HANDBOOK

SAFETY DEVICES FOR REFRIGERATING SYSTEMS

SAFETY DEVICES FOR REFRIGERATING SYSTEMS ed. 001-DS-ENG

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INDEX
Safety valves 3030 07
Safety valves 3060 13
Ball shut-off valves for safety valves 16
Changeover devices for safety valves 18
Safety valves unions 20
Bursting disc safety devices 3070 21
Fusible plugs 25

FROM QUALITY OUR NATURAL DEVELOPMENT

Achieved the goal of fifty years working in the industry of Refrigeration and Air Conditioning, Castel Quality Range of Products is well
known and highly appreciated all over the world. Quality is the main issue of our Company and it has a special priority, in every step,
all along the production cycle. UNI EN ISO 9001:2008, issued by ICIM, certifies the Quality System of the Factory. Moreover Castel
Products count a number of certifications in conformity with EEC Directives and with European and American Quality Approval. We
produce on high tech machinery and updated automatic production lines, operating in conformity with the safety and environment
standards currently enforced. Castel offers to the Refrigeration and Air Conditioning Market and to the Manufacturers fully tested
products suitable with HCFC and HFC Refrigerants currently used in the Refrigeration & Air Conditioning Industry.

SAFETY DEVICES FOR REFRIGERATING SYSTEMS ed. 001-DS-ENG

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 ed. 001-DS-ENG SAFETY DEVICES FOR REFRIGERATING SYSTEMS
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 SAFETY DEVICES

External leakage Guarantee

All the products illustrated in this Handbook are submitted, All Castel products are covered by a 12 – months warranty.
one by one, to tightness tests besides to functional tests. This warranty covers all products or parts thereof that
Allowable external leakage, measurable during the test, turn out to be defective within the warranty period. In this
agrees to the definition given in Par. 9.4 of EN 12284 : case, at his own expenses, the customer shall return the
2003 Standard: defective item with a detailed description of the claimed
“During the test, no bubbles shall form over a period of at defects. The warranty doesn’t apply if the defect of Castel
least one minute when the specimen is immersed in water products are due to mistakes either by customer or by
with low surface tension, …” third parties such wrong installations, use contrary to
Castel indications, tampering. In case of defects of its own
Preassure containment products, Castel will only replace the defective goods and
will not refund damages of any kind.
All the products illustrated in this Handbook, if submitted The technical data shown on this catalogue are indicative.
to hydrostatic test, guarantee a pressure strength at Castel reserves the right to modify the same at any time
least equal to 1,43 x PS in compliance with the Directive without any previous notice.
97/23/EC.
All the products illustrated in this Handbook, if submitted The products listed in this handbook are protected
to burst test, guarantee a pressure strength at least according to the law.
equal to 3 x PS according to EN 378-2 : 2008 Standard.

Weights
The weights of the items listed in this Handbook include
packaging.

SAFETY DEVICES FOR REFRIGERATING SYSTEMS ed. 001-DS-ENG

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 ed. 001-DS-ENG SAFETY DEVICES FOR REFRIGERATING SYSTEMS
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 SAFETY VALVES 3030
gas leak occurs through this orifice.
Utilized material: EN 12420-CW617N brass.

Disc: obtained through bar machining and equipped with

gasket, it ensures the required sealing degree on the valve
seat. The gasket is made in P.T.F.E. (Polytetrafluorethylene), a
material that, during valve estimated service life, maintains
a good strength and does not cause the disc to stick on the
seat. The disc is properly guided in the body and the guide
action can never fail; there are no glands or retaining rings
that hamper the movement thereof.
Utilized material: EN 12164-CW614N brass.

Spring: it opposes the pressure and the fluid dynamic

actions and always ensures valve re-closing after pressure
relief. The spring coils, when the disc has reached the lift
corresponding to the state of relief at full flow rate, are
spaced apart by at least half the wire diameter and, in any
case, by not less than 2 mm. The disc is equipped with a
mechanic lock and when it attains it, the spring set does not
exceed 85% of the total set.
Utilized material: DIN 17223-1 steel for springs.

Setting system: hexagonal head, threaded ring nut to be

screwed inside the body top by compressing the spring
below. On setting completion, the position attained by the
ring nut is maintained unchanged laying, in the threaded
GENERAL DESCRIPTION coupling, a bonding agent with high mechanic strength
Valves series 3030 are safety devices according to the and low viscosity features to make penetration thereof
definition given in Article 1, Point 2.1.3, 2nd dash of 97/23/ easier. The setting system is protected against subsequent
EC Directive and are the subject of Article 3, Point 1.4 of unauthorized interventions by means of a cap nut that is
aforesaid Directive. screwed outside the body and is sealed with lead to it.
The valves above mentioned are standard type, unbalanced,
direct-loaded safety valves. Valve opening is produced by SCOPE
the thrust the fluid under pressure exerts on the disc, when Use: protection against possible overpressures of the
said thrust exceeds, under setting conditions, the opposing apparatuses listed below, with regard to the operating
force of the spring acting on the disc. conditions for which they have been designed:
Valves are identified by means of: • Refrigerating system and heat pump components, for
• a model number formed of an alphanumerical coding instance: condensers, liquid receivers, evaporators,
that includes: liquid accumulators, positive displacement compressor
• in the first part the family identification (e.g. 3030/44C) discharge, heat exchangers, oil separators, piping.
• in the second part the setting pressure, expressed in (reference: EN 378-2:2008 Standard)
bars, multiplied by 10 (e.g. 140) • Simple pressure vessels (reference: 87/404/ EEC
• an alphanumerical serial number. Directive)

CONSTRUCTION Fluids: the valves can be used with:

Body: squared, obtained through die forging and subsequent • Refrigerant fluids, in the physical state of gas or vapour,
machining. It houses the following elements: belonging to Group 2 according to the definitions of
• the nozzle with flat sealing seat 97/23/EC Directive, Article 9, Point 2.2 (with reference to
• the disc guide 67/548/EEC Directive of June 27th, 1967).
• the setting spring holder • Air and nitrogen (reference: 87/404/EEC Directive)
• the threaded seat of the setting adjusting ring nut
In the body, above the disc guide, a small pressure relief MARKING
hole is provided through which the spring holder is put into In conformity with the provisions of Article 15 of 97/23/EC
contact with the atmosphere. For this reason, during relief, a Directive, the EC marking and the identification number of

