i 2 i g . 3 AD 2000-Merkblatt Ics 23.020.30 ‘September 2001 edition Safety devices against excess pressure ~ Safety valves — Equipment, installation and marking of pressure vessels AD 2000-Merkblatt A2 ‘The AD 2000-Morkblater are prepared by the coven aecociations ited balow who logether form the “Arbeitsgomeinschah ruckbebalter” (AD). Tre stucture end tre application of he AD 2000 body of reguiatons andthe procedural Guigelres are Covarac by AD 2000-MerKeat G 1. ‘The AD 2000-Aerkblatter contin safety roquiements (0 Oe Met under nermel operating Condltons. It ebove-normal edings aie to be ‘expected curing the operaton ofthe pressure vessel, this shall be taken into azcourt by masting spacial requrements ‘tere are any avergences rom the requlremens ofthis AD 2000-Merkblat, tsi be posse to prove thet the standard of salty of this body oF eguiaions has been mainiained by other means. e.g. by materiale fasting test, stress analysis, eparating experience Fachverband Campftesse!., Behiler- und Rotvivitungsbau #.V. (FDBR), Disseldort Hayptverband der gewerbicien Borufsgenossenscharten 8.V, Sankt Augustin Verband der Chemischen Industrie ® V.(VC1), FrarkturtiMain Verband Deutscher Maschinen: und Anlagenbau eV. (VDIMA), Fachgemenschat Vertarvenstechnische Maschinen Lund Apparate, Frankiunitdain Voroh Deutscher Eizonhuttanieute (VDE), Disseldon GB PowerTech ev, Essen Verband der Technisshan Oberwachurgs-Vereine «.¥. (VATOV, Eesen, The sbove associations continuously update the AD 2000-MeKolétr inline with technical progress. Pleése adress any proposals for nis to ne puoisrer: Verband der Technischen Overwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen, Contents © Foreword 8 Manufacture, testing and marking of 1 Scope valve bodies 2 General 8 Marking component-tested safety 3 Grading of setety valves valves 4 General requirements for safety valves 10 Oimensicning & Special requirements for controlled 11 Tests safety valves and necessary measures 12 Specal desigr's and applications 6 Installation, lines and cross-sections ‘19 Safty shutoff valves: 7 Materials 0 Foreword 1 Scope ‘The AD 2000 body of regulations can be applied io satsly the basic safety requiremenis of the Pressure Equipment Directive, princpally for the conformity assessment in ‘azcordance with Modules °G” and “B + F". ‘The AD 2000 body of regulations is structured along the lines of a solf-cantainod conoopt I ether technical rules are used in eccordance with ihe state of te art to solve related prob- lems, itis assumed that the overall concopt has been taken g into account, g The AD 2000 body of regulations can be used as eppropriale {or other modules o the Pressure Equipment Directive or for & aitforont sectors of the law. Responsibility for testing is 2s ‘spectiedin the provisionsot therelevant secior of the aw, This AD 2000-Merkblatt applies to safely accessories quard- ing against oxcoss proscuro for proseure vessels in which an unacceptable excess pressure is prevented by the opening of safety valves or closing of safety shut-off valves") 2 General?) 21. Safety valves shall comply with the latest technclegy and be suitable for the intended use. This means mnat they shall satisfy the applicable requiroments as regarde materi als and design, funciion rellably taking into consideration the 1 See ae Fearon 20 3 Fer cfrtons see DI 2259 : 3 } ei j aabe e ospue, he aoa aon of tho German text oy Val, {AD 2200: re potted by copyigt The ghia of oe, prtouay afary Wann, rpredcton, exrar figures aromisenoy prow Imecharical means rd storage in cits rtreral ayes even of saa me ‘measures te ensure he acciecy ots arson but ogrets rat ne responsi ean Be aceeped for any er, ams 9 nacsuracy, in cases vod oe autor Car Meymarn Varag hae taken a es630806AD 2000-Merkblatt ‘method of operation of a given pressure chamber ~ particu- larly 2s regards the medium, pressure and temperature - and be able to draw off he mass flow to be diverted in the event ‘of a fault, while complying with the requirements of AD 2000- Metkblatt 4403, ‘As arule, reliability es regards proper function anc mass flow |g dotormined by a componont test) for tho proposed range: of use (pressure, temperature, medium) without taking iio ‘consideration influences resulting from chemical properties. During ihe acceptance test ofthe pressure vessel, hecoriect dimensioning, adjustment, laycut and suitabilty for the Intended operating conditions and for the working medium Shall be tasted, as well as raiabilty inthe case of safety val- vves not having been subjected to component testing, 22. Safety velves shall be so dimensioned end agjusted in ‘accordance with AD 2000-Merkblatt A 403 that exceecing the maximum allowable pressure by more then 10% is pre- verted 2.3. Safety valves shall open at a pressure which does not dior from tho respense presaure by more than 10%. In tho. case of response pressures <1 bar, the diference in the ‘opening preceure can be up to 0,1 bar. This should be taken Into consideration when specifying the response pressure in ‘accordance with 2.2. 