Refinery Facility, Hungary
Project Background
As global industries continue advancing toward carbon reduction goals and higher energy safety standards, methane leak monitoring has become increasingly important for refineries, oil & gas facilities, and other high-risk industrial environments.Refinery facilities typically contain extensive natural gas pipelines, valves, flanges, compressors, and storage systems within highly complex processing environments. Undetected methane leaks may not only contribute to greenhouse gas emissions but also create serious operational and safety risks.
Traditional inspection methods often rely on manual handheld detectors, fixed gas monitoring systems, or OGI infrared imaging inspections. However, these methods may face limitations in inspection efficiency, large-area coverage, and personnel safety within hazardous operating environments.
To improve gas safety management, a large refinery facility in Hungary deployed the BL-CH4 400 system developed by BLV Technology for UAV-based methane inspection operations.
Solution Overview
UAV Platform
The project utilized an industrial DJI drone platform to perform automated inspection missions across critical refinery areas.
Methane Detection Payload
The UAV was equipped with the BL-CH4 400 based on TDLAS (Tunable Diode Laser Absorption Spectroscopy) technology.
Key capabilities include:
Long-range non-contact methane detection
Real-time concentration data transmission
Dynamic leak hotspot identification
High-sensitivity low-concentration methane detection
Large-area rapid scanning capability
Project Implementation
During field operations, the UAV conducted inspections along predefined routes covering key refinery infrastructure, including:
Process pipeline connection points
Valves, flanges, and pump stations
Tank storage and transfer areas
Compressor and complex facility zones
During flight missions, the BL-CH4 400 continuously performed non-contact methane concentration measurements using TDLAS laser sensing technology.
Detection data was transmitted in real time to the monitoring platform, dynamically generating methane concentration trends and leak hotspot mapping for field engineers.
Even under conditions involving strong wind and complex background gases, the system maintained stable data output and reliable detection performance.
Project Results
Improved Operational Safety
The UAV inspection method significantly reduced the need for personnel to access hazardous refinery areas.
Higher Inspection Efficiency
Compared with conventional manual inspection methods, the system completed large-area refinery inspections within hours, greatly reducing inspection time.
Accurate Leak Identification
The system successfully identified low-concentration methane anomalies and assisted engineers in locating potential leak sources.
Real-Time Visualization
Real-time methane concentration mapping and hotspot visualization enabled faster decision-making and risk response.
Environmental & Compliance Support
The solution supports methane emissions monitoring requirements through data recording and traceability functions.
Customer Feedback
Field engineers positively evaluated the inspection coverage capability, localization accuracy, and operational efficiency of the BL-CH4 400 system.
According to the customer, the solution effectively improved gas inspection efficiency across complex refinery infrastructure while reducing personnel exposure to hazardous environments.
Project Value
This refinery deployment in Hungary demonstrated the practical value of integrating UAV platforms with TDLAS laser methane sensing technology in complex industrial environments.
By combining industrial UAV systems with the BL-CH4 400, BLV Technology provides the energy industry with a safer, smarter, and more efficient methane leak inspection solution.
The solution is expected to see broader adoption across refineries, oil & gas facilities, transmission pipelines, and other industrial infrastructure projects worldwide.
