27 July 2009 I /08. Klenk GmbH Eichelstraße 15, D Bodnegg-Rotheidlen
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1 General Technical Approval German Institute for Construction Engineering PUBLIC-LAW INSTITUTION Approval body for construction products and types of construction German Construction Industry Inspection Authority Member of the European Organisation for Technical Approvals EOTA and of the Member of the European Association for Technical Approval in Construction UEAtc Phone: Fax: Date: Reference 27 July 2009 I /08 Approval number: Duration of validity until: 30 June 2014 Applicant: Klenk GmbH Eichelstraße 15, D Bodnegg-Rotheidlen Object of approval: Flexible double-walled pipe for transport of water-hazardous liquids during transfer and filling procedures (system conceived and made by the company Klenk) The Construction Inspection Industry Authority hereby approves the above-specified product. This General Technical Approval comprises eight pages, including five Annexes (five additional pages). It replaces the General Technical Approval certificate No. dated 8 June 1999 issued by the Construction Inspection, which had last been extended on July 20, German Institute for Construction and Engineering An Institution of the German Federation and of the Federal States DIBt Kolonnenstraße 30 L D Berlin Phone: Fax: dibt@dibt.de j
2 General Technical Approval Page 2 of 8 27 July 2009 I. GENERAL PROVISIONS 1 This General Technical Approval provides evidence that the approved product is suited for application and use within the meaning of the building and construction regulations enacted by the different Federal States. 2 This General Technical Approval does not replace the permits, licences and certifications otherwise required by the German law for the execution of building and/or construction projects. 3 This General Technical Approval is granted without prejudice to the rights, particularly private property rights, of any third parties. 4 The manufacturer and distributor of the approved product must, without prejudice to more extensive regulations contained in the SPECIAL PROVISIONS stated below, provide the user of the approved product with copies of the General Technical Approval by pointing to the fact that the General Technical Approval has to be available at the place where the approved object or system is used. On request, the involved authorities are, likewise, to be provided with copies of the General Technical Approval. 5 The General Technical Approval many be reproduced only in whole. The publication of the Approval in excerpts is subject to the German Construction Industry Inspection Authority's prior consent (Deutsches Institut für Bautechnik, DIBt). Texts and drawings publicized in promotional literature must not be contrary to the specifications laid down in this General Technical Approval. All translations of the General Technical Approval must contain the hint phrase "Translation of the original German version not reviewed by the German Construction Industry Inspection Authority (DIBt)". 6 The General Technical Approval is granted subject to revocation at any time. The terms of the General Technical Approval can subsequently be altered and/or amended, particularly if new technical knowledge requires doing so.
3 General Technical Approval Page 3 of 8 27 July 2009 II. SPECIAL PROVISIONS 1 Object of approval and scope of application (1) This General Technical Approval concerns and relates to flexible double-walled (jacketed) hose lines with leak detection, a system conceived and made by the company Klenk, bearing the type designation DWSL and comprising an associated intermediate layer serving as a spacer element and a hose connection fitting consisting of connection fittings, nipples and sleeves or hose connecting pieces existing on the hose side, including connection parts, such as clamps, hose screw connections or flanges or tanker couplings and the material needed for sealing them. The flexible pipes are manufactured including inner hoses in sizes from DN 15 up to DN 75 and lengths of up to 50m. They are suited for connection to a vacuum leak detector that allows to detect negative pressures of up to -550mbar and alarm vacuum levels of at least -325mbar (as for the design of the flexible double-walled pipe, please refer to Annex 1 hereto). (2) The leak detector reacts and warns optically and acoustically if, in consequence of leaks in the walls of the flexible double-walled pipe, the pressure level in the monitored space rises. (3) The flexible double-walled pipes are admitted for the conveying of water-hazardous liquids during transfer and/or filling operations at pumping pressures of up to 10bar. (4) The flexible double-walled pipes are admitted for use within a temperature range from -20 C up to +60 C on condition that evidence is furnished with regard to their suitability in regard to all materials and liquids that, during the transfer of the related water-hazardous liquid, could get in touch with each other in a certain section of the admissible overall temperature range. (5) The General Technical Approval is hereby granted without prejudice to the provisos on testing or other law sectors, such as the Directive 97/23/EC (Pressure