SGB DLR-P Manuale utente

Overpressure leak detector

DLR-P

Z – 65.26-349

Documentation DLR - P

No.: 604 202

Issue:11/2009

SICHERUNGSGERÄTEBAU GMBH

Hofstraße 10

57076 Siegen

Overview – Design variant

OVERPRESSURE LEAK DETECTOR DLR.. - Ü-1 -

Overview of the design variants

The overpressure leak detectors of the DLR-series are available in different designs which are

described in detail by the suffix characters.

DLR-… …. PM “Manometer“, the leak detector is equipped

with a digital pressure display in the hous-

ing cover.

“Protected“ construction of the leak detector in a

weatherproof housing.

“Numerical value”, for the alarm pressure of the leak

detector in bar.

The alarm pressures range from 1 bar to 18 bar.

“G = gas(bottle)“, a pressure gas bottle is used for

pressure generation, normally nitrogen.

“P = Pump“, a pump integrated in the leak detector is

used for pressure generation.

”GS = gas (-bottle)”, a static pressure generator must

be brought to the site since the leak detector does not

have a pump or automatic feed mechanism.

“Pressure Leak detector Pipe”, the leak detector operates

with overpressures towards the atmosphere and is de-

signed for application on double-walled pipes.

11/09/2006 Your partner for Leak Detection Technology Sicherungsgerätebau GmbH, Siegen

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Content

1 Technical description for the overpressure leak detector DLR-P 13 pages

2 Drawings to the technical description 7 pages

3 Appendix to the technical description 4pages

3.1 Appendix TD

3.2 Appendix TF

3.3 Statement

4 Declaration of conformity 1 page

5 Measuremt and Drilling 2 pages

6 Working sheet AB-820 500 pneumatic connections 2 pages

7 Approval of the DIBT 5 pages

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Contents Page

1 Subject 2

2 Field of application 2

2.1 Requirements for interstitial spaces 2

2.2 Pipes 2

2.3 Fittings 2

2.4 Materials carried in the pipes / leak detection medium 2

3 Description of functions and operation 3

3.1 Switching values and pressure values 3

3.2 Normal operation 4

3.3 Functions in the event of a leak 4

3.4 Air drying / dry filter 4

3.5 Description of the display and control elements 5

4 Installation and assembly instructions 5

4.1 General notes 5

4.2 Personal safety equipment 6

4.3 Installation of the leak detector 6

4.4 Installation of the connecting lines (leak detector -> interstitial space) 6

4.5 Installation of the dry filter 7

4.6 Electrical connections 7

4.7 Example installation 7

5 Commissioning / repairs 7

6 Operating instructions 8

6.1 General notes 8

6.2 Maintenance 8

6.3 Intended use 9

6.4 Functional tests 9

6.5 Alarm / fault 12

7 Disassembly 12

8 Marking 12

9 Abbreviations 13

DIAGRAMS:

Location of the test cocks P – 078 000

Installation example 1 M1 – 078 000

Installation example 2 M2 – 078 000

Installation example 3 M3 – 078 000

Installation example 4 M4 – 078 000

Current flow diagram SL – 853 600

Test device P – 115 395

APPENDIX:

TD Technical data TD – 1

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1. Subject

Overpressure leak detector for double walled pipes, double walled fittings or a combination of

the above with air used as the leak detection medium.

DLR-P .. The dots are used in place of the alarm pressure. The alarm pressure may also be

followed by letters to describe the design variant of the leak detector in more detail.

2. Field of application

2.1. Requirements for interstitial spaces

•Verified pressure resistance of the interstitial spaces (see section 3.1)

•Verification of suitability of the interstitial space (for Germany: Allgemeine bauaufsichtliche

Zulassung (General Building Authority Approval), approval in individual cases).

•Tightness of the interstitial space (see section 6.4.7)

•The number of interstitial spaces to be monitored depends on the overall volume of the

interstitial space. According to EN 13160, this must not exceed 10m3. In order to make it

possible to verify the tightness of the interstitial space, we recommend that a value of 4 m3is

not exceeded.

The length of pipe which is to be monitored (per pipe branch) should not exceed 2500 m,

and it should comply with the approval requirements of the pipe.

2.2. Pipes

Double walled pipes (overground and underground) made of metal or plastic, designs

manufactured in the plant or on-site.

For Germany: More far reaching requirements for double walled pipes may result from TRbF 50,

the DIBt approval principles or EN 13160.

2.3. Fittings

Double walled fittings (overground and underground) made of metal or plastic, designs

manufactured in the plant or on-site.

For Germany: with Allgemeine bauaufsichtliche Zulassung (General Building Authority

Approval), provided this is not part of the approval of the pipeline.

2.4. Products conveyed in the pipes / leak detection medium

•Liquids which are hazardous to waters with a flash point > 55°C

•Liquids which are hazardous to waters with a flash point < 55°C

ONLY for double walled pipes / fittings with walls which are permeation-proof on the side of

the material being conveyed.

On pipes / fittings which are permanently filled with liquid, it must be ensured that the

equipment carrying the product (delivery pumps, ...) is suitable for zone 0, as air is forced

into the product in the event of a leak.

