ICS 27.

040 December 1998 version*)

Technical
Safety guidelines against excess
TRD 421 421
pressure
Regulations for Equipment
- Safety valves -
Steam Boilers (TRD)
for group I, III and IV steam boilers

The technical regulations for steam boilers (TRD) describe the state of the technical safety requirements for materials, manufacture,
calculation, equipping, set-up and testing as well as for the operation of the steam boiler. They were created by the

German Committee for Steam Boilers (DDA)

and are constantly being adapted for the state-of-the-art. Reference is made to Article 6 Section 2 of the Steam Boiler Regulations
(DampfkV) (EC Equivalence Clause). The TRD is published on behalf of the DDA by the Verband der Technischen Überwachungs-
Vereine e. V., PO box 10 38 34, 45038 Essen, Germany.

Contents

1 Scope 6 Installation, lines, cross-sections

2 General 7 Materials
3 Assignment of safety valves 8 Manufacture and testing of the fitting
housing
4 General requirements for safety
valves 9 Sizing
5 Special requirements for controlled 10 Marking
safety valves and necessary
11 Test at installation site
measures
12 Safety shut-off valves

1 Scope Usually, reliability in relation to correct functionality and

This TRD applies for safety devices against excess
pressure for group I, III and IV steam boilers, in which
impermissible excess pressure is prevented by opening
safety valves or closing safety shut-off valves.
This TRD can also be used on other parts of steam
boiler systems, as long as the permissible operating
overpressure reaches more than 1 bar or the permissible
flow temperature more than 120°C.
2 General
2.1 Safety valves must comply with generally recognized
technical practice (e.g. for fitting-housing TRD 110) and be
suitable for the purpose. This means: they must comply
with the applicable requirements for materials and con-
struction type, taking the corresponding mode of operation
of the steam boiler system into account - in particular pres-
sure and temperature - work reliably and in the event of
failure be able to discharge the mass flow within the per-
missible excess pressure.
mass flow is determined by a component test 2) 3) for the
planned area of application (pressure, temperature). In the
preliminary test (Paragraph 10 Section 3 DampfkV), the
report according to Paragraph 12 Section 4 Sentence 5
DampfkV or the acceptance test (Paragraph 15 Section
2 DampfkV) of the steam boiler system, the correct rating,
setting, arrangement and suitability for the planned operat-
ing conditions are inspected.
2.2 Safety valves must be dimensioned and set up so that
the mass flow, which corresponds to the permissible steam
generation, can be discharged, so that in the process the
permissible operating overpressure is not exceeded by
more than 10% if two safety valves are prescribed or the
performance of the steam generator requires multiple safe-
ty valves, their total cross-section must correspond to this
requirement. At least one safety valve must respond when
the permissible operation overpressure is exceeded.
2.3 Opening the safety valves within an opening pressure
difference of 10% of the response pressure. For response

2
) Requests are to be sent to the Verband der Technischen Überwa-
chungs-Vereine e. V., Kurfürstenstrasse 56, 45138 Essen, Germany.
3
) Procedure and scope of component testing see VdTÜV bulletin
Safety valve 100; copies can be obtained from TÜV-Verlag GmbH,
1
) See DIN 3320 for terms
PO box 90 30 60, 51123 Cologne, Germany.

*) Replaces TRD 421, August 1997 version, and draft TRD 421, as of July 1998;
| = Changes compared to TRD 421, 8.97 version

