CASE STUDY
Detecting Hydrogen Leaks in Production Facilities with EmissionsTrack™
Overview
A leading downstream hydrogen producer aimed to improve hydrogen leak detection in production facilities by deploying a continuous emissions monitoring solution. The goal was to identify leak points, understand the behavior of leaks over time, and compare actual emissions with Computational Fluid Dynamics (CFD) gas leak modeling results.
The Challenge
Hydrogen is notoriously difficult to monitor due to its small molecule size, high flammability, and tendency to leak from fittings and equipment. The customer sought a simple to install, continuous monitoring system that could not only detect hydrogen leaks but also quantify them accurately — something that no existing system on the market could provide. They needed a solution to better understand leak dynamics, particularly in the context of their production pipes, tanks, and stacks.
The Solution
The customer deployed NevadaNano’s EmissionsTrack™ system in four sections across three areas of their refinery. The system was configured as follows:
- 20 LoRa Endpoints to detect hydrogen (H2), methane (CH4), and H2/CH4 blends
- 1 LoRa Gateway for wireless connectivity and data transfer to EmissionTrack™
- 1 LoRa Anemometer to measure wind speed for accurate leak localization
The wireless, battery-operated endpoints were installed quickly in areas with a high density of valves and actuators, as well as vertical tanks, relief lines, and stacks, all critical spots for potential leaks.
Implementation
The system was implemented in four sections across three site areas, including:
- Production pipes
- Tops and bottoms of tanks
- High-density valves and actuators
- Vertical tank relief lines and stacks
Results
Over the course of three months, EmissionsTrack™ delivered insightful data from all four sections, uncovering distinct leak “personas” across different equipment types.
- Valves
- Leak Profile: Continuous, small leaks
- Emissions Contribution: 90% of total measured emissions
- Insights: Valves were the primary source of ongoing emissions, providing critical data for more focused LDAR (Leak Detection and Repair) efforts, as well as which assets and equipment should be replaced with like for like, with less leak potential.
- Tanks (Low and Top)
- Leak Profile: High-frequency, short-duration leaks
- Emissions Contribution: Approx. 5% of total measured emissions
- Insights: Leaks were closely linked to pressure changes during tank operation, offering valuable insight into operational behavior and pressure control.
- Stack
- Leak Profile: More challenging application due to complexity
- Emissions Contribution: Less than 5% of total measured emissions
- Insights: Stack emissions proved more difficult to measure, though the system still provided accurate leak identification.
Key Outcomes
- Accurate Quantification and Hydrogen Leak Detection in Production Facilities: EmissionsTrack™ successfully detected and quantified hydrogen, methane and blends across a range of refinery equipment.
- Enhanced LDAR Efficiency: The system significantly improved the efficiency of the customer’s LDAR operations by pinpointing the exact location and volume of leaks.
- Operational Insights: The site operator gained valuable insights into the behavior of their system, allowing them to make more informed decisions around maintenance, future equipment procurement and leak management.
Related Resources
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Revolutionizing Hydrogen Emissions Monitoring for a Greener Future
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National Gas FutureGrid: Emissions Monitoring for Hydrogen Integration with EmissionsTrack™
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Whitepaper
The Future of Hydrogen: Safe, Efficient, & Emission-free