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•The product being conveyed must not react with the leak detection medium.

•The resistance of the pipes / fittings to the material being conveyed must be verified by third

parties (e.g. operator, manufacturer of the pipeline ...).

3. Description of functions and operation

The overpressure leak detector DLR-P monitors both walls of a pipe/fitting for leaks. The

monitoring pressure is high enough to ensure that leaks in the inner or outer wall are indicated

through a pressure loss.

In order to build up the pressure, air is sucked in from the outside by the integrated pump via a

dry filter and then pumped to the interstitial space(s).

The dry filter dries the outside air to a relative humidity of approximately 10%. The drying

process is necessary in order to eliminate any accumulation of moisture or condensation in the

interstitial space. Used dry filter cartridges should be regenerated or replaced.

3.1. Switching values and pressure values in bar

Type

DLR-P pDP

[bar] pAE_ON

[bar] pPA_OFF

[bar] Switch position of the

dip switch PÜDV 11

[bar] pTEST

[bar]

1.1 < 0.1 > 1.1 < 1.45 1.6 ±0.07 ≥2.0

1.5 < 0.5 > 1.5 < 1.9 2.2 ±0.10 ≥2.5

2.0 < 1.0 > 2.0 < 2.4 2.7 ±0.10 ≥3.0

2.3 < 1.3 > 2.3 < 2.8 3.1 ±0.10 ≥3.5

2.5 < 1.5 > 2.5 < 2.9 3.2 ±0.10 ≥3.5

3.0 < 2.0 > 3.0 < 3.4 3.8 ±0.10 ≥4.2

_Special values agreed between SGB and

the customer.

pDP Max. delivery pressure in the inner pipe

pAE "Alarm ON" switching value – an alarm is triggered at the latest when this value is

reached.

pAA "Alarm OFF" switching value – the alarm is cancelled when this value is exceeded.

The switching value "Alarm OFF" is approximately 100 mbar higher than the switching

value "Alarm ON" (pAA = pAE + ~100 mbar)

1In the table, the opening pressure of the overpressure valve is indicated at which the volumetric flow of the pump is

stopped. The response pressure (initial opening) is lower.

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pPA "Pump OFF“ switching value (=setpoint pressure)

pPE "Pump ON" switching value

The switching value "Pump ON“ is around 100 mbar lower than the switching value

"Pump OFF" (pPE = pPA - ~100 mbar)

pÜDV1 Opening pressure of overpressure valve (on the interstitial space side)

The overpressure valves can be omitted if the test pressure of the interstitial space is ≥

3 bar (type 1.1 and 1.5) or ≥10 bar (type 2.0 to 3.0).

pTEST Minimum test pressure of the interstitial space

3.2. Normal operation

The leak detector is connected via the connecting line(s) to the interstitial space(s). The

overpressure generated by the pump is measured via a pressure sensor and regulated.

When the operating pressure (Pump OFF) is reached the pump is switched off. Due to leaks in

the leak detection system which are unavoidable, the pressure will start to slowly rise again.

When the switching pressure "Pump ON" is reached the pump is switched on and the system

builds operating pressure back up again.

During normal operation, the leak detector fluctuates between these two pressure values, with

short run-up times and longer standstill times which depend on the tightness and temperature

fluctuations of the overall plant.

3.3. Functions in the event of a leak

If a leak occurs on the inside wall or the outside wall then air will escape from the interstitial

space. The pressure will drop until the pump is switched on in order to restore operating

pressure. If the volumetric flow escaping through the leak is greater than the (limited) delivery

rate of the pump then the pressure in the system drops and the pump runs in continuous

operation.

Any increase in the size of the leak leads to a further pressure loss until eventually the alarm

pressure is reached. At this point the system will generate visual, audible and potential-free

alarm outputs.

3.4. Air drying / dry filter

The air supplied to the interstitial space is passed through a dry filter in the intake line. The dry

filter dries the air to a relative humidity of around 10% in order to prevent corrosion and

accumulation of condensation in the interstitial space.

The dry filter is designed to last for a year provided the equipment is used for its proper

intended use and no additional temperature fluctuations occur.

Initially the dry filter is an orange colour, but this fades to a colourless (or green) state when the

filter has been used up. Once the filter cartridge has been used up it should be replaced or

regenerated.

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3.5 Description of the display and control elements

3.5.1 Display element states (signal lamps) for type DL ..

Signal lamp Operating status Alarm status Alarm, audible alarm

signal acknowledged Device fault

OPERATION:

green ON ON ON ON

ALARM: red OFF ON FLASHING ON

3.5.2 Operating functions via pushbuttons

Switching off the acoustic alarm signal:

Briefly press the "Audible alarm" button once – the audible alarm signal is then switched off and

the LED flashes.

Pressing the button again will cause the audible signal to be switched on.

(This function is not available in normal operation or during malfunctions.)

Testing the visual and audible alarm signal

Press the "Audible alarm" button and keep it pressed (approx. 10 seconds) – the alarm signals

are triggered until the button is released again.

