consolidated pilot operated safety valve free sample

The 2900/2900 TM Series Gen II is a full-nozzle pilot-operated safety relief valve (POSRV) matching API 526 direct-spring PRV dimensions. Its patented full-nozzle integral sense design allows for easy maintenance as well as simple spring-loaded to pilot-operated PRV conversions throughout the lifecycle of the valve. The 2900 Triple Media (TM) Series is the first full nozzle POSRV engineered to perform on liquid, air/gas, and steam media and is multi-media certified to meet multiple media capacity stamping per ASME B & PVC Code Case 2787. Both valve series use the same pilot valve technology as the 3900 Series including the ‘True Zero Leakage’ modulating pilot, providing a modernized overpressure protection solution for reducing carbon footprint and emissions.

Maximizes throughput by allowing economizer to operate at higher pressures with the use of pilots without seat leakage. Increases efficiency by providing repeatable seat tightness.

For overpressure protection of economizers when a liquid certified safety relief valve or pilot operated safety relief valve cannot be used due to a steam relief scenario. ASME Section 1 certified on steam and water per ASME Code Case 2446.

Safety relief valves often serve as the point-of-protection against potentially dangerous circumstances, so it is important that they be dependable. GE Energy’s Consolidated safety relief valves have maintained a reputation for excellence and reliability for more than a century.

The Consolidated product line has demonstrated a number innovative solutions, too. Safety relief valve innovations from the product line include the Thermodisc® temperature compensating disc and the first modular pilot-operated valve.

GE’s unique pilot valve design combines enhanced performance, capabilities and features within an economical, modular assembly. The 3900 series valve design provides an optimized safety system that offers application versatility while providing cost-effective standardization.

The 2900 series pilot-operated safety relief valve is another innovative Consolidated product line offering from GE, a world leader in pressure relief valve technology. The 2900 series valve is a blend of

GE’s Consolidated pilot valve has a unique design that combines top performance, capabilities and features within an economical, modular assembly. This is based on the successful design of an optimized safety “system” that offers versatility of application, yet provides cost-effective standardization.

GE’s Consolidated* 1982 Series Safety Relief Valves are designed and manufactured in compliance with ASME B & PVC, Section VIII and Section III (Class I, II and III). Mainly used for steam and liquid applications.

Our comprehensive portfolio of safety valves can help to run operations smoothly and cost effectively, particularly in steam service environments. Consolidated safety valves feature a unique pop-action release that can relieve steam over-pressurization if pressures upstream from the valve reach a set point.

What is more, GE’s Consolidated safety valves comply with the ASME Section I code for boiler applications. They are built with many features that meet ASME requirements for steam-compressible fluids. For example, all models feature a lifting lever, required by the code for testing, instead of deadweight or weighted levers. Consolidated safety valves can also withstand set pressures up to 103 percent with a blowdown value of 4 percent, or 96 percent of set pressure drop before the valve re-seats.

The type 1900-30 valve includes the addition of a balanced bellows that is necessary to compensate for the effects of variable back pressure. By isolating the upper structure and allowing the use of less expensive materials, the bellows is also a cost-effective solution in applications where the valve is exposed to highly viscous or corrosive fluids.

The type 1900-DA valve contains an additional O-ring seat seal. This soft seat is the primary seal and it allows the valve to remain leak free at 95 percent of set pressure over 100 psig (6.89 barg). A backup metal seat provides additional safety for fire-relief applications when O-rings can be destroyed by high temperature exposure.

GE’s Consolidated* 19000 Series valves are designed and manufactured in compliance with ASME B & PVC, Section VIII and Section III (Class I, II and III), and are CE compliant to the European Pressure Equipment Directive 97/23/EC.

Improved leak protection and safety. A soft seat design feature helps keep the valve leak free at 95 percent of set pressure over 100 psig., while a backup metal seat provides additional safety.

Compliance to API Standard 526-2002. These valves comply with API Standard 526 Fifth edition, 2002. When required for replacement , Consolidated 1900/P series valves are also available with connections and dimensions in accordance with supplanted API Standard Third edition 1984 and prior editions.

A little product education can make you look super smart to customers, which usually means more orders for everything you sell. Here’s a few things to keep in mind about safety valves, so your customers will think you’re a genius.

A safety valve is required on anything that has pressure on it. It can be a boiler (high- or low-pressure), a compressor, heat exchanger, economizer, any pressure vessel, deaerator tank, sterilizer, after a reducing valve, etc.

There are four main types of safety valves: conventional, bellows, pilot-operated, and temperature and pressure. For this column, we will deal with conventional valves.

A safety valve is a simple but delicate device. It’s just two pieces of metal squeezed together by a spring. It is passive because it just sits there waiting for system pressure to rise. If everything else in the system works correctly, then the safety valve will never go off.