Equipment Directive), the eleventh regulation on the device safety law (regulation on placing devices and safety systems in circulation for hazardous areas - explosion protection regulation and the ordinances on 18 of the German Occupational Safety and Health Act, the German Ordinance on Industrial Safety and Health and the German Ordinance on Hazardous Substances). (6) Owing to this General Technical Approval, the assessment in regard to the approved product's compliance with the regulations of the Federal Water Act, including the type-approval procedure required by the German Water Management Law ( 19 h WHG 1 ) are inapplicable. (7) The validity period of this General Technical Approval (see page 1) relates to the utilisation of the approved product, meaning its installation, mounting or incorporation and not to its possible later use. 2 Provisions concerning the construction of the product 2.1 General The flexible double-walled pipes (jacketed hose lines with leak detection), a system conceived and made by the company Klenk, bearing the type designation DWSL, have to comply with the SPECIAL PROVISIONS as defined in this decision, including the data and details deposited with the German Institute for Construction Engineering. 1 Federal Water Act (Water Management Law, WHG) of 19 August 2002
4 General Technical Approval Page 4 of 8 27 July Characteristics and structure (1) The inner and outer hoses correspond to the type D or SD (i.e. with or without spring steel wire equipment) as specified in the standard DIN EN and the TRbF 131/2 3 (TRbF = Technical Regulations for Combustible Liquids). They must be suited for use within the scope of applications defined in above section 1. The same materials are used for both the inner and outer hoses. The hose material for the realisation of the internal layer according to Table 4 of standard DIN EN is to be chosen so that its suitability in view of the materials and the admitted liquid getting in touch with each other while conveying it through the pipe, is ensured. The same applies also in regard to the operating temperature of the pipe. The materials used for the manufacture of the hose fittings must, likewise, be suited for use in connection with the liquid to be conveyed. (2) The monitored space is realised using an intermediate layer consisting of thermoplastic poly(ether)ester elastomers following the specifications laid down in DIN EN This material is commonly known as Hytrel. This intermediate layer consists of a plastic net that has been pulled over the inner hose. (3) The metal fittings and joints are made in compliance with DIN EN and tested as specified in DIN EN (4) The sealants are made in compliance with DIN 3771, parts 1 to 5 6 and must meet the requirements specified in DIN ISO (5) The mounting of the flexible double-walled pipe is to be realised in compliance with the mounting instructions deposited with the German Institute for Construction Engineering. (6) Proof of the functional reliability of the approved product has been furnished in compliance with the requirements specified in DIN EN and in the "Approval Principles specified for Leak Detectors for Double-walled (Jacketed) Pipes (ZG-LAGR)" issued by the German Institute for Construction Engineering (DIBt) in August 1994 and in the Technical Regulations for Combustible Liquids (TRbF) 131, part 2, No. 5.7, in DIN EN ISO , DIN EN 14420, parts 1 to 6, and DIN 28450, DIN EN /-2, DIN 3771, parts 1 to 5, plus DIN ISO 1817 with respect to the nominal size combinations according to Annex 2 hereto, 2 DIN EN 12115: Rubber and thermoplastics hoses and hose assemblies for liquid or gaseous chemicals Specification; 3 TRbF 131-2: Technical Regulations for Combustible Liquids Hose lines 4 DIN EN : Hose fittings with clamp units - Part 1: Requirements, survey, designation and testing; DIN EN : Hose fittings with clamp units - Part 2: Hose side parts of hose tail; DIN EN : Hose fittings with clamp units - Part 3: Clamp units, bolted or pinned; DIN EN : Hose fittings with clamp units - Part 4: Flange connections; DIN EN : Hose fittings with clamp units - Part 5: Threaded connections; DIN EN : Hose fittings with clamp units - Part 6: TW tank truck couplings; 5 DIN EN : Industrial valves - Testing of metallic valves - Part 1: Pressure tests, test procedures and acceptance criteria - Mandatory requirements; DIN EN : Industrial valves - Testing of metallic valves - Part 2: Tests, test procedures and acceptance criteria - Supplementary requirements; 6 DIN : Fluid systems; O-rings; dimensions as in ISO 3601/1; DIN : Fluid systems, O-Rings; testing, marking; DIN : Fluid systems; O-rings; materials, field of application; DIN : Fluid systems; O-rings; quality acceptance criteria; DIN : Fluid systems; O-rings; methods for calculation and dimensions of housings; 7 DIN ISO 1817: Rubber, vulcanized - Determination of the effect of liquids (ISO 1817:2005) 8 DIN EN ISO 8031: Rubber and plastics hoses and hose assemblies - Determination of electrical resistance and conductivity (ISO 8031:2009);
