Design of Safety Valves

Design standard: DIN EN ISO 4126-1

Design of safety valves – DIN EN ISO 4126-1 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01
Objective
Objective Objective of the presentation
Design of Safety Valves – DIN EN ISO 4126-1
Codes and standards

Design
The objective of the presentation is to show the
design of safety valves in compliance with ISO 4126-1.
inlet pressure loss

Back pressure
 Standard specifications for the design of safety valves
 Formulas for the design of safety valves
 Factors Influencing the stability
in operation

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 2 / 19

Objective National and international standards
for the calculation specifications of safety valves
Codes andstandards
Codes and standards

Design
Calculation levels of safety valves

inlet pressure loss

AD 2000 -
Back pressure ISO 4126-1 API 520 ASME VIII
Merkblatt A2

Calculation levels of inlet pressure loss and back pressure

AD 2000 -
ISO 4126-9
Merkblatt A2
Chapter 7 + 9
Chapter 6

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 3 / 19

Objective What impact does this have on the user?
Codes andstandards
Codes and standards

Design  ISO 4126-1 must be applied in the European region

for size determination of safety valves
inlet pressure loss Size
determination  TRBS is not yet available for specification of the safety
Back pressure valve

 There is no effect on the capacity and function up to a

pressure loss of 3%
inlet  Pressure losses >3% must be taken into account in the
pressure loss capacity calculation. The operation may be affected.

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 4 / 19

Objective What impact does this have on the user?
Codes andstandards
Codes and standards

Design  Effect on the capacity taking the pao/po curve into

consideration
inlet pressure loss
Back pressure  This ratio is observed for absolute pressures.
Back pressure

 Capacity minimisation must also be

taken into consideration for low set
pressures.
rated coefficient of discharge Kdr /αw

 p = 03 bar g (set pressure)

 pao = 1.013 bar a (ambient pressure)

Correction factor for back pressure Kb

 po = (0.3 barg + 0.1 barg + 1.013 bar
a) (pressure in the system to be
secured)
 pao / p0 = 1.013 bar a / (0.3 barg +0.1
bar g + 1.013 bar a) = 0.72
 >> Kb = 0.81

Ratio back pressure / set pressure pao/ po

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 5 / 19

Objective What parameters are important for the
Codes and standards
design, and how are they related?
Design
Design High Performance
inlet pressure loss
 Coefficient of discharge αw:
(kdr acc. to ISO 4126-1)
Back pressure the rated coefficient of discharge from
component testing (often also referred
to as αd)
 Orifice area A0:
actual orifice area
 Substance information
medium-dependent substance data
 Operating data:
state parameters like pressure and
temperature

d0

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 6 / 19

Objective Coefficient of discharge and rated
Codes and standards coefficient of discharge
Design
Design
German Code American Code
inlet pressure loss

Back pressure
VdTÜV Merkblatt ASME-Code Sec.VIII,
SV 100, § 3.3.1 Div. 1, UG-131 (e)

Coefficient of qmeasured qmeasured

discharge = Kd =
qtheoretical qtheoretical

Rated coefficient w = 0.9 x  K = 0.9 x Kd

of discharge

qmeasured = actual measured qm

qtheoretical = calculated qm

 or Kd = coefficient of discharge
d or K = rated coefficient of discharge
0.9 = correction factor

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 7 / 19

Objective Differentiation of media
Codes and standards

Design
Design Subcritical
Steams/
inlet pressure loss gasses
Supercritical
Back pressure

Low viscosity
Liquids
High viscosity
Medium
Saturated steam
Steam
Superheated steam

Two- Liquid phase

phase
flow Gaseous Phase

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 8 / 19

Objective Required data on materials
Codes and standards

Design
Design Gasses/ Saturated Superheated
Liquids
steams steam steam
inlet pressure loss
Set pressure pset psig x x x x

Back pressure Back pressure pa psig x x x

x

Temperature T [°C] x x

Mass flow* qm [kg/h] x x x x

Volumetric flow rate* qv [m³/h] x x x x

(while operating)
Volumetric flow rate* qv [Nm³/h] x

Overpressure c [%] x x x x

Real gas factor Z [-] x

Molar mass M [kg/kmol] x

Isentropic exponent k [-] x

Density  [kg/m³] x

Kinematic viscosity  [m2/s] x

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 9 / 19

Objective Design for gasses/steam
Codes and standards
as per DIN EN ISO 4126-1
Design
Design