A safety valve is NOT 100% tight up to the set pressure. This is VERY important. A safety valve functions a little like a tea kettle. As the temperature rises in the kettle, it starts to hiss and spit when the water is almost at a boil. A safety valve functions the same way but with pressure not temperature. The set pressure must be at least 10% above the operating pressure or 5 psig, whichever is greater. So, if a system is operating at 25 psig, then the minimum set pressure of the safety valve would be 30 psig.

Most valve manufacturers prefer a 10 psig differential just so the customer has fewer problems. If a valve is positioned after a reducing valve, find out the max pressure that the equipment downstream can handle. If it can handle 40 psig, then set the valve at 40. If the customer is operating at 100 psig, then 110 would be the minimum. If the max pressure in this case is 150, then set it at 150. The equipment is still protected and they won’t have as many problems with the safety valve.

Here’s another reason the safety valve is set higher than the operating pressure: When it relieves, it needs room to shut off. This is called BLOWDOWN. In a steam and air valve there is at least one if not two adjusting rings to help control blowdown. They are adjusted to shut the valve off when the pressure subsides to 6% below the set pressure. There are variations to 6% but for our purposes it is good enough. So, if you operate a boiler at 100 psig and you set the safety valve at 105, it will probably leak. But if it didn’t, the blowdown would be set at 99, and the valve would never shut off because the operating pressure would be greater than the blowdown.

All safety valves that are on steam or air are required by code to have a test lever. It can be a plain open lever or a completely enclosed packed lever.

Safety valves are sized by flow rate not by pipe size. If a customer wants a 12″ safety valve, ask them the flow rate and the pressure setting. It will probably turn out that they need an 8×10 instead of a 12×16. Safety valves are not like gate valves. If you have a 12″ line, you put in a 12″ gate valve. If safety valves are sized too large, they will not function correctly. They will chatter and beat themselves to death.

Safety valves need to be selected for the worst possible scenario. If you are sizing a pressure reducing station that has 150 psig steam being reduced to 10 psig, you need a safety valve that is rated for 150 psig even though it is set at 15. You can’t put a 15 psig low-pressure boiler valve after the reducing valve because the body of the valve must to be able to handle the 150 psig of steam in case the reducing valve fails.

The seating surface in a safety valve is surprisingly small. In a 3×4 valve, the seating surface is 1/8″ wide and 5″ around. All it takes is one pop with a piece of debris going through and it can leak. Here’s an example: Folgers had a plant in downtown Kansas City that had a 6×8 DISCONTINUED Consolidated 1411Q set at 15 psig. The valve was probably 70 years old. We repaired it, but it leaked when plant maintenance put it back on. It was after a reducing valve, and I asked him if he played with the reducing valve and brought the pressure up to pop the safety valve. He said no, but I didn’t believe him. I told him the valve didn’t leak when it left our shop and to send it back.

If there is a problem with a safety valve, 99% of the time it is not the safety valve or the company that set it. There may be other reasons that the pressure is rising in the system before the safety valve. Some ethanol plants have a problem on starting up their boilers. The valves are set at 150 and they operate at 120 but at startup the pressure gets away from them and there is a spike, which creates enough pressure to cause a leak until things get under control.

If your customer is complaining that the valve is leaking, ask questions before a replacement is sent out. What is the operating pressure below the safety valve? If it is too close to the set pressure then they have to lower their operating pressure or raise the set pressure on the safety valve.

Is the valve installed in a vertical position? If it is on a 45-degree angle, horizontal, or upside down then it needs to be corrected. I have heard of two valves that were upside down in my 47 years. One was on a steam tractor and the other one was on a high-pressure compressor station in the New Mexico desert. He bought a 1/4″ valve set at 5,000 psig. On the outlet side, he left the end cap in the outlet and put a pin hole in it so he could hear if it was leaking or not. He hit the switch and when it got up to 3,500 psig the end cap came flying out like a missile past his nose. I told him to turn that sucker in the right direction and he shouldn’t have any problems. I never heard from him so I guess it worked.

If the set pressure is correct, and the valve is vertical, ask if the outlet piping is supported by something other than the safety valve. If they don’t have pipe hangers or a wall or something to keep the stress off the safety valve, it will leak.

There was a plant in Springfield, Mo. that couldn’t start up because a 2″ valve was leaking on a tank. It was set at 750 psig, and the factory replaced it 5 times. We are not going to replace any valves until certain questions are answered. I was called to solve the problem. The operating pressure was 450 so that wasn’t the problem. It was in a vertical position so we moved on to the piping. You could tell the guy was on his cell phone when I asked if there was any piping on the outlet. He said while looking at the installation that he had a 2″ line coming out into a 2×3 connection going up a story into a 3×4 connection and going up another story. I asked him if there was any support for this mess, and he hung up the phone. He didn’t say thank you, goodbye, or send me a Christmas present.