SAFETY DEVICES FOR REFRIGERATING SYSTEMS ed. 001-DS-ENG

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the notified body involved in the production control phase provides a general outline of the protection devices to
are reported on the valve body. be adopted in refrigerating systems and their features
Still on the body, the following information is indicated: (par. 6.2.5). It also indicates the criteria for the selection
• Manufacturer's mark, address and manufacture country of the device suitable to the type and sizes of the system
• Valve model component to be protected (par. 6.2.6).
• Flow section EN 13136:2001/A1:2005 Standard “Refrigerating
• Kd discharge coefficient systems and heat pumps – Pressure relief devices
• Indication of flow direction and their associated piping – Methods for calculation”,
• Max allowable pressure harmonized with 97/23/EC Directive, highlights the
• Allowable temperature range possible causes of overpressure in a system and makes
• Set pressure available to users the instruments for pressure relief
• Production date device sizing, among which the safety valves.
• Serial number
SIZING OF SAFETY VALVES DESIGNED TO
VALVE SELECTION DISCHARGE GAS OR VAPOUR AT CRITICAL
97/23/EC Directive requires that pressure equipment, FLOW (Ref. . EN ISO 4126-1: 2004 and EN 13136
in which permissible limits are reasonably likely to be
exceeded, shall be fitted with suitable protection devices, : 2001/A1:2005)
for instance safety devices such as safety valves. Such Critical flow occurs when the backpressure pb (the pressure
devices shall prevent pressure from permanently existing immediately at the outlet of a safety valve) is below
exceeding the max allowable pressure PS of the or equal to the critical pressure:
equipment they protect. In any case, a short pressure
peak limited to 10% of admissible maximum pressure [bar abs]
is permitted.
As to the selection and sizing of the suitable protection with:
device, users shall refer to the specific product and • po = actual relieving pressure, upstream the safety valve;
sector standards. it’s equal to the set pressure plus overpressure. That is a
EN ISO 4126-1: 2004 Standard: “Safety devices for pressure increase over set pressure at which the disc has
protection against excessive pressure – Part 1: Safety its total lift. [bar abs]
valves”, harmonized with 97/23/EC Directive, specifies • k = isentropic exponent of gas or vapour, based on the
general requirements for safety valves irrespective of the actual flowing conditions at the safety valve inlet
fluid for which they are designed.
EN 378-2 : 2008 Standard “Refrigerating systems and If k is unknown or anyway difficult to establish it’s possible
heat pumps – safety and environmental requirements to suppose:
– Part 2: Design, construction, testing, marking and
documentation”, harmonized with 97/23/EC Directive,

TABLE 1: General Characteristics of valves 3030

Catalogue Number 3030/44C 3030/66C 3030/88C
Inlet male 1/2" NPT 3/4" NPT 1" NPT
Connections
Outlet male 3/4" G 3/4" G 1.1/4" G
Inlet connection wrench torque (min/max) [Nm] 21/30 32/45 50/65
Flow Diameter [mm] 12 12 19,5
Flow Section [mm ]
2
113 113 298
Lift [mm] 4,1 4,1 6,8
Discharge Coefficient "Kd" 0,90 0,90 0,83
PS [bar] 55
TS [°C] - 50 / + 150
Set Pressure Range [bar] 8 / 50
Overpressure 5 % of set pressure
Blowdown 15 % of set pressure
Risk Category according to PED IV

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A safety valve, which discharges to atmosphere, works in with Qh = rate of heat production [KW]
critical flow.
The safety valves designed to discharge gas or vapour at • Excessive pressure caused by compressors. The minimum
critical flow must be sized as follow: required discharge capacity shall be determined by the
following:

with: with:
• Ac = minimum flow area of safety valve [mm2] • V = theoretical displacement of compressor [m3]
• Qmd = minimum required discharge capacity, of refrigerant, • n = rotational frequency of compressor [min –1]
of safety valve [kg/h] • ρ10 = vapour density at refrigerant saturation pressure/
• Kd = certified coefficient of discharge dew point at 10 °C [kg/m3]
• po = actual relieving pressure, upstream the safety valve, • ηv = volumetric efficiency estimated at suction pressure
see definition above. [bar abs] and discharge pressure equivalent to the safety valve
• vo = specific volume of gas or vapour at relieving setting
conditions po e To, meaning with To fluid temperature at
valve inlet, settled by the user or by the designer. [m3/kg] EXAMPLE OF CALCULATION OF MINIMUM
• C = function of isentropic coefficient k calculated from: REQUIRED DISCHARGE CAPACITY Qmd AND
SIZING OF THE SAFETY VALVE FOR THE HIGH
PRESSURE SIDE OF A REFRIGERATING SYSTEM
System description
for this calculation the value of k shall be as measured at Compact refrigerating system designed to make refrigerated
25 °C. (Section 7.2.3, EN 13136:2001/A1:2005 Standard). water and consisting of:
Values of k and calculated values of C for all the refrigerants • open type reciprocating compressor.
are given in table A.1 of the aforesaid Standard. Following we • Water-cooled, shell-and-tube horizontally condenser
show the values of k and C for the more useful refrigerants. with lower section of shell used as receiver.
• Shell-and-tube horizontally liquid cooler fed with a
thermostatic valve.
Function of Isen- • Refrigerant fluid R407C
Isentropic
Refrigerant tropic
Coefficient k
Coefficient C
Compressor data
R22 1,17 2,54 • Bore 82,5 mm
R134a 1,12 2,50 • Stroke 69,8 mm
R404A 1,12 2,50 • Cylinder number 6
• Rotational frequency 1450 rpm
R407C 1,14 2,51
• Clearance 4%
R410A 1,17 2,54 The theoretical displacement of compressor is:
R507 1,10 2,48

Calculation of minimum required discharge capacity of

safety valve is closely linked to the type of system where Maximum allowable pressure of the condenser, refrigerant
the valve is installed, with the causes that may arouse the side : PS = 25 bar
opening of safety valve, i.e.:
Set pressure of the safety valve installed on the upper shell
• External heat sources. The minimum required discharge section of condenser:
capacity shall be determined by the following: pset = 25 bar

Actual relieving pressure of safety valve, choosing one

valve type 3030 with an overpressure of 5%:
with:
[bar abs]
• φ = density of heat flow rate, it’s assumed to be 10
[kW/m2]
• Asurf = external surface area of the vessel [m2] Working conditions of compressor corresponding to the
• hvap = heat of vaporization of liquid at po [kJ/kg] relieving of safety valve:
Condensing temperature: + 64 °C (27,25 bar abs)
• Internal heat sources. The minimum required discharge Evaporating temperature: + 10 °C (6,33 bar abs)
capacity shall be determined by the following:
These conditions, settled in any case by the designer, are
considered the most unfavorable for the safety valve in