This test is only possible if the pressure in the system has exceeded the "Alarm OFF" pressure

level.

Testing the tightness of the monitored system

Press the "Audible alarm signal" button and keep it pressed until the "Alarm" signal lamp flashes

at high speed, then release the button. A value for the tightness is indicated through illumination

of the “Alarm” signal lamp. (see Appendix DP)

For this test the leak detector must have performed at least 1 automatic feed interval in normal

operation (i.e. without being filled by an assembly pump) in order to obtain a valid result.

4. Installation and assembly instructions

4.1. General notes

(1) Installation and assembly must only be performed by qualified companies2.

(2) The relevant accident prevention regulations of the Wasserhaushaltsgesetz (Water

Resources Act, WHG) must be complied with.

(3) Explosion protection requirements must be satisfied (where necessary), such as laws on

the basis of the European Directive 1999/92/EG and/or other applicable codes.

(4) A test valve should be provided at the leak detector opposite end of the pipe(s)/fitting(s).

(5) Before accessing control shafts, measure the vapour-air mixture and the O2-level.

2In Germany: Companies who have the status of a “qualified company” in the sense of §19I of the

Wasserhaushaltsgesetz (Water Resources Act, WHG) 19l, who are qualified to carry out installations of

leak detection systems and can demonstrate proof of expertise and knowledge in relation to fire safety

and explosion protection.

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4.2. Personal safety equipment

The parts listed here apply in particular to safety when working on plants which may pose an

potentially risk of explosion.

If work is carried out in industries in which it must be assumed that an explosive atmosphere is

present then the following items of equipment are required as an absolute minimum:

•Suitable clothing (risk of a build-up of electrostatic charge)

•Suitable tools (compliant with EN 1127)

•A suitable gas warning device which is calibrated for the existing vapour-air mixture (work

should only be performed at a concentration of 50% below the lower explosion limit)3

•Measuring device for determining the oxygen content of the air (Ex / O meter)

4.3. Installation of the leak detector

(1) Generally in a wall-mounted installation with wall plugs and screws.

(2) In a dry room, or out in the open in a suitable housing.

(3) NOT in areas with a potentially risk of explosion.

(4) The distance between the leak detector and the interstitial space should be kept as short

as possible (refer also to the next section).

4.4. Installation of the connecting lines (leak detector -> interstitial space)

(1) Metal (generally copper) or plastic tubes with a pressure resistance corresponding to at

least the test pressure of the interstitial space – also applies to fittings and unions.

(Observe the temperature range, particularly when using plastic materials.)

(2) Clear width at least 6 mm.

(3) 50 m should not be significantly exceeded – but if so: use a tube with a greater clear width

with corresponding bridging pieces.

(4) The full cross-section must be retained. Pinching and kinking4are not permitted.

(5) Metal or plastic tubes underground, or plastic tubes routed overground should be routed

inside a conduit.

(6) The conduit should be sealed gas-tight.

(7) The pressure and measuring lines can be combined together underneath the leak detector

via pulsation damper 107 (see installation examples).

(8) Avoid any build-up of electrostatic charge (e.g. when drawing in lines).

(9) For details of the connection technology to be used refer to Work Sheet AB-820 500 (see

Information).

3Other %-specifications may result from works-specific or German Land-specific regulations.

4If required, commercially available shaped sections should be used for plastic tubes (pre-defined

bending radii)

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4.5. Installation of the dry filter

(1) Preferably close to the leak detector.

(2) Vertical with the intake opening facing down, using the enclosed installation materials.

(3) The dry filter and in the intake connection port of the leak detector should be connected via

a PVC hose (or similar).

4.6. Electrical connections

(1) Power supply: in accordance with the imprint on the type plate.

(2) Hard wired, i.e. no plug-in or switchable connections.

(3) The regulations of the electricity supply companies must be satisfied5.

(4) Terminal assignment: (see also SL-853 600)

1 / 2 Mains connection

3 / 4 Assigned (to the internal pump)

5 / 6 External signal (in the event of an alarm, mains voltage is present here - it is

switched off by pressing the "Audible alarm" button).

11 / 12 Potential-free contacts (open in the event of an alarm and in the event of a power

loss)

4.7. Example installation

Example installations are shown in the Appendix.

5. Commissioning / repairs

(1) Note the requirements in section 4.

(2) If a leak detector is taken into operation on a pipe (fitting) which is already in operation,

then special protection measures need to be put in place (e.g. checking that the leak

detector and/or the interstitial space is free of gas). Further measures may depend upon

the local conditions and should be assessed by qualified personnel.

(3) Once the pneumatic connections have been made, make the electrical connections.

(4) Check that the signal lamps for "Operation" and "Alarm" light up and that the audible alarm

signal sounds, if necessary switch off the alarm.

(5) Connect the three-way cock 21 in the position "III", connect a gauge. (Drawing: P-078 000)

(6) The leak detection system should be supplied with the operating pressure according to the

table on page 3. (Use of an assembly pump, with sufficiently dimensioned dry filter or a

nitrogen pressure cylinder).

5In Germany: compliance is also required with the VDE regulations.

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