5 General Technical Approval Page 5 of 8 27 July Manufacture and marking Manufacture of the approved product Marking The manufacture of the approved product must take place in the plants and/or factories, the names of which have been made known to and deposited with the German Institute for Construction Engineering (Deutsches Institut für Bautechnik, DIBt). The applicant must provide the flexible double-walled (jacketed) pipes with the conformity mark (Ü-mark) as required by the ordinances on conformity marks enacted by the different Federal States and must affix said mark(s) to the fittings existing at the end of the hose (flexible pipe). The application of any such marks is admitted only if the requirements specified in below section 2.4 have been met. The flexible double-walled pipes need, apart from the marking required by DIN EN 12115, to be provided with the following indications in addition: - The type designation - The name of the manufacturer 2.4 Proof of conformity General The applicant must furnish proof that the approved product complies with the provisions set out in this General Technical Approval with regard to applicant's factory by providing a corresponding declaration of conformance, which must base on the factory's production control and an initial type test performed by a recognised inspection agency authorised to perform such tests Factory production control (1) The applicant, in his capacity as its manufacturer, must establish and carry out a factory production control system in his own works and must, beyond that, furnish proof that the assembled components, elements and parts of the flexible double-walled pipe comply with the construction documents that have been deposited with the German Institute for Constructional Engineering (DIBt). Factory production control in the above sense means permanent supervision and control of all steps needed for the production of the approved product. The purpose of the factory production control by routine item testing is to ensure that the flexible double-walled pipes comply with the specifications defined in this General Technical Approval. (2) The factory production control of the approved product is to be carried out in the applicant's manufacturing works by submitting all components and/or individual parts to an incoming control on the basis of acceptance test certificates as required in section 3.1 of DIN EN , which need to be prepared based on the following tests and controls: a) The inner and outer hoses of the flexible double-walled pipe are to be subjected to the tests and controls required by DIN EN 12115, DIN EN ISO 8031 and EN ISO If using flexible double-walled pipes for the conveyance of types of liquids, the flash point of which is below 55 C, proof with regard to the electrical characteristics of these liquids is to be furnished as required by DIN EN b) The intermediate layer is to be submitted to the AD test (dimension test) and the AR test (examination of the material certificates) as provided by DIN c) Verification if the sealants tested in compliance with DIN and DIN ISO 1817 are suited for use within the scope of application indicated on the delivery note. 9 DIN EN 10204: Metallic products - Types of inspection documents. 10 DIN : Technical delivery conditions for valves - Compilation of test methods.
6 General Technical Approval Page 6 of 8 27 July 2009 (3) The flexible double-walled pipes must, in addition to the controls and tests provided in Table 6 in the standards DIN EN and EN ISO , be subjected to at least the following tests and controls specified in DIN : - AD test (dimension test) and AR test (examination of the material certificates); - BN test, including proof of compliance with the admissible leak rate 1 (test of the hose connection with water for leakproofness at the maximum allowable operating pressure (10bar)); - BQ test (test of the hose connection with water for leakproofness at the 1.5-fold maximum allowable operating pressure). In addition to the incoming controls, the connection fittings, including nipples and associated sealants, are, in the applicant's factory, to be subjected to the following tests and controls required by DIN ; - AD test (dimension test) and AR test (examination of the material certificates); Prior to using it for the first time, the flexible double-walled hose pipe assembly needs to be subjected to a leak test as provided by DIN EN The medium to be used for testing is gas. The test is to be realised by maintaining, at normal ambient temperature, test pressures of (6 ± 1) bar in the inner hose and of (6 ± 1) bar in the monitored space for at least 60 seconds. No bubbles must rise to the surface of the water if plunging the hose assembly into the water or, if coated with a special leak detection liquid, no continuous formation of bubbles must occur. (4) The results of the factory production control need to be recorded and analysed. The recordings must, at least, contain the following details: - Designation of the approved product; - Type of test or control; - Date of manufacture and testing of the approved product; - Results of the controls and/or tests; - Signature of the person responsible for the factory production control. The applicant must keep all recordings on file for at least five years. If requested to do so, they need to be submitted to the German Institute for Construction Engineering (DIBt) and/or the responsible supreme