Optimizing Sustainability with Digital PRV Monitoring

Digitalizing Pressure Relief Valve (PRV) monitoring improves sustainability and efficiency by reducing leaks, emissions, and product losses. Wireless sensors provide real-time data, enhancing safety, profitability, and compliance with environmental regulations.

Sustainability is a growing priority, but many process plants struggle to monitor the environmental impact of their operations effectively. A critical component often overlooked is real-time monitoring of Pressure Relief Valves (PRVs), which, if not maintained properly, can lead to significant financial and environmental losses.

PRVs typically undergo mandatory inspection, testing, and repairs. However, many plants still rely on manual monitoring methods, which are inefficient and potentially risky. Leaks from PRVs can lead to greenhouse gas emissions, operational downtime, and wasted products, which contribute to fines, environmental penalties, and higher operational costs. A typical 250,000 BPD refinery, for instance, can lose over $1.5 million annually due to undetected PRV leaks. These leaks can release substantial amounts of volatile organic compounds (VOCs) and greenhouse gases, complicating efforts to meet sustainability goals.

Wireless sensors
Introducing digital solutions to PRV monitoring can bring significant benefits. Wireless sensors and real-time data logging allow for continuous monitoring of PRVs, alerting operators to leaks, releases, or valve simmering. This data enables better root cause analysis, improves process safety, and increases efficiency.

For example, a U.S. refinery installed 69 PRV WirelessHART monitors, detecting over 200 release events in 15 months. This led to a significant reduction in product losses and increased profitability, with the system paying for itself within five months.

Future Benefits
Incorporating digital monitoring systems reduces the need for manual rounds, enhances worker safety, and promotes more sustainable operations. As more plants adopt these technologies, they can expect fewer unplanned shutdowns, increased operational efficiency, and progress toward decarbonization and net-zero emissions goals.

In short, digitalizing PRV monitoring can improve both economic performance and environmental sustainability, making it an essential step for process plants aiming to future-proof their operations.