hitma_nov 18-11-2004 08:38 Pagina 1

SAFETY VALVES

Design requirements
for pressure safety
relief valves
In this paper, the authors review the standards applicable to
pressure safety relief valves, such as EN (PED), AD/TRD and
ASME. They also reveal some of the testing and evaluation work
that is required when designing a new pressure safety relief valve,
using a Bopp & Reuther valve as an example.
Fig.1: New type Si 43 EN-conformant pressure
By Dr. Ing. Bernhard Föllmer and Dr. Ing.Armin Schnettler, Bopp & Reuther, Mannheim safety relief valve (closed bonnet)

Introduction Codes: structure & comparison Application, selection and installation of

In Europe, only pressure safety relief
valves with settings above 0.5 barg which
conform with the Pressure Equipment Di-
rective (PED) 97/23 EC may be used.
They are classified PED Category IV.A
Notified Body validates the fulfilment of
the PED requirements in accordance with
a selected conformity evaluation proce-
dure also drawn from the PED.
The harmonized standards or other tech-
nical reference works are stated in a man-
ufacturer’s declaration of conformity,
which is supplied with the pressure safety
relief valve at delivery. Only this ultimate-
ly makes it possible to establish the basis
used for CE certification and the certified
properties which can be derived there-
from. It should be noted that the CE sym-
bol on the identification plate alone does
not supply sufficient information for this
purpose.
A comparative assessment of the harmo-
nized EN standards compared against the
AD and TRD technical rules in this article
discloses differences in the certified prop-
erties and the applications for spring-
loaded pressure safety relief valves.This is
explained in section 5 of the recently de-
veloped new Bopp & Reuther series of
pressure safety relief valves.The ASME
code is also included in the assessment,
since it plays a significant role at least out-
side Europe.
Harmonized European Standards
It is compulsory that the CEN – members
allocate and are obliged to give the new
European standard without any modifica-
tion the full same status as the national
standard.The national standardisation in-
stitute CEN – members are: Belgium,
Denmark, Germany, Finland, France,
Greece, Ireland, Island, Italy, Luxemburg,
Malta,The Netherlands, Norway,Austria,
Portugal, Sweden, Switzerland, Spain, the
Czech Republic and the United Kingdom.
For systems that require an over pressure
protection device the following classifica-
tion is valid:
a) Product standards. Contain definitions,
design requirements, production tests,
type tests, functional characteristics,
definition of size, identification.The
sections are:
- EN ISO 4126-1
Pressure safety relief valves
- EN ISO 4126-2
Bursting disc safety devices
- EN ISO 4126-3
Safety valves and bursting disc safety de-
vices in combination
- EN ISO 4126-4
Pilot operated safety valves
- EN ISO 4126-5
Controlled safety pressure relief sys-
tems (CSPRS)
- EN ISO 4126-6
bursting disc safety devices
- EN ISO 4126-7
Common Data
b) Application standards. Contain the se-
lection of the safety devices, mounting,
requirements pressure drop inlet pipe
and back pressure, recurrent test.The
sections are:
- DIN EN 12952 -10
Water-tube boilers, safety installations
against excessive pressure
- DIN EN 12953 - 8
Shell boilers, safety devices against ex-
cessive pressure
- DIN EN 764 - 7
Unfired pressure vessels
Section 7: Safety devices
Applicable Technical Rules for Germany
AD 2000 - A2 for pressure vessels and
TRD 421 for steam boilers deal with pres-
sure safety relief valves, assisted pressure
safety relief valves and safety shut-off
valves.They contain definitions, functional
characteristics, types, design require-
ments, determination of size, mounting,
requirements pressure loss inlet pipe and
back pressure, recurrent test, identifica-
tion.That means they cover a wide range.
Note:The AD 2000 – rule may be applied
for the implementation of the basic safety
requirements of the Pressure Equipment
Directive.

