed in connection with assembly work. Observes demands from the authorities and directives issued by the client 4. Upholds submitted details 5.A 3. Presents the quality system2 6. self-inspection of joining and work protocols. These can include e.1 Requirements As conditions for authorisation it applies that the company: 1. Holds appropriate liability and contractor insurances 3. Work descriptions must be drawn up which comprise assembly instructions and instructions for handling defective products and nonconformity at the assembly site. Page 27 . Holds approved application documents 2.4.g. Pays established taxes and charges Annual reports are submitted to the authorisation committee with support of Figure 15.

Authorization application .Assembly date . light ram.A 3. steady ram .4.Miscellaneous . Check-box for sunny.Responsible fitter with license number .Workplace .Dimensions .Joint type .Assembly conditions.Pipe temperature supply / return .Ordinances for the district heating industry´s authorisation committee.Air temperature .5 Identification and marking of joints Authorised companies must equip each joint with a label containing the name of the company and a serial joint number. 2008 .Pressure testing of joint .Company and Authorisation number .Signature of inspector / contact person and date A 3.Alarm value . check-box for approved all non-approved + line for remarks .6 Regulations .2 Charges The authorisation committee may levy the charges for authorisation of companies. The size of the label must be at least 5 x 10 cm and the numbers must be clear with a height of at least 8 mm.Excavation.Client . 2008 Page 28 . The label must be impervious to the surrounding environment. cloudy. A 3.Regulations for authorization and licensing. Protocols are to be drawn up in A4 format for the joints and must contain at least the following data: .