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consequence of functional defects as: VALVE INSTALLATION
• Move mistake Safety valves type 3030 are guaranteed for
• Non-working of automatic safety devices, set to operate reproducibility of performance, this means that after
before safety valve. the valves have operated, open/close, the initial setting
It shall be excluded conditions are maintained. Nevertheless it is advisable
• Closeness the refrigerating system, the presence of to replace valve 3030 once it has discharged because
flammable substances in so large quantities to be able during release, piping debris, as metal shavings or solder
to feed a fire. impurities, can place on the valve gasket and then, inhibits
• Inside the vessel, the presence of a heart source. the safety valve from reseating at its originally conditions.
As far as the installation of safety relief valves is concerned,
Calculation of minimum discharge capacity the fundamental points listed below shall be taken into
Prudentially leaving the vapour overheating at the outlet of account:
the liquid cooler out of account, the volumetric efficiency • Safety valves shall be installed near an area of the system
of compressor is: where vapours or gases are present and there is no fluid
turbulence; the position shall be as upright as possible,
with the inlet connector turned downwards.
• Vessels, joined together with piping rightly selected by the
manufacturer and without any stop valve between them,
and so the minimum required discharge capacity: may be considered as only one vessel for the installation
of a safety valve.
• The union between the valve and the equipment to be
protected shall be as short as possible. Furthermore, its
with ρ10 = 26,34 [kg/m3], vapour density of R407C at passage section shall not be narrower than the valve inlet
saturation pressure / dew point at 10 °C section. In any case, EN 13136:2001/A1:2005 Standard
states that the pressure loss between protected vessel
Sizing of minimum flow area of the safety valve and safety valve, at discharge capacity, shall not exceed
3% of the setting value, including any accessory mounted
on the upstream line.
• In selecting the safety valve location, it shall be taken into
account that valve operation involves the discharge of the
refrigerant fluid under pressure, sometimes even at high
with: temperature. Where the risk exists to cause direct injuries
• C = 2,51, corresponding to isentropic exponent k to the persons nearby, an exhaust conveying piping shall
for R407C equal to 1,14, according to table A1 of EN be provided, which shall be sized in such a way as not
13136:2001/A1:2005 Standard to compromise valve operation. EN 13136:2001/A1:2005
• Kd = 0,83, certified coefficient of discharge for safety Standard states that this piping shall not generate, at
valve 3030/88 discharge capacity, a back pressure exceeding 10% of
• vo = 0,0104 [m3/kg], specific volume of overheating pressure po , for standard type valves, unbalanced.
vapour upstream the safety valve during relieving. To calculate the pressure loss either in the upstream line
This value is referred to the following operating conditions, (between vessel and safety valve) or in the downstream
upstream the safety valve: line (between safety valve and atmosphere) refer to EN
• pressure po = 27,25 [bar abs] 13136:2001/A1:2005 Standard, Chapter 7.4.
• temperature To = 100 [°C] (precautionary temperature,
settled in any case by the designer) Pressure loss in the upstream line
Calculation of pressure loss is given by:
Conclusion: the selected safety valve is the model 3030/88
with the following characteristics:
• certified coefficient of discharge, Kd = 0,83
• flow section, Ac = 298 [mm2] with:
• set pressure, pset = 25 bar • Ac = minimum calculated flow area [mm2]
• Ain = inside area of inlet tube to valve [mm2]
In case of single-screw compressor with injection of • Kdr = Kd x 0,9 , derated coefficient of discharge
pressurized oil, the theoretical displacement is: • C = function of isentropic coefficient k
• ξ = addition of pressure loss coefficients ξn of any
component and piping
The coefficients ξn are relevant to:
with: • pipe elements loss, as connections and bends
• D = rotor diameter [m] • valves loss
• L = rotor length [m] • loss along the pipe

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 and are listed in EN 13136:2001/A1:2005 Standard, with:
Table A.4. • P1 = inlet pressure to downstream line [bar abs]
• P2 = outlet pressure to downstream line, equal to
Example: assume to install, on the condenser of the atmospheric pressure [bar abs]
previous example, a safety valve type 3030/88, set to 25 • Ac = minimum calculated flow area [mm2]
bar, using a steel union with the following characteristics: • Aout = inside area of outlet tube to valve [mm2]
• din = 28 [mm] , inside diameter • Kdr = Kd x 0,9 , derated coefficient of discharge
• Ain = 616 [mm2] inside area • po = actual relieving pressure, upstream the safety valve
• L = 60 [mm] , length [bar abs]
• Flush connection to the shell of condenser, with a • C = function of isentropic coefficient k
broken edge • ξ = addition of pressure loss coefficients ξn of piping
From table A.4 it’s possible to have these data: The coefficients ξn are relevant to:
• ξ1 (inlet) = 0,25 • pipe elements loss, bends
• ξ2 (length) = λ x L/ din = 0,02 x 60/28 = 0,043 • loss along the pipe
with λ = 0,02 for steel tube and are listed in EN 13136:2001/A1:2005 Standard,
• ξT = ξ1 + ξ2 = 0,25 + 0,04 = 0,293 Table A.4
Between safety valve and union it’s installed a shut-off
valve type 3033/88. Example: assume to install a discharge pipe on safety
The main characteristics of this valve are: valve type 3030/88 of the previous example, using a
• dR = 20 [mm], inside diameter steel tube nominal size 1.1/2”GAS with the following
• AR = 314 [mm2], inside area characteristics:
• kv = 20 [m3/h], kv factor • dout = 42,5 [mm], inside diameter
Pressure loss coefficient ξR of shut-off valve is given by: • Aout = 1418 [mm2], inside area
• L = 3000 [mm], length
• pipe bend 90° with bending radius R equal to three times
external diameter of tube
The total pressure loss coefficient is: ξT + ξR = 0,933 From table A.4 it’s possible to have these data:
• ξ1 (bend) = 0,25
We remember the previous calculated flow area, the • ξ2 (length) = λ x L/ din = 0,02 x 3000/42,5 = 1,41 with λ =
characteristics of safety valve 3030/88 and refrigerant 0,02 for steel tube
fluid R407C: • ξT = ξ1 + ξ2 = 0,25 + 1,41 = 1,66
• Ac = 154 [mm2] Pressure loss in the downstream line is:
• Kdr = 0,83 x 0,9 =0,747
• C = 2,51

Pressure loss in the upstream line is:

The obtained value is admissible because lower than the
value of 0,10 forecast in EN 13136:2001/A1:2005 Standard.
The obtained value is admissible because lower than the
value of 0,03 forecast in EN 13136:2001/A1:2005 Standard.