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hitma_nov 18-11-2004 08:38 Pagina 2
“VdTÜV Merkblatt Sicherheitsventil 100”
comprises requirements as to the execu-
tion of the type test approval for pressure
safety relief valves and assisted pressure
safety relief valves.
ASME - Code
In the ASME-Code, pressure safety relief
valves are classified into:
- ASME Sec.I
Steam generators (V- Stamp)
- ASME Sec.VIII
Pressure vessels (UV- Stamp)
- ASME Sec. III
Nuclear power stations (NV- Stamp)
Comparison of performance character-
istics for pressure safety relief valves
Functional characteristic
The functional characteristic of spring-
loaded pressure safety relief valves is the
result of the combination of flow force
and spring force. In relation with the set
overpressure where the pressure safety re-
lief valve start to open, the percental in-
crease in pressure (opening pressure dif-
ference = accumulation %) until reaching
the pre-determined lift, is defined as
opening. For closing the decrease in pres-
sure (closing pressure difference = blow
down %) is defined accordingly.
Looking at Tables 1 and 2, in all rules the
function values are fixed at a maximum,
with the exception of EN ISO 4126-1!
Here, those function values which are stat-
ed by the manufacturer are checked and
certified.There is only an upper limit de-
termined compared to which the manu-
facturer indication may be smaller.The
consequence is that the customer, normal-
ly the project engineer, must always speci-
fy the desired function values and insist on
the test reports from the manufacturer!
The following example shows how the
closing pressure difference for gas/steam
can be addressed. In accordance with AD-
A2 / TRD 421 it is fixed to 10%, and ac-
cording to EN ISO 4126-1 it may also be
max 15%. If the Pressure safety relief
valves originally had an approval according
to ASME VIII – and has an adjusting ring,
the manufacturer would also declare 7%
according to EN ISO 4126-1.That means
that it is possible with the certification ac-
cording to EN ISO 4126-1 that the closing
2 Valve World DECEMBER 2004
SAFETY VALVES
AD A2 / TRD 421 EN 4126-1 ASME VIII ASME I
Gas/vapour/steam Gas/vapour/steam Gas/vapour/steam Steam
Open max. 5% / 10% Manufacturer indication max. 10% or 0.2 bar 3%*
or 0.1 bar# max. 10% or 0.1 bar
Close Max. 10% or 0.3 bar Manufacturer indication max. 7%* or 0.2 bar max. 4%*
max. 15% or 0.3 bar or 0.28 bar
Table 1: Comparison: Required function values for pressure safety relief valves, gas and steam
AD A2 / TRD 421 EN 4126-1 ASME VIII ASME I
Liquids Liquids Liquids Liquids
Open max. 10%or 0.1 bar Manufacturer indication max. 10% or 0.2 bar N/A
max. 10% or 0.1 bar
Close max. 20% or 0.6 bar Manufacturer indication Not specified N/A
max. 20% or 0.6 bar
Table 2: Comparison: Required function values for pressure safety relief valves, liquids
Notes:
# Generally,the indication “max.10% or 0.1 bar“,means that the greater value is always applicable.
* obtained only with adjusting ring(s)
pressure difference with the different in AD-A2 and TRD 421 in the sizing equa-
manufacturers is 7%, 10% or under cer- tions.This proceeding is conservative and
tain conditions up to 15%.This results in was adopted by EN ISO 4126-1 or –7, re-
considerable differences relating to the spectively! However, a modification to the
operating pressure which has to be smaller application was carried out:As because of
than the closing pressure of the pressure some degrees of superheating above the
safety relief valve. It is necessary for the saturated steam condition, the isentropic
project engineer to specify the desired exponent increases from approximately
function values in the future and demand 1.1 to 1.3, there is also a sudden increase
them from the manufacturer! in the calculated mass flow within a range
smaller than 200 bar by approximately 5%
Flow capacity comparison until 10%! Of course, this cannot happen
The flow capacity of a pressure safety re- and therefore, in the EN ISO 4126-7
lief valve is determined by the product (Common Data) the steam from the satu-

