Design of Safety Valves

Design standard: DIN EN ISO 4126-1

Objective of the presentation. Design of Safety Valves – DIN EN ISO 4126-1.
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

The objective of the presentation is to show the

design of safety valves in compliance with ISO
4126-1.

 Standard specifications for the design of

safety valves
 Formulas for the design of safety valves
 Factors Influencing the stability
in operation

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National and international standards. For calculation of safety valves.
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

Calculation levels of safety valves

AD 2000 -
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

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What impact does this have on the user?
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

 ISO 4126-1 must be applied in the European region for size determination of
Size safety valves
determination  TRBS is not yet available for specification of the safety 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 capacity calculation.
pressure loss The operation may be affected.

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What impact does this have on the user?
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

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

Back pressure
 This ratio is observed for absolute pressures.

 Capacity minimisation must also be taken into consideration for

low set pressures.
 p = 03 bar g (set pressure)
 pao = 1.013 bar a (ambient pressure)
 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

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What parameters are important for the design, and how are they related?
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

High Performance  Coefficient of discharge αw:

(kdr acc. to ISO 4126-1)
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

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Coefficient of discharge and rated coefficient of discharge.
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

German Code American Code

VdTÜV Merkblatt ASME-Code Sec.VIII,

Coefficient of SV 100, § 3.3.1 Div. 1, UG-131 (e)
discharge qmeasured qmeasured
= Kd =
qtheoretical qtheoretical
Rated coefficient
of discharge
w = 0.9 x  K = 0.9 x Kd

 qmeasured = actual measured qm

 qtheoretical = calculated qm
 or Kd = coefficient of discharge
 d or K = rated coefficient of discharge
 0.9 = correction factor

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Differentiation of media.
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

Subcritical
Steams/
gasses
Supercritical

Low viscosity
Liquids
Medium High viscosity

Saturated steam
Steam
Superheated steam
Two-
phase Liquid phase
flow Gaseous Phase

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Required data on materials.
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

Gasses / steams Liquids Saturated steam Superheated team

Set pressure pset psig x x x x
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

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Design for gasses / steam as per DIN EN ISO 4126-1.
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

Qm Z•T
ISO 4126-1 A= •
C • Kdr • p0 M

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 [-]

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Design for saturated steam as per DIN EN ISO 4126-1.
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

Qm v
ISO 4126-1 A= •
C • Kdr • 0.2883 p0

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]

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Design for saturated steam as per DIN EN ISO 4126-1.
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

v Qm
ISO 4126-1 A= •
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

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Inlet pressure loss. Influencing Factors.
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

p2 = p1 p2 = p1 - p
p = 0 p > 0
Valve is Valve is
closed open

p2 p2

p p

p1 p1

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Inlet pressure loss. Standards and Codes.
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

 A maximum pressure loss of 3% from the vessel to the safety valve is permissible for the most
common international standards and codes.

 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,…

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Calculation.
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

p = (  l/d +  )  /2  w2

Flow Flow
resistance rate

 = Pipe friction coefficient (pipeline)

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

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Inlet pressure loss.
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

The following measures prevent malfunctions

that are caused by an inadmissible inlet pressure
loss:

 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

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Inlet pressure loss.
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

 Reduction of the flow rate

through
 shorter inlet pipeline
 low-resistance connection
to the vessel

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Inlet pressure loss.
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

Reduction of the flow rate is more effective than reduction of the flow resistance

Reduction (%) Reduction of the pressure loss

110

100
90 p = (  l/d +  )  /2
80
 w2
70
60 Reduction of flow resistance
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 (%)

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Back pressure. Definition
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

Back pressure

Built-up External back

back pressure pressure
Back pressure

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

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Back pressure – stability. Setting.
1. Objectives | 2. Codes and standards | 3. Design | 4. Inlet pressure loss | 5. Back pressure

The following measures prevent malfunctions

resulting from the back pressure:
 Constant 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 | 01.06.2018 | Rev. 00 | 20/21
Design of Safety Valves
Thank you for your attention.