Pressure loss in the downstream line

Calculation of pressure loss is given by:

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 TABLE 2: Dimensions and Weights of valves 3030
Catalogue Dimensions [mm] Weight
Number ØD L Ch H1 H2 H3 [g]

3030/44C 38 38 28 44 115 159 780

3030/66C 38 38 28 44 115 159 780
3030/88C 50 56 40 58 158 216 1960

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 SAFETY VALVES 3060
Disc: obtained through bar machining and equipped with
gasket, it ensures the required sealing degree on the valve
seat. The gasket is made in P.T.F.E. (Polytetrafluorethylene), a
material that, during valve estimated service life, maintains
a good strength and does not cause the disc to stick on the
seat. The disc is properly guided in the body and the guide
action can never fail; there are no glands or retaining rings
that hamper the movement thereof.
Utilized material: EN 12164-CW614N brass

Spring: it opposes the pressure and the fluid dynamic

actions and always ensures valve re-closing after
pressure relief.
Utilized material: DIN 17223-1 steel for springs.

Setting system: hexagonal head, threaded ring nut to be

screwed inside the body top by compressing the spring
below. On setting completion, the position attained by the
ring nut is maintained unchanged laying, in the threaded
coupling, a bonding agent with high mechanic strength
and low viscosity features to make penetration thereof
easier. The setting system is protected against subsequent
unauthorized interventions by means of a cap nut that is
housed into the brass body and is fixed in this seat with an
edge calking operation.

SCOPE
GENERAL DESCRIPTION Use: protection against possible overpressures of the
Valves series 3060 are safety devices according to the apparatuses listed below, with regard to the operating
definition given in Article 1, Point 2.1.3, 2nd dash of 97/23/ conditions for which they have been designed:
EC Directive and are the subject of Article 3, Point 1.4 of • Refrigerating system and heat pump components, for
aforesaid Directive. instance: condensers, liquid receivers, evaporators,
The valves above mentioned are standard type, unbalanced, liquid accumulators, positive displacement compressor
direct-loaded safety valves. Valve opening is produced by discharge, heat exchangers, oil separators, piping.
the thrust the fluid under pressure exerts on the disc, when (reference: EN 378-2:2008 Standard)
said thrust exceeds, under setting conditions, the opposing • Simple pressure vessels (reference: 87/404/ EEC
force of the spring acting on the disc. Directive)
Valves are identified by means of:
• a model number formed of an alphanumerical coding that Fluids: the valves can be used with:
includes: • Refrigerant fluids, in the physical state of gas or vapour,
• in the first part the family identification (e.g. 3060/45C) belonging to Group 2 according to the definitions of
• in the second part the setting pressure, expressed in 97/23/EC Directive, Article 9, Point 2.2 (with reference to
bars, multiplied by 10 (e.g. 140) 67/548/EEC Directive of June 27th, 1967).
• an alphanumerical serial number. • Air and nitrogen (reference: 87/404/EEC Directive)

CONSTRUCTION MARKING
Body: squared, obtained through die forging and subsequent In conformity with the provisions of Article 15 of 97/23/
machining. It houses the following elements: EC Directive the following information are reported on the
• the nozzle with flat sealing seat valve body.
• the disc guide • Manufacturer's mark, address and manufacture country
• the setting spring holder • Indication of flow direction
• the threaded seat of the setting adjusting ring nut • Max allowable pressure
In the body, above the disc guide, a small pressure relief • Set pressure
duct is provided through which the spring holder is put into • Allowable temperature range
contact with the output connection. • Production date
Utilized material: EN 12420-CW617N brass.

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• Serial number VALVE INSTALLATION
The following data are stamped on the cap: Safety valves type 3060 are NOT guaranteed for
• EC marking and the identification number of the reproducibility of performance, this means that after
notified body involved in the production control phase the valves have operated, open/close, the initial setting
• Valve model conditions are NOT maintained. Then it is necessary to
• Flow section replace valve 3060 once it has discharged.
• Kd discharge coefficient For installation of safety valves series 3060 see the previous
chapter of safety valves series 3030.
VALVE SELECTION Utilized material: EN 12164-CW614N brass.
97/23/EC Directive requires that pressure equipment,
in which permissible limits are reasonably likely to
be exceeded, shall be fitted with suitable protection
devices, for instance safety devices such as safety valves.
Such devices shall prevent pressure from permanently
exceeding the max allowable pressure PS of the equipment
they protect. In any case, a short pressure peak limited to
10% of admissible maximum pressure is permitted.
As to the selection and sizing of the suitable protection
device, users shall refer to the specific product and
sector standards.
EN ISO 4126-1: 2004 Standard: “Safety devices for
protection against excessive pressure – Part 1: Safety
valves” , harmonized with 97/23/EC Directive, specifies
general requirements for safety valves irrespective of the
fluid for which they are designed.
EN 378-2 : 2008 Standard “Refrigerating systems and
heat pumps – safety and environmental requirements
– Part 2: Design, construction, testing, marking and
documentation”, harmonized with 97/23/EC Directive,
provides a general outline of the protection devices to be
adopted in refrigerating systems and their features (par.
6.2.5). It also indicates the criteria for the selection of
the device suitable to the type and sizes of the system
component to be protected (par. 6.2.6).
EN 13136:2001/A1:2005 Standard “ Refrigerating systems
and heat pumps – Pressure relief devices and their
associated piping – Methods for calculation” , harmonized
with 97/23/EC Directive, highlights the possible causes of
overpressure in a system and makes available to users the
instruments for pressure relief device sizing, among which
the safety valves.
For sizing of safety valves series 3060 see the previous
chapter of safety valves series 3030.

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 TABLE 3: General Characteristics of valves 3060
Catalogue Number 3060/23C 3060/24C 3060/33C 3060/34C 3060/45C 3060/36C 3060/46C
Inlet male 1/4" NPT 1/4" NPT 3/8" NPT 3/8" NPT 1/2" NPT 3/8" NPT 1/2" NPT
Connections
Outlet male 3/8" SAE 1/2" SAE 3/8" SAE 1/2" SAE 5/8" SAE 3/4" G 3/4" G
Inlet connection wrench torque (min/max) [Nm] 10/15 10/15 14/20 14/20 21/30 14/20 21/30
Flow Diameter [mm] 7,0 9,5 10,0
Flow Section [mm2] 38,5 70,9 78,5
Discharge Coefficient "Kd" 0,63 0,69 0,63 0,69 0,45 0,92 0,93
PS [bar] 55
TS [°C] - 50 / + 150
Set Pressure Range [bar] 9 / 50
Overpressure 10 % of set pressure
Risk Category according to PED IV

TABLE 4: Dimensions and Weights of valves 3060

Catalogue Dimensions [mm] Weight
Number ØD L Ch H1 H2 H3 [g]

3060/23C 21,5 35 20 33,5 46,5 80 180

3060/24C 21,5 35 20 33,5 46,5 80 195
3060/33C 21,5 35 20 33,5 46,5 80 195
3060/34C 21,5 35 20 33,5 46,5 80 195
3060/45C 24,5 39,0 23 37 52,5 89 240
3060/36C 30 40 27 37 59,5 96,5 360
3060/46C 30 40 27 40 59,5 99,5 380