w*A0. In this connection
w is the certi- rated line until 10°C superheating was
fied discharge coefficient (or flow coeffi- treated as dry saturated steam. For steam
cient) and A0 is the smallest cross-section with a superheating from 10°C until 30°C
area inside the inlet nozzle ahead of the superheating, the values v (spec. volume),
valve seat.The certified discharge coeffi-  (isentropic exponent) were linearized
cient (or flow coefficient) may also have and adapted!
the formula symbol Kdr (discharge coeffi- ASME sizing differs for steam. Here, an
cient). It is always reduced by approxi- empiric equation, the so-called Napier-
mately 10%, either
w =
/1.1 is valid or formula, is applied which results for satu-
Kdr = Kd * 0.9. rated steam within a pressure range small-
However, there are differences in the de- er than 200 bar a mass flow approximately
termination of the discharge coefficients. 3% greater and for a pressure range ex-
Generally, the conditional equations ac- ceeding 210 bar a mass flow which is up to
cording to AD-A2 / TRD 421 and EN ISO 5% smaller. For superheated steam there
4126-1 correspond to each other, even if is then a correction factor KSH indicated in
the forms look different. table form in the “API Recommended
For saturated steam the sizing coefficient x Practice 520“, the accuracy of which may
(“Druckmittelbeiwert”) is formed with be checked in comparison!
the isentropic exponents of the “wet side“
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hitma_nov 18-11-2004 08:38 Pagina 3
Determining discharge coefficients
according to ASME
The discharge coefficients of a maximum
of 3 x 3 test valves must be within ± 5%
of their average value at 10% above the set
pressure.Then, the average value, multi-
plied by 0.9, will be declared as the certi-
fied discharge coefficient. By this, the dis-
charge coefficient is independent of the
pressure ratio for gas/vapour/steam and
it is accepted that the safety margin of the
discharge capacity is between 5% and
15%! Note:The dependence of the dis-
charge coefficient on the lift is not deter-
mined so that the possibility of a lift re-
striction in case of over dimensioning is
not included.
The test condition is with low pressure
loss in the inlet (well rounded connection)
and relief into the atmosphere without
back pressure.A detailed report concern-
ing the requirements, development and
approval of a new pressure safety relief
valve series according to ASME VIII and at
the same time TÜV – type approval in
1995 is contained in [1].
Determining discharge coefficients ac-
cording toVdTÜV 100 for AD and TRD
Instead of 3 x 3 individual tests according
to ASME the function values are deter-
mined by means of function records ac-
cording to VdTÜV 100 for AD and TRD
not only for fixed spring adjustments but
also over the adjusting range of the indi-
vidual spring. In this connection the ob-
tained lift is demonstrated.These meas-
urements are carried out with
representative valve sizes and pressures.
Then, the discharge coefficient of repre-
sentative valve sizes is measured versus the
lift and for gas / vapour / steam also ver-
sus the pressure ratio pa/p.The certified

