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Increasing refinery efficiency-II: Real time monitoring of PRVs can save 20% in operating cost
Mar 19: Let us consider the common Pressure Relief Valve (PRV). The PRV is supposed to discharge excess gas from containers and pipes beyond a set pressure. Over a period, springs in the PRVs suffer from fatigue and their set-points change and the PRVs start leaking gas into the environment at a lesser pressure.
8This leads to loss of product while also being an environmental and safety hazard. PRVs are un-instrumented and also mounted in inaccessible places making manual inspection challenging. Therefore, they are left to be tested only during turnarounds or shutdowns.
8However, new regulations may make it mandatory to monitor PRVs electronically.
8The solution is to add an IIoT differential pressure sensor across the PRV that will monitor its health in real time. This will transmit the real-time information directly to an IIoT platform, without having to be connected to the DCS or PLC.
8Any malfunctioning PRVs will be detected immediately in real time and can be actioned upon without having to wait for months for the next shutdown.
8Imagine this happening with thousands of PRVs in a refinery.
8Studies have shown that real-time monitoring of all PRVs in a refinery can potentially lead to additional 20% savings in operating costs.
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