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 BALL SHUT−OFF VALVES FOR SAFETY VALVES
Any intervention for periodic checking or replacement of an
installed safety valve becomes very difficult if the protected
vessel is not equipped with a shut-off valve.
The shut-off valves series 3033 and 3063, installed
between vessel and safety valve, allow removing the valve
for periodic checking or replacement without blowing off all
the refrigerant from a section of the system. These valves
can be used with the same fluids foreseen for safety valves
series 3030 and 3060, in particularly:
• Refrigerant fluids, in the physical state of gas or vapour,
belonging to Group 2 according to the definitions of
97/23/EC Directive, Article 9, Point 2.2 (with reference to
67/548/EEC Directive of June 27th, 1967).
• Air and nitrogen (reference: 87/404/EEC Directive)

CONSTRUCTION
Castel supplies to its customers the valves series 3033 and
3063 in open position and the ball spindle is protected by
means of a cap screwed to the body and sealed with lead to
it. Any closing intervention on the valve forcedly causes the
tampering of the seal and then these interventions shall be
performed exclusively by:
• staff authorized to work on the system
• public servant of a Competent Body
These persons will be responsible for the next valve
reopening and the new cap sealing with their own lead.

APPLICATIONS The main parts of these valves are made with the
We would like to remember to our customer that the running following materials:
of pressure equipments and pressure assemblies is excluded • Hot forged brass EN 12420 – CW 617N for body
by the scope of Directive 97/23/EC but it‘s regulated in • Hot forged brass EN 12420 – CW 617N, chromium plated,
compliance with national regulations of Member States of for ball
European Communities. • Steel, with proper surface protection, for the spindle.
We think that these regulations, actually on updating with • P.T.F.E. for seat ball gaskets
the Competent Bodies of all the states to avoid conflicts with • Chloroprene rubber (CR) for outlet seal gaskets
the ESR of PED, could provide for periodical checks on the • Glass reinforced PBT for cap that covers the spindle
pressure equipments and assemblies.

ed. 001-DS-ENG SAFETY DEVICES FOR REFRIGERATING SYSTEMS

16
 TABLE 5: General Characteristics, Dimensions and Weights of valves 3033, 3063
TS [°C] Dimensions [mm] Inlet connection Risk
Kv
Catalogue Designed PS wrench torque Weight Category
Factor
Number for valve [bar] (min/max) [g] according
[m3/h] min max ØD A C L H1 H2 H3 [Nm] to PED

3060/23C 1/4"
3063/22 2,5 7 78 58 39,5 77,5 155 10/15 500
3060/24C NPT
3060/33C 3/8"
3063/33 5 10 78 58 39,5 77,5 155 14/20 530
3060/34C NPT
3060/45C
3063/44 5 -50 +150 55 10 78 58 44,5 84,5 162 21/30 560 Art. 3.3
3060/46C 1/2"
NPT
3033/44 3030/44C 10 13 101 73 59 100 245 21/30 710

1"
3033/88 3030/88C 20 20 107 77 72 123 323 50/65 1070
NPT

SAFETY DEVICES FOR REFRIGERATING SYSTEMS ed. 001-DS-ENG

17
 CHANGEOVER DEVICES FOR SAFETY VALVES
These components ensure the perfect alignment of two
safety valves 3060/33 or 3060/34 or 3060/36.
Valve type 3032/44 is supplied with:
• Two female threaded connections 1/2” NPT with swivel
nut, code Castel 3039/4
• two O-Ring
These components ensure the perfect alignment of two
safety valves 3060/45 or 3060/46.
The valves series 3032 can be used with the same fluids
foreseen for safety valves series 3030 and 3060, in
particularly:
• Refrigerant fluids, in the physical state of gas or vapour,
belonging to Group 2 according to the definitions of
97/23/EC Directive, Article 9, Point 2.2 (with reference to
67/548/EEC Directive of June 27th, 1967).
• Air and nitrogen (reference: 87/404/EEC Directive)

CONSTRUCTION
The valve 3032 is designed so that it is never possible to
close off both ports at the same time, excluding all the two
safety valves. Under working conditions, the shutter must
be clamped against one of the two seats of the valve, front
port or back port, in order to ensure always full discharge
to the corresponding safety valve. Intermediate positions
of the shutter are not acceptable in order not to affect the
operation of both safety valves. The valve ensures a pressure
drop perfectly compatible with the safety valve operation
APPLICATIONS under conditions of discharge of saturated vapour as well
The changeover device type 3032 is a service valve for as overheated vapour.
dual pressure relief valves that allows using one valve while The main parts of these valves are made with the following
isolating the other from the system. This device allows the materials:
user to work on the isolated valve, for periodic checking or • Hot forged brass EN 12420 – CW 617N for body
replacement, while the system is completely operative and • Steel, with proper surface protection, for the spindle
the other valve is in service. • Chloroprene rubber (CR) and aramidic fibers for gland seal
N.B. : each safety valve placed on a changeover device must • Chloroprene rubber (CR) for outlet seal gaskets
have sufficient capacity to protect the vessel alone. • Glass reinforced PBT for cap that covers the spindle
Valve type 3032/33 is supplied with:
• Two female threaded connections 3/8” NPT with swivel
nut, code Castel 3039/3
• two O-Ring

ed. 001-DS-ENG SAFETY DEVICES FOR REFRIGERATING SYSTEMS

18
 TABLE 6: General Characteristics, Dimensions and Weights of valves 3032
TS [°C] Dimensions [mm] Inlet connec- Risk
Kv
Catalogue Designed PS tion wrench Weight Category
Factor
Number for valve [bar] torque (min/ [g] according
[m3/h] min max D A B H1 H2 L1 L2 L3 max) [Nm] to PED
3060/33C
3/8" 3/8"
3032/33 3060/34C 2,5 13 117 45 33 91 50 14/20 775
NPT NPT
3060/36C
3060/45C 1/2" 1/2"
3032/44 3,3 13 117 45 33 91 50 21/30 775
3060/46C NPT NPT
3/4" 1/2"
3032/64 3030/44C 9,0 17,5 95 52 48 133 80 32/45 1750
NPT NPT
-50 +150 55 Art. 3.3
3/4" 3/4"
3032/66 3030/66C 9,0 17,5 95 52 48 133 80 32/45 1750
NPT NPT
1" 1"
3032/88 14,5 22,0 120 71 66 185 110 50/65 3200
NPT NPT
3030/88C
1. 1/4" 1"
3032/108 20,0 31,0 123 74 66 185 110 60/80 3200
NPT NPT