w-curves are defined from the measured

-curves by division by 1.1.Thus, a capac-
ity reserve of at least 10% in contrast to
ASME is always assured and by determina-
tion of the discharge coefficient versus the
lift, precise capacity limitations by lift re-
strictions can be applied if necessary.
The test conditions may be well rounded
inlet (with low pressure loss) or max.
sharp-edged inlet. In the last time the in-
fluence of the built-up back pressure is
also measured.
SAFETY VALVES
The test conditions are recorded in the
test report and conclusions for the appli-
cation are specified.The essential results
of the type approval are published in a
VdTÜV-Merkblatt under the so-called
BKZ-number (type approval number) and
are freely accessible.
Determining discharge coefficients
according to EN ISO 4126-1
In principle the procedure according to
VdTÜV 100 or ASME is possible, but it
must be identified or asked for, respective-
ly. However, there is no publication in-
tended as for the TÜV type approval for
instance in a VdTÜV – Merkblatt.
Sizing and spring setting according to
DIN EN 764-7
The discharge pressure for the sizing, i. e.
the calculation of the smallest flow area of
a Pressure safety relief valve, is generally
1.1 times the maximum allowable operat-
ing pressure.This is also valid if the valve
reaches the required lift at a smaller over-
pressure than 10% above set pressure.
Even if the set pressure is smaller than the
maximum allowable operating pressure,
the discharge pressure for the sizing would
be 1.1 times the maximum allowable op-
erating pressure.
Furthermore, it is possible in accordance
with DIN EN 764-7 that in cases of over-
pressure smaller than/equal to 5% the set
pressure of the pressure safety relief valve
may be setted to up to 105% of the maxi-
mum allowable operating pressure if at
least one pressure safety relief valve out of
several is adjusted and set to the maxi-
mum allowable operating pressure.Anoth-
er option is that the set pressure of even
one pressure safety relief valve may be
higher than the maximum allowable oper-
ating pressure if an additional “pressure
limiting device” is provided.
Controlled safety pressure relief
systems (CSPRS)
Commonly known as “Gesteuerte Sicher-
heitsventile” (assisted safety valves).These
safety valve systems have only been ap-
proved in accordance with the Technical
Rules AD-A2 or TRD 421 or by special
authorization (Stoomwezen).With the
Pressure Equipment Directive and the
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harmonized European Standards, CSPRSs
are authorized in the CEN – member
countries.The “Assisted pressure safety re-
lief valves“ are dealt with in the product
standard EN ISO 4126-5 and have the des-
ignation in the English version “Controlled
safety pressure relief system“ (CSPRS).
For an extensive treatment of the assisted
pressure safety relief valves and a compar-
ison with pilot operated pressure safety
relief valves according to EN ISO 4126-4
we refer to the publication[2]. It was pub-
lished in 1995 and at that time the product
standards were called EN 1268-1 until –7
although they are now EN ISO 4126-1
until –7, all other parts from the profes-
sional statements of the publication [2] are
entirely valid.
”New” designed pressure safety relief
valve Type Si 41/43/44 according to
EN Standard
As early as 1995 Bopp & Reuther demon-
strated how a pressure safety relief valve
(Series Si 81/83/84 according to design
API 526) could be generated (without the
use of the rings) using a systematic devel-
opment method [1].Approval was simul-
taneously obtained according to ASME
VIII by N.B. (national board) and accord-
ing to TRD and AD by TÜV.
In accordance with the same criteria, the
development of a new pressure safety re-
lief valve type Si 41/43/44 (Figure 1) was
launched and approved in 2002 according
to (i) PED category IV by conformity
evaluation procedure module B, i.e. EG
design test, in combination with module
D, i.e. quality assurance production and
(ii) by TÜV - type test with type test ap-
proval number SV.02-1094 according to
VdTÜV-Merkblatt Pressure safety relief
valve 100/1 (10.2002) with requirements
according to prEN ISO 4126-1 (12.2002)
and AD 2000 – A2 ,TRD 421.
In accordance with the statements of the
previous chapters a number of character-
istics were stated and specified:
* Conservatively, the lowest discharge co-
efficient curve
w(h/do) of several rep-
resentative valve sizes was reduced by
division by 1.1.Thus, a capacity reserve
of 10% is always safeguarded and if nec-
essary, capacity limitations may be ap-
plied by lift restrictions (Figure 2).
DECEMBER 2004 Valve World 3
hitma_nov 18-11-2004 08:38 Pagina 4
* Opening pressure differences 5% and
closing pressure difference 7% for
gas/vapour/steam (follows from the
manufacturer’s indication with EN ISO
4126-1 documented according to
VdTÜV-Merkblatt SV 100).
This generates advantages for the effi-
ciency of the process conditions
The opening pressure difference 5%
permits, according to DIN EN 764-7,
that one or more pressure safety relief
valves may be adjusted to until 105% of
the maximum allowable operation pres-
sure if at least one out of several pres-
Steam / gas:
w D/G = 0.81* /0.78**
* with low pressure loss inlet (well rounded)
** with pressure loss at sharp edged inlet
Liquids:
w F = 0.57
Dotted line: with sharp edged inlet (
w = 0.78 for D/G):
If the inlet line fulfils the requirement L/D < 5 or L
< 200 mm (holds for the larger value) then no design
report for pressure loss less than 3% required.
For longer inlet line a design report for pressure loss
is required not taking into account the pressure loss
of the sharp edged inlet.
L = Length of the inlet line, mm
D = Diameter of the inlet line, mm
h = lift, mm
do = flow diameter, mm
pa = back pressure, bara
p = system pressure, bara
Fig.2: Discharge coefficient
w
4 Valve World DECEMBER 2004
SAFETY VALVES
sure safety relief valves is set to the max-
imum allowable operation pressure. De-
viating from this, the adjusting pressure
of a pressure safety relief valve may be
higher than the maximum allowable op-
eration pressure, if an additional “pres-
sure limiting device” is installed.
* The closing pressure difference of 7%
permits a higher operating pressure than
with greater closing pressure differences
as the service pressure must always be
considerably lower than the closing pres-
sure of the pressure safety relief valve.
* The new Bopp & Reuther pressure safe-
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Pg Exhaust pipe
Nozzle set up for testing with
different back pressure Pg
Sharp-edged inlet
Fig.3: Test condition with slip-through sharp-
edged inlet L= 5 * D and nozzle set up for
testing with different built up back pressure in
the exhaust pipe; certification of performance
at back pressure Pg = 20% of the set pressure
ty relief valve was checked according to
“VdTÜV Merkblatt SV 100“ with well
rounded inlet (low pressure loss inlet).
Under these conditions the
w–value is
0.81 for gas/vapour/steam.
* The pressure safety relief valve was also
stringently tested according to VdTÜV
Merkblatt SV 100 with sharp-edged
inlet. Under these conditions the