315
 Page 2 TRD 421. 12/98 version
421 pressure < 1 bar the opening pressure difference can be up to
0.1 bar. This is to be taken into account during definition of the
response pressure according to section 2.2.
2.4 Safety valves close within a pressure drop of 10% for
compressible and 20% for incompressible media under the
response pressure. For safety valves of up to 3 bar response
pressure, for compressible media 0.3 bar and for incompress-
ible media 0.6 bar pressure drop may be borne for the closure.
If in the framework of component testing there are deviations
from Clauses 1 and 2 in special cases, this is to be recorded in
the component test report and specified in the corresponding
VdTÜV safety valve leaflet.
2.5 Response pressure and time between reaching response
pressure and reaching the necessary stroke to discharge the
mass flow must especially be adjusted for controlled safety
valves to the largest pressure change speed of the system to
be secured.
For controlled valves, the time frame is to be given which will
be needed after achieving the response pressure until the re-
quired stroke to discharge the specified mass flow is reached.
It is also indicated to which unit state of the medium the spec-
ifications apply in the control system.
3 Assignment of the safety valves
3.1 Assignment of the safety valves according
to their opening characteristics
3.1.1 Standard safety valves
After response within a pressure rise of maximum 10%, these
safety valves reach the stroke required for the mass flow to
be discharged. See Section 2.3 for exceptions. No further re-
quirements are made on the opening characteristics.
3.1.2 Full stroke safety valves
Full stroke safety valves open suddenly after the response
within 5% pressure drop up to the constructionally limited
stroke. The portion of the stroke until the sudden opening
(proportional area) may not exceed 20% of the total stroke.
3.1.3 Proportional safety valves
Proportional safety valves open virtually continuously in de-
pendence of pressure increase. Here, a sudden opening
without pressure increase over a range of more than 10% of
the stroke does not occur. After response within a pressure
rise of maximum 10%, these safety valves reach the stroke
required for the mass flow to be discharged (see section 2.3
for exceptions).
3.2 Assignment of the safety valves according
to their construction type
3.2.1 Directly acting safety valves
Directly acting safety valves are safety valves in which the
opening force acting under the valve ball opening is counter-
acted by a mechanical load (a weight, a weight with a lever or
a spring) as a closing force.
4
) Directly acting proportional safety valves are currently not practical
for hot water generators.
316
3.2.2 Controlled safety valves
Controlled safety valves consist of a main valve and a control
device. This also includes directly acting safety valves with ad-
ditional load, in which an additional force reinforces the closing
force until the response pressure is reached.
The closing force or the additional force can be applied me-
chanically (e.g. via a spring), through external energy (e.g.
pneumatic, hydraulic or electromagnetic) and/or through an
internal medium. They are autonomously canceled by ex-
ceeding the response pressure or reduced so much that the
main valve opens through the medium pressure acting on the
valve plate or through another force acting in the opening di-
rection. Here, the main valve can be actuated by the loading
or unloading principle and the control devices can act accord-
ing to the idle or working principle.
The loading principle is marked by the main valve opening
when applying the load.
The unloading principle is marked by the main valve opening
when lifting the load.
The idle principle of the control is marked by the control de-
vice causing loading or unloading in the event of failure of the
control energy. Control devices with internal medium are as-
signed to the idle principle.
The working principle of the control is marked by the control
device acting on loading or unloading in the event of failure of
the control energy.
4 General requirements for safety valves
4.1 Securing against alteration
Safety valves must be secured against unauthorized alter-
ations of the setting pressure and the functionality. In the con-
text of component testing or individual testing, the reliability of
the security provided will be tested. Safety valves for ship's
steam boilers must be able to be secured by split locking
sleeves.
4.2 Guiding the moving parts
The safety valves are to be designed so that the moving parts
are not hindered from moving by different thermal stresses.
Seals which can prevent the function through frictional forces
occurring are not permitted.
4.3 Ability to ventilate
4.3.1 Safety valves must be able to open at >= 85% of the
response pressure without external aids.
4.3.2 The requirements according to Section 4.3.1 can be
ignored if this is necessary for operational reasons, or if the
functionality of the safety valve can also be tested via other
means (e.g. via shuttle valves).
4.3.3 Safety valves which need to be put into a depressur-
ized state for opening must be specially designed for this (e.g.
through a positive connection between the valve plate and
valve spindle).