SAFETY DEVICES FOR REFRIGERATING SYSTEMS ed. 001-DS-ENG

19
 SAFETY VALVES UNIONS
Unions series 3035 allow assembling safety valves series
3030 and 3060 or shut-off valves series 3032, 3033 and
3063 close to the pressure equipments to protect, set up in
a refrigerating system.
These unions are designed for installations according to the
following two ways:
• Make a copper tube jointing the pressure equipment to the
union, fit the end of this tube into the solder connection of
the union and then make a capillary brazing.
• Drill the inner/outer pipe close to the pressure equipment
(if possible make a collar on the pipe), put the end of the
union into this drill and then make a braze welding.
The unions series 3035 are machined by brass bar EN
12164-CW614N

TABLE 7: General Characteristics, Dimensions and Weights of unions 3035

Connections Dimensions [mm]
Catalogue PS Weight
Number ODS [bar] [g]
NPT D L Ch
Ø [mm]
3035/2 1/4” 12 18 33 21 58
3035/3 3/8” 18 22 36,5 26 90,5
3035/4 1/2” 22 28 44 32 165
55
3035/6 3/4” 28 35 51 40 255
3035/8 1” 35 42 72 45 364
3035/10 1.1/4" 42 54 67 55 613

ed. 001-DS-ENG SAFETY DEVICES FOR REFRIGERATING SYSTEMS

20
 BURSTING DISC SAFETY DEVICES 3070
Standard, to burst at an established pressure. This pressure
is called specified burst pressure, quoted with a coincident
temperature and with a performance tolerance. The disc is
manufactured with a sheet of material of calibrated width,
Nickel, contained in a copper ring case.

SCOPE
Use: protection against possible overpressures of the
apparatuses listed below, with regard to the operating
conditions for which they have been designed:
• Refrigerating system and heat pump components, for
instance: condensers, liquid receivers, evaporators,
liquid accumulators, positive displacement compressor
discharge, heat exchangers, oil separators, piping.
(reference: EN 378-2:2008 Standard)
Fluids: the valves can be used with:
• Refrigerant fluids, in the physical state of gas or vapour,
belonging to Group 2 according to the definitions of
97/23/EC Directive, Article 9, Point 2.2 (with reference to
67/548/EEC Directive of June 27th, 1967)

MARKING
In conformity with the provisions of Article 15 of 97/23/
EC Directive the following information are reported on the
bursting disc holder.
• Manufacturer's mark
• EC marking and the identification number of the notified
GENERAL DESCRIPTION body involved in the production control phase
Bursting disc safety devices 3070 are safety devices • Valve model
according to the definition given in Article 1, Point 2.1.3, 2nd • Flow section
dash of 97/23/EC Directive and are the subject of Article 3, • Indication of flow direction
Point 1.4 of aforesaid Directive. • Bursting pressure
Safety device 3070 is a non-reclosing pressure relief device • Performance tolerances
where the bursting disc is sensitive to a positive differential • Coincident temperature to bursting pressure
pressure between upstream and downstream and it is • Production date
designed to burst at a specified pressure. • Lot number
Safety devices 3070 are identified by means of:
• a model number formed of an alphanumerical coding that
includes:
BURSTING DISC DEVICES SELECTION
97/23/EC Directive requires that pressure equipment,
• in the first part the family identification (e.g. 3070/44C)
in which permissible limits are reasonably likely to be
• in the second part the setting pressure, expressed in
exceeded, shall be fitted with suitable protection devices, for
bars, multiplied by 10 (e.g. 140)
instance safety devices such as bursting disc safety devices.
• a serial number for lot production
Such devices shall prevent pressure from permanently
exceeding the max allowable pressure PS of the equipment
CONSTRUCTION they protect. In any case, a short pressure peak limited to
Bursting disc holder: it is the body of the device, 10% of admissible maximum pressure is permitted.
manufactured in two half parts screwed together, that holds The bursting disc safety device 3070 may be used either as
the bursting disc in the proper position. The two half bodies sole pressure relief device or in conjunction with a Castel
are obtained through bar machining; the lower body houses safety valve (types 3030 e 3060). The combination disc
the inlet connection, while the upper body houses the outlet plus valve prevents the refrigerant leakage through the
connection and two service pressure 1/8”NPT. safety valve and the total loss of refrigerant after the disc
burst. This combination may be also equipped with a proper
Bursting disc: The discs are designed and tested, pressure switch to detect if the valve has discharged.
according to the requirements of EN ISO 4126-2:2003

