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ANNEX IVU.K. Conformity assessment procedures
PART IIU.K. DESCRIPTION OF CONFORMITY ASSESSMENT PROCEDURES
MODULE A1 – INTERNAL PRODUCTION CONTROL PLUS SUPERVISED PRODUCT TESTINGU.K.
4.Product checks for oil retention and detonation resistanceU.K.
4.4.Detonation resistance test referred to in point 5 under PFC 1(C)(I)(a)(i-ii)(A) in Annex IU.K.
4.4.1.DescriptionU.K.
4.4.1.1.The test shall be carried out on a representative sample of the EU fertilising product. Before being tested for resistance to detonation, the whole mass of the sample is to be thermally cycled five times in accordance with point 4.3.U.K.
4.4.1.2.The EU fertilising product shall be subjected to the detonation resistance test in a horizontal steel tube under the following conditions (the details of the materials are in point 4.4.3):U.K.
seamless steel tube:
Tube length: 1 000 mm at least,
Nominal external diameter: 114 mm at least,
Nominal wall thickness: 5 mm at least,
booster: the type and mass of the booster chosen shall be such as to maximise the detonation pressure applied to the sample in order to determine its susceptibility to the transmission of detonation,
temperature of the sample: 15 °C to 25 °C,
witness lead cylinders for detecting detonation: 50 mm diameter and 100 mm height,
placed at 150 mm intervals and supporting the tube horizontally.
NOTE: The test is to be carried out twice. The test is deemed conclusive if in both tests one or more of the supporting lead cylinders is crushed by less than 5 %.U.K.
4.4.2.PrincipleU.K.
The test sample is confined in a steel tube and subjected to detonation shock from an explosive booster charge. Propagation of the detonation is determined from the degree of crushing of lead cylinders on which the tube rests horizontally during the test.
4.4.3.MaterialsU.K.
Plastic explosive containing 83 % to 86 % penthrite
density: 1 500 kg/m3 to 1 600 kg/m3
detonation velocity: 7 300 m/s to 7 700 m/s
mass: (500 ± 1) g;
or any other plastic explosive with similar detonation characteristics.
Seven lengths of flexible detonating cord with non-metallic sleeve
filling mass: 11 g/m to 13 g/m
length of each cord: (400 ± 2) mm.
Compressed pellet of secondary explosive, recessed to receive detonator
explosive: hexogen/wax 95/5 or similar secondary explosive, with or without added graphite
density: 1 500 kg/m3 to 1 600 kg/m3
diameter: 19 mm to 21 mm
height: 19 mm to 23 mm
mass of the compressed pellet: maximum 10 g
central recess to receive detonator: maximal diameter 7,0 to 7,3 mm, depth about 12 mm. In case of detonators with large diameters, the diameter of the recess shall be slightly larger (e.g. 0,5 mm) than the diameter of the detonator.
Seamless steel tube as specified in ISO 65 – 1981 – Heavy Series, with nominal dimensions DN 100 (4'')
outside diameter: 113,1 mm to 115,0 mm
wall thickness: 5,0 mm to 6,5 mm
length: 1 005 ± 2 mm.
Bottom plate
material: steel of good weldable quality
dimensions: 160 mm × 160 mm
thickness: 5 mm to 6 mm.
Six lead cylinders
diameter: 50 ± 1 mm
height: 100 mm to 101 mm
materials: soft lead, at least 99,5 % purity.
Steel block
length: at least 1 000 mm
width: at least 150 mm
height: at least 150 mm (alternatively a stack of several beams can be used to achieve this height)
Mass: at least 300 kg if there is no firm base for the steel block.
Plastic or cardboard cylinder for booster charge
wall thickness: 1,5 mm to 2,5 mm
diameter: 92 mm to 96 mm
height: 64 mm to 67 mm.
Detonator (electric or non-electric) with initiation force 8 to 10
Wooden or plastic disc
diameter: 92 mm to 96 mm. Diameter to be matched to the internal diameter of the plastic or cardboard cylinder (point (h))
thickness: 20 mm.
Wooden or plastic rod of same dimensions as detonator (point (i))
Small split pins (maximum length 20 mm)
Split pins (length about 20 mm)
4.4.4.ProcedureU.K.
4.4.4.1.Preparation of booster charge for insertion into steel tubeU.K.
Depending on the availability of equipment, the explosive can be initiated in the booster charge either
by seven-point simultaneous initiation as referred to in point 4.4.4.1.1, or
by central initiation by a compressed pellet as referred to in point 4.4.4.1.2.
4.4.4.1.1.Seven-point simultaneous initiationU.K.
The booster charge prepared for use is shown in Figure 2.
4.4.4.1.1.1.Drill holes in the wooden or plastic disc (point (j) under point 4.4.3) parallel to the axis of the disc through the centre and through six points symmetrically distributed around a concentric circle 55 mm in diameter. The diameter of the holes shall be 6 mm to 7 mm (see Section A-B in Figure 2), depending on the diameter of the detonating cord used (point (b) under point 4.4.3).U.K.