4.4 Loading weight
For safety valves that are loaded by weight acting via a le-
ver, the loading weight must consist of one piece. For safety
valves with more than one valve plate, the loading of the indi-
vidual plates must take place independently of one another.
4.5 Formation of the coil springs
Coil springs of spring-loaded safety valves must be designed
so that all coils of the springs for the required stroke still have
a reciprocal distance of 0.5 • wire diameter or at least 2 mm.
If springs and sliding or rotating metallic parts are protected by
membranes, stem bellows, covers or the like against dirt or
corrosive attack, smaller distances may be permitted.
4.6 Requirements on the valve housing
If necessary, blow-out lines must be able to be attached to the
housing of the safety valves. Furthermore, the housing must
be provided with a special attachment option if the connection
nozzles cannot transfer the reaction forces that occur during
blowing out. No condensate may be able to collect in the valve
housing.
5 Special requirements for controlled safety
valves and required measures
5.1 The interval for regular functional testing on controlled
safety valves are to be defined according to the operating
conditions by the operator where the recommendations of the
manufacturer and the expert serve as a base; one annual test
is deemed necessary at a minimum. Functional testing is to
be carried out so that alongside the function of the main valve
also the functionality of the individual control strands can be
assessed.
It must be checked whether the opening criteria, e.g. size and
timely course of the loading and unloading forces, ensure fault-
less function up to full opening of the main valve.
5.2 Every control strand is to be measured so that in the event
of failure of the other control strands the corresponding main
valve still works reliably. The failure of a control strand may not
impair the functionality of the others in the loading principle.
5.3 The main valve must be able to be opened by manual op-
eration of the controller. This requirement must also be fulfilled
in the event of failure (e.g. during testing) of a control strand.
The opening option of the main valve by manual operation can
be ignored in the cases of Section 4.3.2.
5.4 For control, at least three separate control strands, i.e.
three pulse generators and three control elements, must be in
operation each with an independent pressure extraction, pulse
and control line.
For testing and repair, a control strand can be temporarily
taken out of operation. At least two control strands must be
switched according to the rest principle. Electronic or micro-
processor-controlled devices are permitted if their reliability is
demonstrated, e.g. in context of the component test.
With a controller such as this, multiple main valves can be con-
trolled.
For actuation of the main valves according to the unloading
5
) Line to pulse generator
6
) Line between pulse generator and control element
7
) Line between control element and main valve
Page 3 TRD 421. 12/98 version
principle, two control lines are sufficient. One control line is suf-
ficient for the unloading principle if a blockage of the line can be
421
safely excluded. Provided that: external medium control, instal-
lation of fine filters and diameter clearance of the control line
are at least 15 mm without any narrowing. It must be possible
to test the faultless interaction of the controller with the main
valve in the system. For controlling, only media may be used
in which pollution or corrosion of the control system is not to be
expected. Collection of condensate must be prevented in the
control system if functional reliability is impaired by it.
5.5 Two control strands per main valve are sufficient, if
- the main valve in the event of failure of both control strands,
at the latest when reaching 1.2 times the permissible oper-
ating overpressure8) is fully open or
- a separation of the mass flow to be discharged takes place
via multiple main valves and separate control of each main
valve, as long as in the event of failure of one of the main
valves at least the remaining 2/3 of the required mass flow
can still be discharged.
5.6 On actuation of the main valve according to the loading
principle, two energy sources that are independent of each
other and have independent energy supply lines must be avail-
able for the loading. In the event of failure of an energy source
or energy supply line, the functionality of the main valves may
not be impaired. The failure also of only one of both energy
sources must be displayed so that it is noticed immediately.
This is not necessary if the main valve opens automatically
in the event of failure of an energy source. A second energy
source is not required if internal media are used.
5.7 For main or control valves in which the system or the control
medium pressure work in the direction of closure on the valve
plate, the opening force is to be measured so that the main
valve still opens fully at twice the permissible system pressure
or twice the highest working pressure of the control medium.
5.8 Every control strand from pulse generator up to and in-
cluding the corresponding control element must be able to be
tested in operation, without having to make the main valve
respond. Through suitable equipment it is to be ensured that
for testing of the pulse generator and the control element, only
one control strand at a time can be made inoperable.
Pressure measuring points must be available in the scope
required for the assessment of functional reliability. Pressure
measurement lines in the control systems should be as short
as possible.
5.9 Control valves for internal medium with relat-
ed lines and fittings
5.9.1 Control valves for internal medium must have a narrow
flow diameter d0 of at least 10 mm. The stroke to be set for
each opening process must be three times the size of the
smallest stroke at which the main valves starts to open (but
at least 2 mm). This stroke is to be defined in context of the
component or individual test.
5.9.2 Control lines should be short and laid for the best flow.
Collection of condensate in the control strands as well as
freezing of the control strands must be prevented. For the
condensate drainage, a line inclination of at least 15 % should
be complied with.
8
) This should not insinuate that during operation of the steam boiler
the basic requirement according to Section 2.2 may be violated.
317
 Page 4 TRD 421. 12/98 version

421 In the event of deviations, it must be ensured that the function

of the controlled safety valves can still be guaranteed.
5.9.3 Control lines for media in which pollution or corrosion
cannot be excluded are to be implemented with at least 15
mm diameter clearance and may not exhibit any narrowing.

