Lower Total Cost of Ownership, Increased Operating Efficiency, and a Smaller Carbon Footprint: Why the Consolidated 2900 Series Gen II POSRV Is a Game-Changer

Valve technology doesn’t change all that frequently. But every once in a while, a new technology appears that truly changes the game. Consolidated’s 2900 Series Gen II pilot-operated safety relief valve is one of these game changers.

This innovative valve provides all of the benefits of pilot-operated valves without the cost or hassle of having to make piping modifications.

In a video for the 2900 Gen II launch, Baker Hughes Senior Product Manager Brian Burkhart laid out how this valve solves many of the challenges customers in industries like chemical and petrochemical, refinery, LNG, and pulp and paper face every day. This article provides an overview. For details or if you have any questions, watch the video or contact our valve experts.

Industrial customers’ biggest challenges

No matter what industry they’re in, industrial processors all have similar goals: they want to increase profits by boosting efficiency and reducing costs. In particular, Baker Hughes found that customers were looking for two main things when selecting pressure relief valves.

Reducing their total cost of ownership

Total cost of ownership (TCO) looks beyond the initial cost investment in the equipment, installation, and commissioning to what the product costs over its entire life cycle. For PRVs, those costs can include the following:

  • Service and maintenance
  • Replacing damaged bellows
  • Lapping the nozzle and disc on metal-seated valves to check for leaks
  • Wasted process due to seat leakage
  • Repairing or replacing damaged equipment

Economically reducing their carbon footprint

Naturally, industrial processors want to boost their operating efficiency. This is the key to increasing profits. But they also want to reduce their carbon footprint by curbing fugitive emissions.

As Burkhart points out, these goals are sometimes in conflict with one another. Increasing operating efficiency typically means running systems closer to their set pressure, which can result in more fugitive emissions. On the other hand, running systems at a lower pressure is beneficial for your carbon footprint, but not for your bottom line.

How the Consolidated 2900 Series Gen II POSRV Tackles These Challenges

Consolidated 2900 Gen II

The new 2900 features several design innovations that solve both of the challenges above.

Centerline-to-face dimensions compatible with any API 526 valve = no piping modifications required

Upgrading “bad actor” direct-spring API 526 valves to pilot-operated safety relief valves is one way to improve performance. The problem with most POSRVs, however, is that they won’t fit easily into the space occupied by direct-spring PRVs. The centerline-to-face dimensions aren’t ready for a pilot valve, which means piping modifications are necessary. This takes the TCO up, not down.

The 2900 Series Gen II POSRV is the first and only drop-in solution for direct-spring API 526 valves. Its centerline-to-face dimensions are compatible with any API 526 valve. This feature alone can reduce installation costs between $5,000 and $15,000.

Full-nozzle pilot = lower cost of materials and maintenance

Unlike most pilots, the 2900 Gen II has a full nozzle that sticks out the bottom and isolates the valve body from coming into contact with corrosive service. This means you can save money by using lower-cost body materials.

Maintenance is also simplified because the nozzle easily threads in and out of the body.

Integral sense configuration = lower TCO

On other full-nozzle valves, there’s the potential for the nozzle to not fully align with the sensing tube. The 2900 Gen II default recommended configuration includes an integral sense ring that wraps around the nozzle (as opposed to sitting beneath it) and can spin freely. The integral sense ring picks up the pilot valve pressure, ensures the 2900 Gen II will match all API 526 direct spring PRV centerline-to-face dimensions, and guarantees perfect alignment following assembly and service.

True zero leakage modulating pilot comes standard

A typical POSRV uses internal modulating technology. At around 95% of set pressure, the valve will enter the null zone and then relieve into the pilot and the atmosphere, causing fugitive emissions.

The 2900 Gen II uses all-time modulating technology. It waits until the system reaches 100% of set pressure and then drops immediately to the dome pressure when it’s time to relieve. This allows facilities to operate more efficiently and also reduce their carbon footprint.

As you can see, the Consolidated 2900 Gen II really does change the game for industrial facilities.

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