w–value is 0.78 for gas/vapour/steam
(Figure 3).Than the verification of the
pressure loss less than 3% by the project
engineer is not necessary if the sharp-
edged inlet pipe has a length of L/D < 5
or L < 200 mm in accordance with the
test condition in Figure 3. Otherwise in
the required pressure loss verification
the resistance coefficient of the sharp-
edged inlet (usually  = 0.5) need not
be taken into consideration.
Back pressure conditions
In order to justify that the pressure safety
relief valve, under back pressure condi-
tions, functions and provides the required
lift, these were measured at a built-up
back pressure of 20% of the set pressure
for gas/vapour/steam.The test condition
in Figure 3 shows how the back pressure
in the discharge pipe of the pressure safety
relief valve was obtained by throttling by a
nozzle at the end of the pipe. In Figure 4 a
functional test with air is shown where the
back pressure was not additionally in-
creased by the throttle.As a consequence
of the large discharge capacity of the type
Si 41/43/44 a built-up back pressure of
15% without throttling is already generat-
hitma_nov 18-11-2004 08:38 Pagina 5

SAFETY VALVES

ed.The lift-pressure-diagram shows sud-
den opening at an increase in pressure of
only 2% and a stable lift stop with great
force reserve until closing at approximate-
ly 10% blow down. Figure 5 shows the
functional test where the only modifica-
tion is the throttle at the end of the pipe,
with which a built-up back pressure was
accumulated until 29.6%.The result is a
still stable functional behaviour with full
lift, i. e. without capacity reduction. In
this connection, the closing pressure dif-
ference has decreased until approximately
3% and furnishes information with regard
to the quality of the flow force curves and
an optimal balancing with the spring
which is a result of the development
method with the force-characteristic-
measurement [1].
Finally, the nameplate was produced ac-
cording to PED, i.e. CE marked and addi-
tionally indication of the type approval
symbol “TÜV.SV.02-
1094.do.D/G(F).
w.p”.Thus, the access
to the published VdTÜV – Merkblatt is
also possible.
Final observation
Anyone who acts as a manufacturer in the
industrial power and process markets in
Germany as well as the rest of Europe, as
well as in the field of pressure safety relief
valves outside of Europe, has to fulfil dif-
ferent requirements. However, the project
engineer, too, has to specify with better
care and more precision what is required
and has to consider these aspects accord-
ingly during the plant-planning.
The new pressure safety relief valve type
Si 41/43/44 presented here combines ad-
vantages for the user which are “New” in
this combination. Furthermore, require-
ments according to PED and AD-/TRD-
Code are fulfilled at the same time. ■

Lift versus time

Test – No FUL02384.BSN

Suggested reading
With exhaust pipe DN 40
[1] Föllmer, B., Schnettler, A.
Without nozzle set-up
Challenges in designing API safety relief
valves, Valve World, October 2003, p 39.
Pressure versus time Test specimen
[2] Bung, W., Föllmer, B.
Si 4302 A
Assisted safety valves in power stations
DN 25 x 40
according to the German Rules. VGB
do = 22mm
Kraftwerkstechnik 75, (1995), issue 9, p.
771 – 776.
Results
Lift and back pressure versus system pressure [3] Lester Millard.
Set pressure P 14.5 bar_g
Safety relief valves protecting life and
Opening pressure Pc 14.8 bar_g
property, Valve World, June 2002, p. 39.
Closing pressure Ps 13 bar_g
Accumulation dPc 2%
Blow down dPs 10.3%
Back pressure Pg 2.3 bar_g
Pg / P 15%
Fig. 4: Function test with air without nozzle set up for built up back pressure in the exhaust pipe
according to Fig. 3.
Lift versus time
Test – No FUL02381.BSN

With Exhaust pipe DN 40

With nozzle set-up
About the authors

Test specimen
Dr. Ing. Bernhard Follmer,
Pressure versus time
Si 4302 A
born 17.05.1950.
DN 25 x 40
Head of Design and
do = 22mm
Development of Bopp &
Reuther Sicherheits- und
Results
Regelarmaturen GmbH.
Lift and back pressure versus system pressure Set pressure P 14.5 bar_g
Opening pressure Pc 14.8 bar_g
Closing pressure Ps 14.1 bar_g
Dr. Ing. Armin Schnettler,
Accumulation dPc 2%
born 08.09.1950.
Blow down dPs 2.8%
Head of Development/
Back pressure Pg 4.3 bar_g
Test Laboratory of Bopp &
Pg / P 29.6%
Reuther Sicherheits- und
Regelarmaturen GmbH.

Fig. 5: Function test with air with nozzle set up for built up back
pressure in the exhaust pipe according to Figure 3.

www.valve-world.net DECEMBER 2004 Valve World 5