6 Installation, lines, cross-sections

6.1 Installation and lines
6.1.1 Safety valves may not be made inoperable by shut-off
devices. The installation of quick-change fittings or blocking
devices is permissible if by construction of the device it can
be ensured that the required blow-out cross-section is also
released during switching. For systems that are equipped with
multiple independent safety valves, during the test of a safety Image 1
valve the remaining valves may be blocked for correspond-
ingly reduced system output.
6.1.2 Direct acting safety valves are principally to be installed DE = diameter of the supply line [mm]
upright taking the flow direction into consideration. The supply AE = cross-section of the supply line [mm2]
line should be short and as straight as possible. Outlets to LE = total length of the supply line [mm]
safety valves should not lie opposite other branches. Supply
lines and blow-out lines from safety valves are to be laid to aid A0 = do ‘ _ = narrowest flow cross-section [mm2]
the flow. Safety valves are to be protected against damaging k = isentropic exponent
external effects, e.g. weathering effects, which could impair αw = discharge coefficient awarded
the function. Transmissions of vibrations to the safety valve
are to be avoided. λ = friction coefficient of the pipe
Blow-out lines from safety valves must lead out safely. No liq- ζz = perm. drag coefficient
uid may collect in the blow-out system. If there is a danger ζi = drag coefficient for line and fitted parts
of freezing, the line must be protected accordingly. The lines
K = equivalent roughness [mm]
must be dimensioned and laid taking the local operating con-
ditions into account, so that the static, dynamic (reaction forc-
es) and thermal demands can be securely incorporated. In as 6.2.2 The pressure loss in the supply line may for the largest
much as drainage of exhaust and vaporous liquids, e.g. hot mass flow not exceed 3% of the pressure difference between
water, is to be expected for safety valves, pressure-relief de- the response pressure and the superimposed back pressure.
vices of sufficient size must be arranged in the immediate vi- Prerequisite for an undisturbed function at this pressure loss
cinity of the valve. On these pressure-relief devices, openings is that the closing pressure difference of the fitted safety valve
with a sufficient cross-section both to drain the depressurized is at least 5%. For closing pressure differences smaller than
steam (gas) as well as to drain the liquid are to be provid- 5%, the difference between the pressure loss in the supply
ed. On safety valves in which an escaping medium, e.g. also line and the closing pressure difference must be at least 2%.
through an open cover, could result in direct or indirect dan-
gers for personnel or the environment, suitable safety devices
Table 1. Pipe friction coefficient A for K = 70 //m
must be attached. The marginal escape of vapor through the
(Reference value)
spindle bushing is permissible.
6.2 Cross-section DE [mm] 20 50 100 200 500
6.2.1 The cross-section of the supply line may not be smaller λ 0.027 0.021 0.018 0.015 0.013
than the inlet cross-section of the safety valve.
The cross-section of the blow-out line may not be smaller than The following applies:
the outlet cross-section of the safety valve.
The diameter and the length of the blow-out lines, the man- 2.0
ifold, the muffler etc. determine the magnitude of the back 3.71
pressure. These parts are to be dimensioned and laid so that
the permissible back pressure specified by the manufacturer For controller valves, the requirements for the pressure loss
will not be exceeded. in the supply line only apply if they also work as direct acting
safety valves in the event of failure of the controller

318
Table 2. Drag coefficients ζi (reference values) Page 5 TRD 421. 12/98 version

Elbow Deflection losses for δ = 90° and K =70 μm 421

DE 20
50 100 200 500
R/DE [mm]
1.0 0.42 0.33 0.27 0.24 0.19
1.25 0.35 0.28 0.23 0.20 0.16
1.6 0.29 0.23 0.19 0.17 0.14
2 0.25 0.19 0.16 0.14 0.12
2.5 0.22 0.17 0.15 0.13 0.10
3.15 0.20 0.15 0.13 0.11 0.10
for δ ≠ 90° 4 0.18 0.14 0.12 0.10 0.10
5 0.16 0.12 0.10 0.10 0.10
6.3 0.14 0.11 0.10 0.10 0.10
8 0.12 0.10 0.10 0.10 0.10
10 0.14 0.11 0.10 0.10 0.10
ζi

