Comparative Analysis of Ultrasonic and Traditional Gas-Leak Detection Systems in the Process Industries: A Monte Carlo Approach

Abstract

Gas leaks can cause disasters at process sites, including fires and explosions, and thus, effective gas-leak detection systems are required. This study investigated the limitations of conventional detectors and introduced an innovative ultrasonic sensor-based approach for continuous monitoring. A new configuration for a stationary remote ultrasonic gas-leak monitoring system is proposed. The selected material was 1-Butene. The detection probability was assessed through a simulation based on a gas-leak scenario, detailing the selection criteria for leak sites and simulation conditions. Computational fluid-dynamics (CFD) simulations were used to evaluate the detection capability of the existing system, whereas Monte Carlo simulations were used to compare it with the proposed ultrasonic system. The CFD simulation was performed by setting the lower detection limit of the concentration-measurement-type gas detector to 600 ppm, and the leak-detection time was approximately 8.895 s. A Monte Carlo simulation accounting for wind direction showed that the existing system’s average detection probability was 3.41%. By integrating the existing and new systems, the detection probability increased by 96.58% and 3.92% compared with that using only the concentration-measurement and ultrasonic measurement methods, respectively. These rates provide valuable insights for future applications in oil refining and petrochemical industries.