An IIoT predictive maintenance framework for relief valves Enhancing the operational reliability of relief valves in refinery units and reducing flare-related hydrocarbon losses
Sourav Mukherjee Engineers India Limited
S ignificant volumes of hydrocarbons are flared annually in oil and gas complexes around the world, resulting in the loss of valuable hydrocarbons and contributing to climate change by releasing greenhouse gases such as carbon dioxide (CO2) into the atmosphere. Apart from normal flaring, which is associated with process upsets, the leaks in flare systems cause continuous loss of valuable hydrocarbons, contributing to the wastage of valuable energy resources. The World Bank’s Global Flaring Tracker Report 2025 indicates a flare volume of 151 billion m3 in 2024 (see Figure 1 ). Of this, India contributed 1,484 million m3 of flare gas (see Figure 2 ). This article aims to identify major sources of leaks in the flaring system of the hydrocarbon industry and initiate their round-the-clock,
effective monitoring. Considering that relief valves are a major source of leaks to refinery flares, the implementation of Industrial Internet of Things (IIoT)-based Edge devices in relief valves in refineries facilitates the detection of hydrogen leaks, allowing prompt identification and necessary corrective actions. By leveraging such IIoT technologies, industry can achieve more efficient flare management, minimise emissions, cut losses, and contribute to both environmental sustainability and operational excellence. This article takes a comprehensive approach, beginning with a description of the IIoT technological framework. It then provides an estimation of leakages from relief valves across various major refinery units, followed by an economic impact analysis of the proposed solution. Finally, it discusses the challenges
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Figure 1 Year-wise flaring volume for major flaring countries. Source: World Bank’s Global Flaring and Methane Reduction (GFMR) Partnership
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