4.4.4.1.1.2.Cut seven lengths of flexible detonating cord (point (b) under point 4.4.3) each 400 mm long, avoiding any loss of explosive at each end by making a clean cut and immediately sealing the end with adhesive. Push each of the seven lengths through each of the seven holes in the wooden or plastic disc (point (j) under point 4.4.3) until their ends project a few centimetres on the other side of the disc. Then insert a small split pin (point (l) under point 4.4.3) transversally into the textile sleeve of each length of cord 5 mm to 6 mm from the end and apply adhesive around the outside of the lengths of cord in a band 2 cm wide adjacent to the pin. Finally, pull the long piece of each cord to bring the pin into contact with the wooden or plastic disc.U.K.
4.4.4.1.1.3.Shape the plastic explosive (point (a) under point 4.4.3) to form a cylinder 92 mm to 96 mm in diameter, depending on the diameter of the cylinder (point (h) under point 4.4.3). Stand this cylinder upright on a level surface and insert the shaped explosive. Then insert the wooden or plastic disc(1) carrying the seven lengths of detonating cord into the top of the cylinder and press it down onto the explosive. Adjust the height of the cylinder (64 mm to 67 mm) so that its top edge does not extend beyond the level of the wood or plastic. Finally, fix the cylinder to the wooden or plastic disc for instance with staples or small nails, around its entire circumference.U.K.
4.4.4.1.1.4.Group the free ends of the seven lengths of detonating cord around the circumference of the wooden or plastic rod (point (k) under point 4.4.3) so that their ends are all level in a plane perpendicular to the rod. Secure them in a bundle around the rod by means of adhesive tape(2).U.K.
4.4.4.1.2.Central initiation by a compressed pelletU.K.
The booster charge prepared for use is shown in Figure 3.
4.4.4.1.2.1.Preparing a compressed pelletU.K.
Taking the necessary safety precautions, place maximum 10 g of a secondary explosive (point (c) under point 4.4.3) in a mould with an inside diameter of 19 mm to 21 mm and compress to the correct shape and density (the ratio of diameter: height should be roughly 1:1). In the centre of the bottom of the mould there is a peg, 12 mm in height and 7,0 mm to 7,3 mm in diameter (depending on the diameter of the detonator used), which forms a cylindrical recess in the compressed cartridge for subsequent insertion of the detonator.
4.4.4.1.2.2.Preparing the booster chargeU.K.
Place the explosive (point (a) under point 4.4.3) into the cylinder (point (h) under point 4.4.3) standing upright on a level surface, then press it down with a wooden or plastic die to give the explosive a cylindrical shape with a central recess. Insert the compressed pellet into this recess. Cover the cylindrically shaped explosive containing the compressed pellet with a wooden or plastic disc (point (j) under point 4.4.3) having a central hole 7,0 mm to 7,3 mm in diameter for insertion of a detonator. Fix the wooden or plastic disc and the cylinder together with a cross of adhesive tape. Ensure that the hole drilled in the disc and the recess in the compressed pellet are coaxial by inserting the wooden or plastic rod (point (k) under point 4.4.3).
4.4.4.2.Preparing steel tubes for the detonation testsU.K.
At one end of the steel tube (point (d) under point 4.4.3), drill two diametrically opposed holes 4 mm in diameter perpendicularly through the side wall at a distance of 4 mm from the edge. Butt weld the bottom plate (point (e) under point 4.4.3) to the opposite end of the tube, completely filling the right angle between the bottom plate and the wall of the tube with weld metal around the entire circumference of the tube.
4.4.4.3.Filling and charging the steel tubeU.K.
See Figures 2 and 3.
4.4.4.3.1.The test sample, the steel tube and the booster charge shall be conditioned to temperatures of (20 ± 5) °C. About 20 kg of the test sample should be available for two detonation resistance tests.U.K.
4.4.4.3.2.1Place the tube upright with its square bottom plate resting on a firm, flat surface, preferably concrete. Fill the tube to about one-third of its height with the test sample and drop it 10 cm vertically onto the flat surface five times to compact the prills or granules as densely as possible in the tube. To accelerate compaction, vibrate the tube by striking the side wall with a 750 g to 1 000 g hammer between drops for a total of 10 times.U.K.
4.4.4.3.2.2.Repeat this charging method with another portion of the test sample. Finally, a further addition shall be made such that, after compaction by raising and dropping the tube 10 times and a total of 20 intermittent hammer blows, the charge fills the tube to a distance of 70 mm from its orifice.U.K.
4.4.4.3.2.3The filling height of the sample shall be adjusted in the steel tube so that the booster charge (referred to in point 4.4.4.1.1 or 4.4.4.1.2) to be inserted later will be in close contact with the sample over its entire surface.U.K.
