Eliminating Recurring Valve Failures to Protect Generation and Profitability
At a large baseload power plant, reliability issues were quietly eroding financial performance. Relief valves were functioning as designed—opening under pressure—but failing to re-close, resulting in forced de-rates lasting nearly 48 hours and lost generation capacity of roughly 400 MW per event. Occurring about three times per year, these disruptions forced operators to manage ongoing consequences rather than optimize performance, creating a costly gap between system design and real-world operation.
To solve the issue, the team implemented the Emerson Anderson Greenwood 800 Series Pilot Operated Relief Valve, designed with a modulating opening style that allows it to open only as needed and re-close once conditions stabilize. Since installation, the plant has seen zero “stuck open” events and eliminated de-rates tied to valve behavior. With an approximate $65,000 investment avoiding losses of about $1,000,000 per event, the solution now delivers an estimated ~$3,000,000 in annual savings—transforming a recurring reliability challenge into a controlled, predictable outcome.
To solve the issue, the team implemented the Emerson Anderson Greenwood 800 Series Pilot Operated Relief Valve, designed with a modulating opening style that allows it to open only as needed and re-close once conditions stabilize. Since installation, the plant has seen zero “stuck open” events and eliminated de-rates tied to valve behavior. With an approximate $65,000 investment avoiding losses of about $1,000,000 per event, the solution now delivers an estimated ~$3,000,000 in annual savings—transforming a recurring reliability challenge into a controlled, predictable outcome.