SAFETY DEVICES FOR REFRIGERATING SYSTEMS ed. 001-DS-ENG

21
The bursting pressure of the safety device 3070 is affected with:
by the operating temperature of fluid contained into the • Ac = minimum flow area of bursting disc [mm2]
equipment to be protected. The specified bursting pressure • Qmd = minimum required discharge capacity of bursting
Pb, stamped on the body, is the nominal bursting pressure disc [kg/h]
at the coincident temperature of 22 °C: At higher operating • α = bursting disc coefficient of discharge
temperatures the nominal bursting pressure is reduced • po = relieving pressure. [bar abs]
while at lower operating temperatures the nominal bursting • vo = specific volume of gas or vapour at relieving
pressure is increased. Refer to table 1 for temperature conditions po e To, meaning with To fluid temperature at
adjustment factors of Pb. valve inlet, settled by the user or by the designer. [m3/kg]
As to the selection and sizing of the suitable protection • C = function of isentropic coefficient k. To calculate
device, users shall refer to the specific product and sector C and to find the values of k and C for the more useful
standards. refrigerants, see the chapter of safety valves series 3030
EN ISO 4126-2: 2003 Standard: “Safety devices for
protection against excessive pressure – Part 2: Bursting disc EN ISO 4126-6:2003 Standard establishes different
safety devices” , specifies general requirements for design, values for the coefficient of discharge “α” depending on
manufacturing, inspection, testing, certification, marking, the nozzle entry configuration where the bursting disc is
packaging of bursting disc safety devices mounted. The following cases are shown in the aforesaid
EN ISO 4126-3: 2006 Standard: “Safety devices for protection Standard, Par. C.2.2.1:
against excessive pressure – Part 3: Safety valves and • In case of an internally protruding branch/nozzle: α = 0,68
bursting disc safety devices in combination”, harmonized • In case of a flush branch/nozzle whose inlet is not of
with 97/23/EC Directive, specifies general requirements for hydrodynamic configuration: α = 0,73
design, application and marking for a product assembled • In case of a branch/nozzle with rounded or chamfered
from the in-series combination of safety valve and bursting inlets (hydrodynamic configuration): α = 0,80
disc safety device.
EN ISO 4126-6: 2003 Standard: “Safety devices for Calculation of minimum required discharge capacity of
protection against excessive pressure – Part 6: Application, bursting disc safety device is closely linked to the type of
selection and installation of bursting disc safety devices” , system where the valve is installed, with the causes that
gives guidance on the application, selection and installation may arouse the opening of safety device, i.e.:
of bursting disc safety devices used to protect pressure • External heat sources
equipment from excessive pressure • Internal heat sources
EN 378-2 : 2008 Standard “Refrigerating systems and heat • Excessive pressure caused by compressors
pumps – safety and environmental requirements – Part 2: For the calculation of minimum required discharge
Design, construction, testing, marking and documentation”, capacity in these three cases see the chapter of safety
harmonized with 97/23/EC Directive, provides a general valves series 3030.
outline of the protection devices to be adopted in refrigerating
systems and their features (par. 6.2.5). It also indicates the SIZING OF COMBINATED SAFETY DEVICES
criteria for the selection of the device suitable to the type DESIGNED TO DISCHARGE GAS OR VAPOUR AT
and sizes of the system component to be protected (par.
6.2.6). CRITICAL FLOW (Ref. . EN ISO 4126-3: 2006)
EN 13136:2001/A1:2005 Standard “ Refrigerating systems The combination is an installation which comprises
and heat pumps – Pressure relief devices and their a bursting disc safety device installed within five pipe
associated piping – Methods for calculation” , harmonized diameters before the inlet of a safety valve. The combination
with 97/23/EC Directive, highlights the possible causes of of a specified safety valve with a bursting disc device is
overpressure in a system and makes available to users the characterized by a combination discharge capacity factor
instruments for pressure relief device sizing, among which “Fd”. According to EN ISO 4126-3: 2006 Standard the
the safety valves. coefficient “Fd” is the ratio of the average of coefficients
of discharge “Kd” of combination, determined by the
combination tests, to the certified coefficient of discharge
SIZING OF BURSTING DISC DEVICES DESIGNED “Kd” of the sole safety valve.
TO DISCHARGE GAS OR VAPOUR AT CRITICAL As a alternative to testing to determine the “Kd” factor of
FLOW (Ref. . EN ISO 4126-6: 2003) the combination, the same standard permits the use of a
For the definition of critical flow see the chapter of safety default combination discharge capacity factor of 0,9, value
valves series 3030. A bursting disc safety device, which quite lower than the one obtained from testing. Then to size
discharges to atmosphere, works in critical flow. a combination, safety valve /3030 or 3060) with bursting
The bursting disc device designed to discharge gas or disc safety device (3070), follow the calculation indicated
vapour at critical flow must be sized as follow: in the chapter of safety valve 3030 , but multiply for 0,9 the
certified coefficient of discharge “Kd”.

ed. 001-DS-ENG SAFETY DEVICES FOR REFRIGERATING SYSTEMS

22
INSTALLATION OF BURSTING DISC DEVICES
AND COMBINATIONS
Never expose a 3070 safety device to a negative
differential pressure between upstream and
downstream (for example equipment internal pressure
lower than atmospheric pressure) to avoid possible
damage to the disc. For this reason the 3070 safety
device must always used coupled with a shut-off
device (for example 3033/44 ball valve), so it is possible
to exclude the 3070 device every time it is necessary to
make vacuum in the equipment to be protected.

When the bursting disc discharges it is necessary the

replace all the safety device because 3070 devices are a
sealed components with not replaceable bursting disc.

Max operating pressure of equipment to be protected

shall be no more than 75 % of burst pressure of
safety device 3070, to avoid disc damages o leakage.
If operating pressure exceeds 85 % of burst pressure,
safety device 3070 should be replaced immediately.

As far as the installation of bursting disc safety devices and

combination devices is concerned, the fundamental points
listed below shall be taken into account:
• Safety devices shall be installed near an area of the
system where vapours or gases are present and there is
no fluid turbulence.
• Vessels, joined together with piping rightly selected by the
manufacturer and without any stop valve between them,
may be considered as only one vessel for the installation
of a safety device.
• The union between the combination and the equipment to
be protected shall be as short as possible. Furthermore, its
passage section shall not be narrower than the valve inlet
section. In any case, EN 13136:2001/A1:2005 Standard
states that the pressure loss between protected vessel
and combination, at discharge capacity, shall not exceed
3% of the setting value, including any accessory mounted
on the upstream line.
• In selecting the safety device location, it shall be taken into
account that its operation involves the discharge of the
refrigerant fluid under pressure, sometimes even at high
temperature. Where the risk exists to cause direct injuries
to the persons nearby, an exhaust conveying piping shall
be provided, which shall be sized in such a way as not to
compromise device operation. EN 13136:2001/A1:2005
Standard states that this piping shall not generate, at
discharge capacity, a back pressure exceeding 10% of
pressure po , for standard type valves, unbalanced.
To calculate the pressure loss either in the upstream line
(between vessel and safety valve) or in the downstream
line (between safety valve and atmosphere) refer to EN
13136:2001/A1:2005 Standard, Chapter 7.4.

SAFETY DEVICES FOR REFRIGERATING SYSTEMS ed. 001-DS-ENG

23
 TABLE 1: General Characteristics of rupture discs 3070
Catalogue Number 3070/44
Inlet male 1/2" NPT

Connections Outlet female 1/2" NPT

Service 2 x 1/8" NPT

Inlet connection wrench torque (min/max) [Nm] 21/30
Flow Diameter [mm] 12
Flow Section [mm2] 113
TS [°C] - 50 / + 150
14
16
21
Bursting Pressure Pb [bar] 24
24,8
27,5
28
from 14 up to bar +/- 15 %
Pb tolerance
from 24 up to 28 bar +/- 10%
Coincident temperature Ta [°C] 22
-50 °C 1,13
-35 °C 1,12
-25 °C 1,10
-10 °C 1,03
-0 °C 1,03
Correction factor of Pb
22°C 1,00
for Ta ≠ 22 °C
40°C 0,99
60 °C 0,97
80 °C 0,95
100 °C 0,94
150 °C 0,93
Max operating pressure 75 % Pb
Risk Category according to PED IV

ed. 001-DS-ENG SAFETY DEVICES FOR REFRIGERATING SYSTEMS

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 FUSIBLE PLUGS
SCOPE
Use: the fusible plugs are basically used to protect the
components in a refrigerating system or heat pump against
possible overpressures, with regard to the operating
conditions for which they have been designed, in case of an
excessive external heat source, such as fire (point [Link] of
EN 378-2:2008)
Fluids: the fusible plugs can be used with refrigerant fluids
belonging to Group 2 according to the definitions of 97/23/
EC Directive, Article 9, Point 2.2 (with reference to 67/548/
EEC Directive of June 27th, 1967).

