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An Automated Sensor Network System and Innovative Approach for VOC Leak Detection
Citation:
Peng, W., D. Masner, L. Lin, A. Chernyshov, B. Kelly, M. Clausewitz, D. Cartwright, K. Anderson, H. Lane, AND E. Thoma. An Automated Sensor Network System and Innovative Approach for VOC Leak Detection. 2019 American Fuel and Petrochemical Manufactures (AFPM) Environmental Conference, Salt Lake City, UT, October 27 - 29, 2019.
Impact/Purpose:
Energy production operations, refineries, chemical plants, and other industries and waste facilities can emit air pollutants and odorous compounds from fugitive leaks, process malfunctions, and area sources that are hard to detect and manage. From the shared perspective of industries, regulators, and communities, improved understanding of stochastic industrial sources (SIS) can yield many benefits such as safer working environments, cost savings through reduced product loss, lower airshed impacts, and improved community relations. The emergence of lower-cost sensors and inverse modeling approaches is enabling new cost-effective ways to detect and analyze SIS emissions. Under its next generation emissions measurement (NGEM) program, EPA is working with a range of partners to develop and test NGEM tools that can assist facilities in detection and management of sources. As described in the below abstract, the following product contributes to the general advancement and communication of NGEM concepts.
Description:
Leak Detection and Repair (LDAR) programs have historically relied on EPA Method 21 (M21), a sensitive but labor-intensive manual inspection procedure. In addition to high implementation and documentation burden, M21 has several characteristics that limit operational efficacy. Since M21 is conducted on a quarterly to yearly schedule, the time between leak occurrence and detection can be significant. M21 monitoring efficiency and coverage are also less than optimal. For example, each year Flint Hills Resources (FHR) completes approximately 1.5MM M21 monitoring events with >98% of expended monitoring resources spent on non-leaking components. In 2017, FHR, Molex, and EPA’s Office of Research and Development (ORD) initiated a project under a Cooperative Research and Development Agreement to explore a new next generation emission measurement (NGEM) approach that can help support future emissions management strategies. The innovative system being developed and evaluated is based on a wireless network of leak detection area sensors (LDAS) and a proceduralized detection response framework. The sensor-based leak monitoring system is configured to detect plumes of volatile organic compounds within the boundaries of a facility and it consists of a network of gas sensors, meteorological stations, edge gateways, and Molex’s mSyte™ software platform. The sensors are installed in fixed locations throughout the plant or process unit and they wirelessly transmit data via Wi-Fi to local gateways for forwarding to the cloud. The data is then analyzed using appropriate gas dispersion models and advanced algorithms to both identify the presence of a gas leak and to determine its general location. When a significant leak is detected, mSyte™ sends an alert to designated individuals via text or email in addition to visual and/or audible alarms. An LDAR technician may then be dispatched to the defined area to locate the leak source by utilizing mobile devices such as a handheld leak detector and/or an optical gas imaging camera. The new sensor-based system approach has shown quick detection of VOC leaks as low as 1.5 grams per hour and could potentially replace up to 98% of the current routine Method 21 monitoring activities. This presentation describes the innovative LDAR approach and presents preliminary results and lessons learned from long-term prototype implementation testing at two FHR facilities.