building control authority. Once the test results are insufficient, the applicant must immediately take all measures required in order to eliminate the related fault and/or insufficiency. Inner and outer hoses, intermediate layers, connection fittings, nipples, sleeves and associated sealants that fail to meet the requirements, are to be handled in such a manner that they cannot be confused with conforming components of the same kind. After elimination of the fault and/or insufficiency, the corresponding test or control must, as far as technically feasible and required as evidence that the fault and/or insufficiency has been eliminated, be repeated immediately Initial type test of the approved product by a recognised inspection agency Within the limits of the initial type test, the requirements specified in DIN EN 12115, DIN EN and in the "Approval Principles for Leak Detectors suited for use with Double-walled Pipelines" issued by the German Institute for Construction Engineering (DIBt) of August 1994, the Technical Regulations for Combustible Liquids (TRbF 131-2), in DIN EN /2, DIN and DIN ISO 1817 have to be met. Once the results of the tests performed on samples from the current production underlying the General Technical Approval have been furnished, these will replace those obtained in the course of the initial type-testing procedure. EN ISO 1402: Rubber and plastics hoses and hose assemblies - Hydrostatic testing
7 General Technical Approval Page 7 of 8 27 July Design-related provisions (1) The utilisation of the flexible double-walled pipe and the associated intermediate layer is limited to the types of water-hazardous liquids of the suitability category A listed in the chemical resistance chart specified on the supplementary sheet 1 to DIN EN as suitable for use with the corresponding material. The approved product may also be used for the conveyance of other types of waterhazardous liquids if proof has been furnished that, if handled at the provided temperatures, these liquids meet the requirements specified in the Technical Regulations for Combustible Liquids (TRbF) 131, part 2, No (2) To ensure the flexible double-walled pipe is monitored as required, the vacuum leak detector admitted for use with the related type of liquid specified in the Technical Description 13 is to be connected. Regarding the connection and operation of the vacuum leak detector, the instructions contained in the Technical Descriptions need to be followed and adhered to. (3) When using the product in exceptional cases for suction operations as admitted in below section 4, par. (7), the vacuum leak detector must be temporarily put out of operation. 4 Utilisation-related provisions (1) The approved product is to be used in compliance with the specifications set out in the "Technical Description". Only specialised companies within the meaning of 19, par. I, of the German Water Management Act (WHG) may be charged with the installation, maintenance and repair and/or cleaning of the approved product. They need to possess the knowledge required for the installation of leak detectors in compliance with the TRbF 503 (directive concerning the supervision of the installation of leak detectors, version dated May 1987) and must have been trained by the applicant. This training is to be repeated annually. Each time after an inspection of the leak detector, the expert charged with doing this work must issue a corresponding installation and test certificate. (2) No specialised companies need to be charged with the execution of the works and activities specified in above sub-section (1), if they, as an exception under German Federal State Law, are exempted from the obligation to register as certified specialists or if the manufacturer of the approved product carries out these works and/or activities using his own qualified staff. In such a case, the application of the occupational safety and health requirements remains unaffected. (3) Leak detection systems working on the vacuum principle only may be connected to the flexible jacketed pipe. In the case of a leakage, the leak detector must be able to withstand overpressures of up to 10bar or must trigger automatic (self-acting) shut-off valves (magnetic valves, f. ex.) to prevent its components from being exposed to inadmissible pressure levels. (4) The vacuum leak detector must comply with the applicable legal provisions and its suitability for use with the flexible double-walled pipe within the scope of application it has been designed for must have been proven. At the latest when reaching a negative pressure of -325mbar, the vacuum leak detector must trigger an alarm. Once such an alarm is triggerd, the leak detector must deactivate the vacuum pump to discontinue the vacuuming procedure. (5) The liquids provided for being transferred must not have a tendency to thicken or to separate solid materials and their kinematic viscosity should not exceed 5000cSt at +4 C. Supplementary sheet 1 to 12 DIN EN 12115: Rubber and thermoplastics hoses and hose assemblies for liquid or gaseous chemicals - Specification; 13 Technical Description of the double-walled hose line manufactured by the applicant as examined by TÜV-Nord Systems GmbH & Co. KG on June 19, 2009.