Qm Z•T
•
inlet pressure loss
ISO 4126-1 A=
C • Kdr • p0 M
Back pressure

ISO 4126-1

 Actual orifice area A [mm²]

 Mass flow Qm [kg/h]
 Functional isentropic exponent C [-]
 Rated coefficient of discharge Kdr
 Set pressure p0 [bar abs]
 Temperature T [K]
 Molar mass M [kg/kmol]
 Real gas factor Z [-]

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 10 / 19

Objective Design for saturated steam
Codes and standards
as per DIN EN ISO 4126-1
Design
Design

Qm v
•
inlet pressure loss
ISO 4126-1 A=
C • Kdr • 0.2883 p0
Back pressure

ISO 4126-1

 Actual orifice area A [mm²]

 Set pressure p0 [bar abs]
 Functional isentropic exponent C
 Mass flow Qm [kg/h]
 Specific volume v [m3/kg]
 Rated coefficient of discharge Kdr [m3/kg]

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 11 / 19

Objective Design for liquids
Codes and standards
as per DIN EN ISO 4126-1
Design
Design

v Qm
•
inlet pressure loss
ISO 4126-1 A=
Back pressure
p0 - pb 1.61 • Kdr • Kv

ISO 4126-1

 Actual orifice area A [mm²]

 Set pressure po [bar abs]
 Back pressure pb [barü]
 Mass flow Qm [kg/h]
 Specific volume v [m3/kg]
 Rated coefficient of discharge Kdr
 Viscosity correction factor Kv

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 12 / 19

Objective Inlet pressure loss
Influencing Factors
Codes and standards

Design
p2 = p1 p2 = p1 - p
inlet pressureloss
inlet pressure loss p = 0 p > 0

Back pressure
Valve is Valve is
closed open

p2 p2

p p

p1 p1

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 13 / 19

Objective Inlet pressure loss
Standards and Codes
Codes and standards

Design
 A maximum pressure loss of 3% from the vessel to the safety valve
is permissible for the most common international standards and
inlet pressureloss
inlet pressure loss
codes.
Back pressure

 ISO 4126-9 Chapter 6.2

Unless otherwise specified by national codes or regulations, the inlet
line shall be so designed that the total pressure drop to the valve inlet
does not exceed 3 % of the set pressure of the safety device,…

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 14 / 19

Objective Calculation
Codes and standards

Design p = (  l/d +  )  /2  w2

inlet pressureloss
inlet pressure loss
Flow Flow
Back pressure
resistance rate

 = Pipe friction coefficient (pipeline)

l/d = Length and diameter of a pipe
 = Friction coefficient (components)
 = Density
w = Speed

I d
p

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 15 / 19

Objective Inlet pressure loss
Codes and standards

Design
The following measures prevent malfunctions that are caused by an
inadmissible inlet pressure loss:
inlet pressureloss
inlet pressure loss

Back pressure  Reduction of the flow rate through

– increasing the pipe diameter
– reducing the mass flow through a smaller valve
– reducing the mass flow through a lift stopper
– reducing the mass flow through an O-ring-damper

 Reduction of the flow rate

through
– shorter inlet pipeline Incorrect Correct
– low-resistance connection
to the vessel

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 16 / 19

Objective Inlet pressure loss
Codes and standards

Design
Reduction of the flow rate is more effective
than reduction of the flow resistance
inlet pressureloss
inlet pressure loss

Back pressure
Reduction (%) Reduction of the pressure loss
110

100
90 p = (  l/d +  )  /2  w2
80

70
Reduction of flow resistance
60
50
40

30
20
Reduction of the flow rate (w)
10

0
10,0 20,0 30,0 40,0 50,0 60,0 70,0 80,0 90,0 100,0
Reduction of the pressure loss (%)

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 17 / 19

Objective Back pressure
Definition
Codes and standards

Design
Back pressure
inlet pressure loss

Back pressure
Back pressure
Built-up External back
back pressure pressure

Constant Variable Back pressure

Exists
Exists only in the permanently in the
outlet while the outlet system The
safety valve external back
blows off. It is pressure is
dependent on the dependent on the
flow loss in the blow-off of the
discharge line. safety valve Back pressure = built-up back pressure
+ external pressure

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 18 / 19

Objective Back pressure – stability
Setting
Codes and standards

Design
The following measures prevent malfunctions
resulting from the back pressure:
inlet pressure loss
 Constant back pressure
Back pressure
Back pressure
– settings to differential set pressure (CDTP)
– use of stainless steel bellows
 Variable back pressure
– use of stainless steel bellows

Design of safety valves | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 19 / 19