MARKING
In conformity with the provisions of Article 15 of 97/23/EC
Directive and of Point 7.3.3 of EN 378-2:2008 Standard the
following data are reported on the hexagonal nut:
• EC marking
• Manufacturer's logo
• Max allowable pressure PS
• Melting point

INSTALLATION
If a fusible plug is mounted on a pressure vessel or any other
part which it protect it shall be placed in a section where
superheated refrigerant would not affect its correct
function. Fusible plug shall not be covered by thermal
insulation. Discharge from fusible plugs shall take place
GENERAL DESCRIPTION so that persons and property are not endangered by the
Fusible plugs series 3080/.C and 3082/.C are safety devices
released refrigerant. (point. [Link] of EN 378-2:2008)
according to the definition given in Article 1, Point 2.1.3, 2nd
EN 378-2:2008 Standard, harmonized with the 97/23/EC
dash of 97/23/EC Directive and are the subject of Article 3,
Directive, establishes that a fusible plug shall not be used
Point 1.4 of aforesaid Directive.
as pressure relief device on vessels containing refrigerants
According to the definition given in Point 3.6.4 of EN 378-
proper to A2 , B1 , B2 , A3 e B3 groups. The same Standard
1:2008 Standard, fusible plug is a device containing material
establishes that a fusible plug shall not be used as the sole
that melts at a predetermined temperature and thereby
pressure relief device between a refrigerant containing
relieving the pressure.
component and the atmosphere for systems with a
Castel has resolved to classify fusible plugs series 3080/.C
refrigerant charge larger than 2,5 kg of group A1 refrigerant
and 3082/.C in the Category of Risk I therefore fixing their
(ex. R22 ; R134a ; R404A ; R407C ; R410A ; R507).
use, as protection devices, on specific pressure equipments,
proper to the same Category of Risk I , in compliance with
Annex II, Point 2, of 97/23/EC Directive. FUSIBLE PLUG SELECTION
In consequence of this choice, fusible plugs series 3080/.C 97/23/EC Directive requires that pressure equipment,
and 3082/.C cannot be used, as sole protection devices, in which permissible limits are reasonably likely to be
on pressure equipments proper to Categories of Risk higher exceeded, shall be fitted with suitable protection devices, for
than first. instance safety devices such as fusible plugs. Such devices
shall prevent pressure from permanently exceeding the max
allowable pressure PS of the equipment they protect. In any
CONSTRUCTION case, a short pressure peak limited to 10% of admissible
The body of the fusible plug is an NPT plug drilled with a
maximum pressure is permitted.
taper hole. A predetermined quantity of fusible alloy, with
As to the selection and sizing of the suitable protection
checked melting point, is poured inside this hole.
device, users shall refer to the specific sector or product
The parts of the fusible plugs are made with the following
standards.
materials:
EN 378-2:2008 Standard “Refrigerating systems and heat
• Brass EN 12164 – CW 614N, hot tinned, for the plug
pumps – safety and environmental requirements – Part 2:
• Eutectic alloy with several components, cadmium free, for
Design, construction, testing, marking and documentation”
the fusible material

SAFETY DEVICES FOR REFRIGERATING SYSTEMS ed. 001-DS-ENG

25
provides a general outline of the protection devices to be • C = function of isentropic coefficient k (as measured
adopted in refrigerating systems and their features (par. at 25 °C, see Section 7.2.3, EN 13136:2001/A1:2005)
6.2.5). It also indicates the criteria for the selection of calculated from:
the device suitable to the type and sizes of the system
component to be protected (par. 6.2.6).
EN 13136:2001/A1:2005 Standard “ Refrigerating systems
and heat pumps – Pressure relief devices and their
associated piping – Methods for calculation”, harmonized To find the values of k and C for the more useful
with 97/23/EC Directive, highlights the possible causes of refrigerants, see the chapter of safety valves series 3030.
overpressure in a system and makes available to users the Calculation of minimum required discharge capacity of
instruments for pressure relief device sizing, among which fusible plug is closely linked to the main cause that may
the fusible plugs. arouse the opening of fusible plug, which is the external
heat source.
The minimum required discharge capacity shall be
SIZING OF FUSIBLE PLUGS (Ref. EN 13136:2001/ determined by the following:
A1:2005)
As the fusible plugs discharge to atmosphere, they always
work in critical flow (to know the definition of critical flow,
see the chapter of safety valves series 3030). with:
The fusible plugs must be sized as follow: • φ = density of heat flow rate, it’s assumed to be
10 [kW/m2]
• Asurf = external surface area of the vessel [m2]
• hvap = heat of vaporization of liquid at po [kJ/kg]
with:
• Ac = minimum flow area of fusible plug [mm2] EN 13136:2001/A1:2005 also establishes that the following
• Qmd = minimum required discharge capacity, of refrigerant, values for Kdr shall be the maximum used depending on
of fusible plug [kg/h] how the pipe between the vessel and the fusible plug is
• Kdr =derated coefficient of discharge of fusible plug, mounted on the vessel:
equal to 0,9 x Kd • flush or flared connection: Kdr = 0,70
• po = pressure upstream the fusible plug, inside the • flush or flared connection: Kdr = 0,55
equipment to be protected [bar abs]
• vo = specific volume of gas or vapour at relieving
conditions po e To, [m3/kg] (To is the fluid temperature at
plug inlet, settled by the user or by the designer)

TABLE 8: General Characteristics, Dimensions and Weights of fusible plugs 3080 and 3082
Maximum Wrench Risk
NPT Flow Flow Melting PS
Catalogue working Hexago- Torque Weight Category
Connec- Diameter Section Kd Point [bar]
Number temperature nal Key min/max [g] according
tions [mm] [mm2] [°C] (1)
[°C] [Nm] to PED
3080/1C 1/8" 4,9 18,8 12 7 / 10 11
3080/2C 1/4” 5,7 25,5 10 / 15 23
79 68 42 17
3080/3C 3/8” 8,5 56,7 14 / 20 39
3080/4C 1/2” 9,3 67,9 22 21 / 30 76
0,91 I
3082/1C 1/8" 4,9 18,8 12 7 / 10 11
3082/2C 1/4” 5,7 25,5 10 / 15 23
138 127 30 17
3082/3C 3/8” 8,5 56,7 14 / 20 39
3082/4C 1/2” 9,3 67,9 22 21 / 30 76

(1) : at maximum working temperature

ed. 001-DS-ENG SAFETY DEVICES FOR REFRIGERATING SYSTEMS

26
 [Link]

Castel Srl
ed. 001-DS-ENG SAFETY DEVICES FOR REFRIGERATING SYSTEMS
ed. 001-DS-ENG Via Provinciale 2-4 - 20060 Pessano con Bornago - MI