Refinery Site, Malaysia
Background
A refinery in Malaysia recently conducted an on-site evaluation of the BL-CH4 400drone-mounted methane detection system to assess its performance under tropical operating conditions.
Refineries contain extensive networks of pipelines, valves, storage tanks, process units, and elevated structures where methane leaks may occur. Routine inspection of these assets is essential for operational safety, emissions management, and preventive maintenance. However, conventional inspection methods often require personnel to access hazardous areas and can be time-consuming for large facilities.
This field test was performed to evaluate the suitability of BL-CH4 400 for routine methane inspection in a real refinery environment.
Challenges
The refinery presented several operational challenges commonly encountered in Southeast Asian industrial facilities.
Tropical Climate
High temperatures, high humidity, and coastal salt-laden air can affect equipment durability and inspection reliability, requiring instruments capable of stable operation under demanding environmental conditions.
Complex Facility Layout
The site included storage tanks, distillation towers, elevated pipe racks, valves, and densely distributed process equipment, making many inspection points difficult to access using conventional handheld instruments.
Safety and Environmental Requirements
Methane leakage management is important for both process safety and greenhouse gas emission control. Small leaks from flanges, valves, and fittings require timely identification before they develop into larger issues.
Limitations of Traditional Inspection
Manual inspections often require working at height or entering hazardous areas, while handheld gas detectors generally provide only point measurements and may require close proximity to potential leak sources.
Solution
The refinery deployed the BL-CH4 400, a drone-mounted methane detector based on Tunable Diode Laser Absorption Spectroscopy (TDLAS)technology.
Installed on an enterprise UAV platform, the system enables remote methane screening from a safe distance while collecting geo-referenced inspection data for subsequent analysis.
Field Test Results
During the site evaluation, the BL-CH4 400 demonstrated stable performance across multiple refinery inspection scenarios.
High-Sensitivity Leak Detection
With a detection sensitivity of 1 ppm·m, the system was capable of identifying low-concentration methane emissions around pipelines, valves, and flange connections, supporting early identification of potential leak sources.
Remote Inspection Capability
The detector supports non-contact inspection distances of up to 150–300 meters, allowing operators to inspect elevated structures and restricted areas while reducing personnel exposure to operational hazards.
Fast Leak Localization
The system responds to methane concentration changes within 5 msand combines methane measurements with GPS positioning and optical imagery, helping maintenance teams efficiently locate and document potential leak sources.
Reliable Operation in Tropical Conditions
Throughout the field test, the system operated reliably under Malaysia's high-temperature and high-humidity environment. Its IP54-ratedenclosure provides protection against dust and moisture, making it suitable for outdoor industrial inspection.
Digital Inspection Workflow
Inspection data can be synchronized to the cloud, enabling centralized data storage, historical record management, automated reporting, and support for LDAR documentation and emissions management programs.
Key Benefits
High-sensitivity methane detection for refinery assets
Safe remote inspection of elevated and hazardous areas
Reduced reliance on manual inspection activities
Rapid leak localization with GPS-enabled data recording
Stable performance under tropical environmental conditions
Digital inspection records for maintenance and compliance workflows
Conclusion
The successful field validation in Malaysia demonstrates the applicability of the BL-CH4 400for methane inspection in refinery environments with challenging climatic and operational conditions.
By combining drone deployment with TDLAS-based remote sensing technology, the system enables efficient inspection of complex industrial facilities while improving inspection safety, operational efficiency, and data traceability.
As industrial operators continue to strengthen methane management and emissions monitoring programs, drone-based inspection technologies provide a practical solution for supporting routine asset integrity inspections and long-term facility management.