2.4 Safety valvas close ata pressure whichis not more than 10% below the response pressure in the case of compres- sible media ard 20% in the casa of incomprasstole media. In the case of safety valves having a response pressure of up 10 3 bats. the reduction in pressure below the response ppresaure can be up to 0,3 bar in the case of compressible media and 0,6 bar in the case of incompressible media, 2.5 The response pressure and time between reaching the response prossure and reaching the dogros of litnocossary {or diverting the mass flow shal be adaptedito the maximum, rate of change of prescurein the system being protected, par- Uiculaly in he case of controled safety valves. For controlled valves the period af ime is to ba indicated, which is required alter reaching the response pressure, before the necessary lito divert the indcated mass flowis reached. It shallfurther be indicated for which state of aggregation of the medium in the control system the data apy. 3. Grading of safety valves 3.41 Grading of safety valves according totheiropening characteristics 344 Standard safety valves “These safety valves reach the degree ofl necessary forthe mass low tobe diverted following response withnapressure rise of not more than 10% (se0.2.3 for exception). Nofurthor requirements are made of the opening characteristics. 34.2 Full lift safety valves Full it safety valves, following response within the 5% pres- sure rise. open suddenly up to the full as liited by the design. The amount of lift upto the sudden opening (oropor- tonal range) shai net be more than 20% of the total lit. 9 ape retats an exe ol he soreceact ne sn VeTOV erin 10000 ‘Seley Vaves.cbtanasis ton Be TUV-Veeag Grohe P.O Box 593900, Beitz3 Cacene 3.1.2 Proportional safety valves Proportional safety valves open more or less steadily in ela tion to the increase in pressure. No sudden opening occurs Urlless the pressure increases beyond the rangeotmore than 10% of the lit. Following response within a pressure Increase of up to 10%, tnese safety valves achieve the It nocossary for the mass low to be diverted (20 2.9for axoop- tion). 32. Classification of safety valves according to thelr type 321 Direct-acting safety valves Direct-acting safety valves are safety valvesin which a direct ‘mechanical loading (a weight, a weight and lever ora spring) acts as a closing force against the epaning force acting on the underside of the vaive disc. 322 Controlled safety valves Controlled safety valves consist of he main valve and acon= trol device, They also include direct-acing safety valvas with supplemertary loading in which, until the response pressure is reached, an additional force increases the closing force The closing force and additional force can be applied mechs- ically (e.g, by @ spring), by outside energy (e.g. pneumat= cally, hydraulically or elactromagnetcally) andior by tha internal medium. Ifthe response pressure is exceeded, the force is automatically ifted or so reduced that the main valve is opened by the pressure of the medium acting on the valve disc or by some otner force acting in the direction of opening, The main valve can bo operated hore according tothe prin ciple otloading or unioading, and control devicescan operate ‘according to the principle of rost or operation. Tho loading principle is charactorized by the fact that tho ‘main valve opens when the load is applied. ‘The unioading principle is characterized by the fact that tha ‘main valvo opens whon the load is removed. The rest principle of control ie characterized by the fact that ‘on failure othe control energy the control device etfects oad ing orunloading. Control cevices with an internal medium are located to the rest principe. ‘The oparation princiola of controlis characterized by the fact, that on failure of the control energy the canirol device does rot effect any loading or unloading. 4 General requirements for safety valves 4.1 Protection against shift of adjustment ‘Safety valves shall be secured against unauthorized attera- tion of te set pressure or response pressure and the method Cf operation. Safety valves shall be secured to prevent their mode of operationboing altorod, 0.9.y means ofalead seal Detween the valve bedy and spring pipe or by means of a positive connection betwoen the disc and tho stem of the valve (not rigid) 42 Guidance of the moving paris Safety valves are to be so designed that movement of the moving parts is not hindered even with unequal heating Whoro doposits aro to be anticipated (0.g. dust) as a result of the operating medium or an external influence, the guides shall be s0 designed, or sufficiently protected against depo- sits, that the function of the safely valve is not impaired.AD 2000-Merkblatt Packings which might hinder the werking of tho valve by causing friction are not permissible. 43. Lifting ability 4.34 It shall be possible for safety valves to be made to ‘open without extemal aids in the range > 85% of the response pressure, 4.3.2 The roquirement socerdingte 4.3.1 canbe dispersed with i this is necessary for operational reasons4) orif ine ser- viceabilty of tho safoty valve can be chackod in some othor way (e.g. by means of change-over valves) 433. Safety valves which are able to be opened in the Lunpressurized state shall be specially constructed for this purpose (e.9. by positive connecton between the disc and ‘stam a! the valve. 44 Loading weight In tne case of safely valves which are loaded by a weight through a lover, tho loading weight shall be mado in ono Diece. In the case of safely valves having more than one valve dise, the individual cscs chall bo indepencentyloaded. 