4.4.4.3.3.Insert the booster charge into the tube so that it is in contact with the sample; the top surface of the wooden or plastic disc shall be 6 mm below the end of the tube. Ensure essential close contact between explosive and test sample by taking out the booster charge and adding or removing small quantities of sample. As shown in Figures 2 and 3, split pins should be inserted through the holes near the open end of the tube and their legs opened flat against the tube.U.K.
4.4.4.4.Positioning of the steel tube and lead cylinders (see Figure 4)U.K.
4.4.4.4.1.Number the bases of the lead cylinders (point (f) under point 4.4.3) 1, 2, 3, 4, 5 and 6. Make six marks 150 mm apart along a line on a steel block (point 4.4.3(g)) lying on a horizontal base, with each mark at least 75 mm from any edge of the block. Place a lead cylinder upright on each of these marks, with the base of each cylinder centred on its mark (see Figure 4).U.K.
4.4.4.4.2.Lay the steel tube prepared according to point 4.4.4.3 horizontally on the lead cylinders so that the axis of the tube is parallel to the centre line of the lead cylinders and the welded end of the tube extends 50 mm beyond lead cylinder No 6. To prevent the tube from rolling, insert small wooden or plastic wedges between the tops of the lead cylinders and the tube wall (one on each side) or place a cross of wood between the tube and the steel block or stack of beams. (see Figure 4).U.K.
Note: Make sure that the tube is in contact with all six lead cylinders; a slight curvature of the tube surface can be compensated for by rotating the tube about its longitudinal axis; if any of the lead cylinders is too tall, tap the cylinder in question carefully with a hammer until it is the required height.U.K.
4.4.4.5.Preparation for detonationU.K.
4.4.4.5.1.Set up the apparatus as described in point 4.4.4.4 in a bunker or suitably prepared underground site or suitable location. Ensure that the temperature of the steel tube is kept at (20 ± 5) °C before detonation.U.K.
Note: Detonation can cause steel fragments to be projected with high kinetic energy, therefore, firing shall be carried out at a suitable distance from dwellings or thoroughfares.
4.4.4.5.2.If the booster charge with seven-point initiation is used, ensure that the detonation cords are stretched out as described in the footnote to point 4.4.4.1.1.4 and arranged as horizontally as possible.U.K.
4.4.4.5.3.Finally, remove the wooden or plastic rod and replace with the detonator. Do not carry out firing until the danger zone has been evacuated and the test personnel have taken cover.U.K.
4.4.4.5.4.Detonate the explosive.U.K.
4.4.4.6.1.Allow sufficient time for the fumes (gaseous and sometimes toxic decomposition products such as nitrous gases) to disperse, then collect the lead cylinders and measure their heights with a Vernier caliper.U.K.
4.4.4.6.2.Record for each of the marked lead cylinders, the degree of crushing expressed as a percentage of the original height of 100 mm. If the cylinders are crushed obliquely, record the highest and the lowest values and calculate the average.U.K.
4.4.4.7.Detonation velocity measurement can also be performed.U.K.
4.4.4.8.Two detonation tests per sample are to be carried out.U.K.
4.4.5.Test reportU.K.
Values for the following parameters are to be given in the test report for each of the detonation resistance tests:
the values actually measured for the outside diameter of the steel tube and for the wall thickness,
the Brinell hardness of the steel tube,
the temperature of the tube and the sample shortly before firing,
the packing density (kg/m3) of the sample in the steel tube,
the height of each lead cylinder after firing, specifying the corresponding cylinder number,
method of initiation employed for the booster charge.
4.4.6.Evaluation of test resultsU.K.
If, in each firing, the crushing of at least one lead cylinder is less than 5 %, the test shall be considered conclusive and it shall be considered that the sample presented is resistant to detonation.
4.4.7.The test report shall form part of the technical documentation.U.K.
Figure 2U.K.
Booster charge with seven-point initiation
:
Steel tube
:
Wooden or plastic disc with seven holes
:
Plastic or cardboard cylinder
:
Detonating cords
:
Plastic explosive
:
Test sample
:
4 mm hole drilled to receive split pin
:
Split pin
:
Wooden or plastic rod surrounded by 4
:
Adhesive tape for securing 4 around 9
Figure 3U.K.
:
Steel tube
:
Wooden of plastic disc
:
Plastic or cardboard cylinder
:
Wooden of plastic rod
:
Plastic explosive
:
Compressed pellet
:
Test sample
:
4 mm hole drilled to receive split pin
:
Split pin
:
Wooden or plastic die for 5
Figure 4U.K.
Numbers in circles:
:
Steel tube
:
Lead cylinders
:
Steel block or stack of beams
:
Bottom plate
:
Booster charge
Numbers in squares:
Lead cylinders 1 to 6
The diameter of the disc must always correspond to the inside diameter of the cylinder.
NB: When the six peripheral lengths of cord are taut after assembly, the central cord must remain slightly slack.