150 Years of overpressure protection and valve innovation.

Crosby pressure relief valves continue tp deliver reliable overpressure protection across a wide range of critical applications.

Recent valve innovation milestones include: 2019 – PRV monitoring and RFID technologies are released for the Crosby J-Series. 2020 – Actuated J-Series valves attain SIL3 (Safety Integrity Level 3) certification. 2022 – Emerson introduces Crosby Balanced Diaphragm Technology. 2022 – Emerson introduces Bellows Leak Detection for Crosby valves. 2024 – Crosby H-Series limits are extended to over 7,250 pounds per square inch/500 bar and 1,200 degrees F/648 degrees C.

Emerson recognises the 150th anniversary of its Crosby™ line of pressure relief valves (PRVs), marking a significant milestone in the history of PRVs and overpressure protection products. Crosby technologies are field-proven and engineered to meet the latest regulatory standards with improved performance, greater reliability, and enhanced safety.

“Emerson remains committed to innovation and excellence, continuously enhancing its range of overpressure products to meet and exceed the evolving needs of end users,” said Judson Duncan, the president of Emerson’s pressure management business. “With a steadfast dedication to regulatory compliance, safety, and customer satisfaction, Crosby is positioned to lead a safer, more sustainable industry over the next 150 years.”

Current Crosby offerings include:

• J-Series – Robust and proven technology providing reliable overpressure protection in various applications, including air, gas, steam, vapor, liquid and two-phase media. Used extensively in the oil and gas, refining, and chemical industries.
• OMNI-TRIM® – Proven solution for overpressure protection and thermal relief applications in air, gas, vapor, liquid, and steam applications. A straightforward design makes it ideal for refineries, chemical and petrochemical plants, power plant auxiliary systems, and pulp and paper mills.
• H-Series – High performance PRVs for overpressure protection in power industry steam safety applications, including economizers, steam drums, superheaters, reheaters and more.

The company is continuously developing new valve technologies based on their deep experience in critical service applications. For example, Crosby Balanced Diaphragm technology eliminates bellows in PRVs, ensuring reliable, balanced operation against backpressure. This innovation reduces maintenance costs, improves performance, and enhances safety with its robust design. In a related development, the world’s first Bellows Leak Detection solution provides instant notification of ruptures to enable prompt maintenance, reduce fugitive emissions, and provide event logging for intelligent root cause failure analysis—enhancing productivity and environmental protection.

All these overpressure protection products are field-proven technologies, engineered to meet the latest user demands.

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Pressure relief valves reinvented!

Two new-to-the-world technologies for the Crosby™ J-Series pressure relief valve (PRV) product line have been announced by Emerson. The first is a Balanced Diaphragm, which eliminates the need for bellows in PRVs, while providing balanced operation against backpressure to lower cost of ownership and enhance performance. The second technology is Bellows Leak Detection, enabling remote detection of bellows ruptures in PRVs, with the capability to reduce and accurately calculate volumetric emissions in real-time.

Top: Bellows Leak Detection;
Below: Balanced Diaphragm

“With the growing global emphasis on sustainability, an increasing number of PRVs that currently vent to the atmosphere will require connections to flare systems to curb emissions. The resulting higher backpressures will push the limits of existing PRV designs, and the Balanced Diaphragm and Bellows Leak Detection breakthrough innovations will help our customers address this need,” said Judson Duncan, president of Emerson’s pressure management business.

Where backpressure is present, spring-loaded PRVs often utilise bellows to ensure balanced operation. Data analysis from 30,000 PRV service records across different industries and valve brands shows a bellows failure rate between 2% and 6%. In other words, a plant with 1,000 bellows PRVs may have between 20 and 60 PRVs continuously operating with damaged bellows. The most common causes of bellows failures are excessive backpressure and rapid cycling. Ruptured bellows will cause fugitive emissions and may prevent valve operation at the designed set pressure, with the risk of overpressure events.

The Crosby Balanced Diaphragm can replace bellows in PRV applications to address these and other issues. Its innovative design extends the backpressure limits from 60% to 80% and increases the Kb backpressure correction factor by up to 15%, expanding the application range of spring-loaded PRVs. The Kb factor is used to size PRVs when they are installed in closed systems subject to backpressure. Extending the backpressure limit and increasing the Kb factor often permits the use of smaller valves. In addition, diaphragms are inherently more resilient than bellows for higher backpressures and rapid cycling applications. Upgrading to a Balanced Diaphragm therefore lowers maintenance costs, improves reliability and increases stability.

The second technology, Bellows Leak Detection, addresses the problem of bellows failures, which are challenging to detect and often remain unnoticed for years until removal of the valve for periodic service. Leak detection and repair (LDAR) programmes may include PRVs, but their target sources for leakage detection are flanges or valve seats, so bellows ruptures will generate fugitive emissions through the PRV bonnet vent that may not be in the LDAR scope. In addition, PRV installations are often difficult to access and in hazardous locations, making leak detection difficult.

The Bellows Leak Detection solution is a safer and more efficient method for detecting bellows failures and emissions. It consists of a back-up piston and a Rosemount™ wireless or wired pressure transmitter. The back-up piston can reduce emissions by over 90% in the event of a bellows rupture because it has a much smaller clearance than a standard bonnet vent, and it ensures balanced operation. The pressure transmitter provides instant timestamped notification of bellows failure and emissions volume data in real-time.

Upgrade kits for existing Crosby J-Series PRVs are available for both new technologies, and new PRVs can be purchased with these features pre-installed.

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