8 General Technical Approval Page 8 of 8 27 July 2009 (6) The flexible double-walled pipe must, at one of its ends, be provided with a nozzle for the connection of the leak detector. The other end of the flexible double-walled pipe needs to be provided with a control-screw that allows to check if the leak detection medium can pass freely. (7) Only in exceptional cases may the flexible double-walled pipe be used for suction operations. This is admissible if, as specified in DIN EN 12115, the possible negative suction pressure with respect to the actually applied hose, suffices to ensure the vacuum stability in an acceptable manner. (8) The bolts used for the fixing of the flexible double-walled pipe, including connection fittings and nipples need to be protected against accidental loosening. (9) If using the approved product for the conveyance of types of liquids, the flash point of which is below 55 C, or if using it in explosion hazardous areas, the requirements for its electrical conductivity characteristics specified in DIN EN 12115, including the guidelines issued by the employers' liability insurance association for preventing ignition hazards resulting from electrostatic charge, need to followed an complied with. The manufacturer is obliged to provide corresponding evidence. If using the metal insert of the pipe for connecting it with the hose fitting, proof is to be furnished that, while integrating the pipe into an overall system, the electrical contact between the metal inserts and the hose or pipe fitting(s) is absolutely perfect and works faultless. (10) Regarding each flexible double-walled pipe, a corresponding installation and test certificate is to be produced. 5 Provisions regarding use, maintenance and care, including recurring checks and inspections (1) The applicant must include the Technical Description in his delivery. (2) The usability of the approved product is to be reconsidered and checked recurrently at reasonable intervals, but at least once every year. During the first start-up / commissioning of the flexible doublewalled pipe system and also the recurring functional checks, the unobstructedness and free passability of the monitored space between the inner and outer hose is to be checked by opening the controlscrew provided for this purpose and checking the pressure change occurring within the monitored space. It is the responsibility of the operator to decide in what manner and at what intervals the checks are to be made within the above-specified timeframe. (3) The admissible leak detectors connected to the monitored space between the inner and outer hose need to be checked in compliance with the Technical Description established for the corresponding device type. (4) All checks, inspections or tests prescribed under different laws shall remain unaffected. Eggert Certified
9 Pages 9 to 12 (non editable technical drawings) As for the translation of the texts on these drawings, please refer to the separately attached MS Word document or corresponding printout.
10 Annex 2 to the General Technical Approval No. dated 27 July 2009 Technical characteristics and materials used with combined nominal hose sizes Type name designating the combined nominal hose sizes Sizes of inner hoses Sizes of outer hoses Monitored space, volume in litres / m Design of connection and drawing No. Metals used with the fittings DWSL 1 DN 15 DN With union joint Screw connections made of brass (Ms58) or stainless steel (1/2") (1 ¼") Piece list dated 29/10/2008 Pinned clamp fitting made of aluminium Drwg No /1_0 Stainless steel socket (connecting piece on the hose side) DWSL 2 DN 20 DN With union joint Screw connections made of brass (Ms58) or stainless steel (3/4") (1 ½") Piece list dated 29/10/2008 Pinned clamp fitting made of aluminium Drwg No /1_0 Stainless steel socket (connecting piece on the hose side) DWSL 3 DN 20 DN With union joint Screw connections made of brass (Ms58) or stainless steel (3/4") (1 ½") Piece list dated 29/10/2008 Screwed clamp fitting made of aluminium Drwg No /1_0 Stainless steel socket (connecting piece on the hose side) DWSL 4 DN 40 DN With union joint Screw connections made of brass (Ms58) or stainless steel (1 ½") (2 1/2") Piece list dated 29/10/2008 Screwed clamp fitting made of aluminium Drwg No /1_0 Stainless steel socket (connecting piece on the hose side) DWSL 5 DN 40 ON With union joint Screw connections made of brass (Ms58) or stainless steel (1 ½") (2 1/2") Piece list date 29/10/2008 Screwed clamp fitting, pinned, made of aluminium Drwg No /1_0 Stainless steel socket (connecting piece on the hose side) DWSL 6 DN 65 DN With union joint Screw connections made of brass (Ms58) or stainless steel (2 ½") ") (4") Piece list dated 29/10/2008 Screwed clamp fitting made of aluminium Drwg No /1_0 Stainless steel socket (connecting piece on the hose side) DWSL 7 DN 50 DN With tanker coupling Made of brass (Ms58) or stainless steel DWSL 8 (2") (3") Piece list dated 18/03/2009 Screwed clamp fitting, pinned, made of stainless steel or aluminium Drwg No. 7-8NM_0 Stainless steel socket (connecting piece on the hose side) 7-8/3_0 7-8/2_0 With flange connection Piece list dated 28/10/2008 Drwg No. 7-8/F_0 7-8/1_0 7-8/2_0 DWSL 9 DN 75 DN With tanker coupling Made of brass (Ms58) or stainless steel plus DWSL 10 (3") (4") Piece list dated 28/10/2008 Drwg No. 9-10/VM_0 Pinned clamp fitting made of stainless steel or aluminium Stainless steel socket (connecting piece on the hose side) 9-10/3_0 9-10/2_0 With screwed flange connection Piece list dated 28/10/2008 Drwg No. 9-10/F_0 7-8/1_5 7-8/2_0
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