Supply line well rounded 0.1

connecting piece Edge chamfered normally 0.25

Sharp edge or set-through pipe 0.50

continuous
cross-section
narrowing in relation to the narrowed cross-section 0.1

right-angled Nozzle in passage 0.353)

T-pieces inserted with
sharp edges in branch 1.283)
Nozzle expanded in passage 0.23)
or superimposed, infeed
rounded off1) in branch 0.753)
Shuttle valve / blocking devices 2
)
1
) For T-pieces usually extended in high pressure pipelines
2
) ζ value determination required
3
) In relation to the dynamic pressure in the outgoing line from the safety valve

For a pressure loss of 3% in the supply lines of safety valves,
the permissible drag coefficient ζz of the supply line and from
this its maximum length LE can be determined with help of the
diagram according to Image 2.
With the sum of the drag coefficients ζi (Table 2) of the indi-
vidual line and fitting parts as well as the drag coefficient of
LE
the straight pipe λ • the permissible line length LE can be
DE
calculated with λ from Table 1:
6.3 Back pressures on the outlet side which act on the re-
sponse overpressure and on the opening forces or the mass
flow are to be considered. The manufacturer is to specify up
to which back pressure pa intended use of the safety valve
can be guaranteed and the mass flow to be discharged (sec-
tion 2.2) is reliably reached. If the blow-out line of a safety
valve leads to a downstream network, the safety valve is to
be set and dimensioned so that, at the maximum, external
back pressure paf starts to blow out at the right time and at
the highest possible back pressure pa the required mass flow
can be discharged.

6.4 Safety valves must be accessible for testing functionality

if the calculated supply line length LE is smaller than required, and for maintenance.
the safe functionality under the existing installation conditions
must be determined by experimentation and the actual pres-
sure loss in the supply line taken into consideration in the siz- 6.5 The manufacturer's installation instructions are to be fol-
ing of the safety valve. lowed.

319
 Page 6 TRD 421. 12 98 version

421

0.2
0.4

0.6
0.8
1.0

0.5

0.1

1.1

Image 2. Permissible resistance coefficient ζz (for k = 1.3) for 3% pressure loss

320
 Page 7 TRD 421. 12/98 version
larger pressure differences in the pre-pressure and post-pres-
sure part and carried out taking the applicable pressure into
421
Explanation of image 2
account.

1.1

9 Sizing
with 9.1 The required narrowest flow cross-section in front of the
valve seat A0 is to be calculated according to the formula in
0.03
Section 9.4.

and
9.2 The narrowest flow diameter in front of the valve seat must
for be at least 15 mm (the one from the control valves at least 10
mm according to Section 5.8.1). With safety valves for steam
boilers of group I, the narrowest flow diameter can be reduced
or to 6 mm.
for
9.3 The discharge coefficient for full stroke safety valves
should be the value aw = 0.5 - apart from valves, which are
limited in stroke - and for standard or proportional safety valves
may not fall below aw = 0.08. Structural stroke limitations must
Limit curve for permit a stroke of at least 1 mm.

0.03
0.97 1.1 9.4 Water vapor
With the help of leverage coefficient x, which takes the prop-
Δ pR
= the ratio of pressure loss to absolute Po pressure be- erties of the water vapor flowing out and the conversion of
p0 the incoherent units into account, results in the narrowest flow
fore infeed in component to be secured
cross-section for water vapor
pa0
= the ratio of the absolute external back pressure Po
p0
to absolute pressure, before the infeed in the compo-
nent to be secured
with
0.6211

7 Materials
The materials for all parts affected by the medium must be The leverage coefficient x is shown in image 3 for supercritical
selected in accordance with the current generally recognized relief.
technical regulations, so that they are suitable for the pres- For sub-critical relief and for pressures < 2 bar, the leverage
sures and temperatures which occur and are sufficiently cor- coefficient is to be determined mathematically.
rosion-resistant. This also applies for supply, blow-out and
condensate discharge lines. Materials for control lines are to
be selected accordingly from TRD row 100. Housing materi-
als must comply with TRD 110. Safety valves are to be de- For sub-critical pressure conditions is
signed so that the functionality is not impaired by baking. This
is for example to be achieved if for the valve plate and valve
seat different types of materials, e.g. martensitic and austensi-
tic materials or corrosion-resistant hard alloys are used.