45. Design of the coil springs Coil springs of spring 4oaded safety valves shall be made so that al the cols of the spring stil remain at a distance one from ine other of 0.5 tes te diameter ofthe wire orat least 2mm at the roquired lft If springs and sicing or rotating ‘metal pars are protected by diaphragms, belows, covers or the like against dit or corrosion, smaller stances can be permitted 48 Requirements of the valve body Hf nocossary, it chal be posable to ft discharge pipes tothe safety valve bodes. It shall iso be possible © tthe bosies with a epocial means of fastoningifthoreaction oreos arising dlurng alscharge cannot be wansmitted by ne branch pipes. Itshall not be possible for condensate to callact in the valve bocy. 47 Functional teste Toste on the rosponso proscuro and chocks on tho emooth running of moving parts within the guides shal be carried out at regular intervals (s00 also 4.2). The intervals for regular tests shall be stipulated by the user in accordance with the ‘operating conditions, using as a basis the recommendations (the manufacturer and te relevant third party. These tests land chacks shall be carriag cut atthe latest cn the occasion Of the external o: internal tests on the relevant pressure ves: sel 5 Special requirements for controlled safety valves and necessary measures 5.1 Each contol ine is tobe so dimersioned that the tele vant main valve sill operates reliably in the case of failure of the other lines. With the erinciple of loacing the failure of one ccortrol line shal not affoct the serviceabiliy of the others. 5.2. Itchall bo possible to open the main valve by manully overriding the contol. This requirement shall be satisfied even in the case of failure (0.9. during testing) of a control line. The facility for opening the main valve manually can be dispensed with in the cases in 4.3.2. 7 For maglem te cana otntaluton operating wih'ntanmataorplanous (Seve abe can overt pos 5.3 At loact three soparate control linos, io, threo pulse transmitters ang three conirol elements each with an inde pondont prossure samplingS), pulse®) and cortrolline?), shall 'be in operation for the purposes of control. A control ine can be temporarily takon out of service for purposes of testing and repair. At least two control lines shell comply wih the principleof rast. With such control, more than onemain valve ‘ean be contioled ‘When operating the main valves according to the unloading principle, two control pipelines are sufficient. One control Pipeline is suffcient with the principle o! unloading if @ Blockage of the pipeline can safely be excluded. Prerequisi- tes for this are outside mecium control, the installation offine fiters and a clear diameter of the control pipeline of at least 15 mm without any constriction Itahell be possible to test on the installation that thorois sats {factory interaction between the control and the main valve. Only those media with which fouling or corrosion of the con: trol system is not anticipated may De used for contol purpo: 206, The accumulation of concensats in the central systom shall be prevented if tis affects operatonal reliably. 5.4 Two control lines per main valve are sufficient i, — should both control lines fail, the main valve is fuly open by the time 1.2 times tne maximum allowable pressure is reached or — the mass flow to be discharged is civided over a number ‘of main valves and each vaive is separately controle, if ‘on failure of ne of the main valves the others can stil dis- charge at least sof the required mass flow. 5.5 When the main valveis operated according to the prin Ciple of loading, twoindependent energy sources andenergy ‘supply lines shall be available for loading. On the failure of fone energy source o: energy supoly line. the serviceabilty (of the main valve ahall not bo affected. Even failure of only ‘one of the two eneray scurces shall be incicated in such a way that ite cortain to be noticed immediately. This can be ‘spensed with if the main valve opens automatically on the failure of an energy source. A second energy source is not necessary when an intemal medium 's used 5.6. Inte case of main and control valves wherethesystern pressure or control medium pressure acts on the valve dise In the Grection of closing the opening force shall be designed ‘so that the main valve sill opens fully even at 2 times the maximum allowable pressure or 2 times the maximum work ing pressure of the control medium. 5.7 It shallbe possible to test in operaticn each cortrol ine from the pulse transmitter up to and including the rolovent ‘control elements witnout t being necessary for the main valve to tigger. it shall be onourod by moans oF suitable equipment tnat only one control line can be put cut faction in each case for purposes of testing the pulse elements and the contol elements. Pressure measuring points shal be available to tho extent necessary for assossmant ofoperatio ral relabilly. Pressure measuring lines in contiol systems ‘shall be as short as possible 5.8 Control valves for internal media with associated pipelines and fittings. 5.8.1 Contrl velves for intemal media shall have a mini ‘mum flow diameter dq o! at least 10 mm, The lit occurring in each opening procedure shall be three times the minimum 5 Une w pase wanna 2) Une btreen cowl rt on am vars