For supercritical discharge function calculated according to

8 Manufacture and testing of the fitting formula (4) or in dependence on the pressure condition and
housings taken from isentropic exponents in image 4.
The pressure-bearing housing parts of the fittings are to be
manufactured and tested according to TRD 110. The required
pressure test can, if necessary, be separated for both parts for

321
 Page 8 TRD 421. 12/98 version

421 Mean here: aw = Discharge coefficient -

pa0 = absolute back pressure [bar]
A0 = = narrowest flow cross-section in front of k = Isentropic exponent of the
the valve seat [mm2] medium in the pressure chamber -
d0 = narrowest flow diameter in front of the
valve seat [mm] For water vapor, the specific volume v and the isentropic
qn = mass flow to be discharged exponent k are to be taken from the VDI (The Association
(see TRD 401 section 2.8) kg/h] of German Engineers) water vapor table, 7th Edition 1968,
p0 = absolute pressure in the pressure chamber of the VDI-Verlag, Düsseldorf, Germany,
steam boiler; 1.1 times the permissible operating
overpressure plus environmental pressure of one 9.5 Hot water
bar[bar]
If on the steam boiler to be secured a smaller pres- Design rules are being prepared for hot water.
sure should be used during dimensioning for tech- 10 Marking
nical process reasons. e.g. the absolute permissible
operating pressure, this is to be agreed. 10.1 Fitting-housing must be marked in accordance with TRD
110. Component-tested safety valves must additionally be
v = specific volume in pressure chamber [m /kg]
3
provided with the recognized component marking that is per-
Ψ = Discharge function - manent and easily legibly. Adhesive film is not permitted.

Temperature in °C
2.8

2.6

2.4
h • mm2 • bar
kg

2.2
Leverage coefficient x in

2.0

Saturated steam

1.8

1.6

1.4

Response pressure p0 (absolute) in bar

Image 3. Leverage coefficient x for water vapor

322
 Page 9 TRD 421. 12/98 version

421
0.6

k= Ψmax=
1.8 0.527
0.5 1.6 0.507
1.4 0.484
1.2 0.459
1.0 0.429

0.4
Discharge function Ψ

0.3

0.2

0.1

0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Pressure ratio pa0/p0

10.2 By attaching the component mark, the manufacturer 10.4 The manufacturer must include the installation and
bears liability for compliance of the safety valve with the operating instructions in the delivery.
component test report including systems, the correct set-up
consistent with the pressure specifications in the component
mark and for securing against alteration.
10.3 The component mark consists of the following
requirements (see below): 11 Testing at installation site
For safety valves that were tested for different media, Testing is to be carried out according to TRD 504. 505 and
multiple code letters can be given. 601 Sheet 2.

TÜV SV 98-xxx xx D 0,xx x

TÜV symbol
Safety valve
Year of component testing
Component test number
Narrowest flow diameter d0
before the valve seat in mm
Code letter: D planned for steam
Discharge coefficient awarded aw
Gauge pressure p in Bar

333
 Page 10 TRD 421. 12/98 version
421 12 Safety shut-off valves
12.1 Safety shut-off valves are controlled safety devices cor-
responding to Section 3.2.2, but with direction of action op-
posite to the main valve. They are upstream of the system
to be secured and open in normal operation. In the event of
impermissible pressure increase, they automatically block the
flow of media. Sections 2.5, 4, 5, 6.5 up to 6.8, 7, 8, 10 and 11
are logically to be applied in this case. Dimensioning in accor-
dance with section 9 is not required.
12.2 Devices, such as perforated disks or sieves are to be fit-
324
ted in the direction of flow in front of the main valve, which en-
sure that larger foreign bodies do not end up in the valve seat.
12.3 Despite upstream protective devices in the sense of
Section 12.2, foreign bodies of the diameter of the large sieve
perforation can prevent full closure of the main valve. The sys-
tem which is to be secured downstream of the safety shut-off
valve must therefore additionally be fitted with a safety device
against excess pressure. When dimensioning this safety de-
vice against excess pressure, the possible leak mass flow ac-
cording to clause 1 must be considered.