Shell Validates HA3LX for Next-Gen Methane Leak Detection in Active Oil & Gas Operations
How a global energy major is using HERTZINNO's acoustic-TDLAS fusion camera to enhance personnel safety and pinpoint fugitive emissions from safe distances.
Executive Summary
For global energy leaders like Shell, the challenge of methane leak detection has always been a trade-off: sensitivity vs. accessibility, quantification vs. speed. Traditional Optical Gas Imaging (OGI) cameras require thermal contrast and line-of-sight, while portable gas sniffers demand close proximity—often placing personnel in harm's way.
In a series of field validations at active Shell facilities, the HERTZINNO HA3LX—the world's first handheld acoustic imager integrating a 144-channel MEMS array with TDLAS laser spectroscopy—demonstrated a new paradigm. It successfully detected, localized, and quantified methane leaks in real-world conditions where conventional tools struggle or fail.
This case study examines two distinct applications: dynamic personnel safety during active operations and static infrastructure inspection at tank farms, showcasing how HA3LX delivers "absolute certainty" across diverse scenarios.
The Challenge: Invisible Threats in Complex Environments
Oil & Gas facilities present a multi-layered inspection nightmare:
Shell needed a tool that could operate safely, quickly, and provide actionable data—not just another image.
The Solution: HA3LX – Acoustic + TDLAS Fusion
The HERTZINNO HA3LX is purpose-built for these demands:
Application 1: Dynamic Personnel Safety (Active Operational Zone)
Environment: An active operational zone with personnel moving through the area, carrying portable gas sampling gear.
Target: Potential leaks along temporary hoses and connections used during maintenance or turnaround activities.
The HA3LX in Action:
An inspector, moving through the zone with the HA3XL, scanned a high-pressure hose connection. Despite the surrounding mechanical noise, the camera's beamforming algorithms instantly isolated an ultrasonic signature. The acoustic image overlay pinpointed a micro-leak at the hose fitting—a leak invisible to the naked eye and inaudible over the facility's roar.
The Result:
The leak was located while the inspector was in motion, without stopping or approaching the hazard closely. The TDLAS laser simultaneously quantified the methane concentration, allowing the team to assess severity and schedule immediate repair. This transformed a potential safety incident into a quick, data-driven maintenance action.
Key Takeaway: HA3LX enables "in-motion" inspection, allowing safety personnel to scan dynamic environments continuously without slowing down operations or exposing themselves to unnecessary risk.
Application 2: Static Infrastructure Integrity (Outdoor Tank Farm)
Environment: An outdoor tank farm facility with multiple methane storage tanks.
Target: High-altitude relief valves and roof seals on storage tanks—traditionally difficult and dangerous to access.
The HA3LX in Action:
Inspectors faced the challenge of checking relief valves located tens of meters above ground. Using the HA3LX from a safe ground position, they scanned the tank roof. The camera's long-range acoustic sensitivity locked onto a high-frequency emission from a relief valve. The on-screen visual showed the exact leak location superimposed on the real-world image, while the TDLAS laser displayed the methane concentration in ppm·m.
The Result:
A potentially catastrophic leak at a high-altitude point was identified without scaffolding, without rope access, and without shutting down the tank. The quantified data (concentration, leak rate) enabled the team to prioritize this repair against other maintenance tasks, optimizing resource allocation and preventing an unplanned emission event.
Key Takeaway: For hard-to-reach static assets, HA3LX eliminates the need for dangerous physical access, providing laboratory-grade diagnostic data from a safe distance.
Beyond OGI: Why HA3LX Redefines Leak Detection
Shell's field team observed several distinct advantages over traditional OGI cameras during these trials:
|
Feature |
Traditional OGI Camera |
HERTZINNO HA3LX |
Strategic Edge |
|
Gas Detection |
VOCs only (requires specific gas type) |
Any pressurized gas (methane, hydrogen, compressed air, SF6) |
One tool for all leaks, not just VOCs. |
|
Thermal Dependency |
Requires ΔT (thermal contrast) between gas and background |
Zero ΔT dependency—purely sound-based |
Works 24/7, in any weather, any time of day. |
|
Quantification |
Needs complex secondary software |
Built-in TDLAS calculates ppm·m, L/min, and cost instantly |
Immediate, actionable data for repair decisions. |
|
Obstacle Handling |
Strict line-of-sight required |
Acoustic reflections can reveal leaks behind obstacles |
Finds leaks OGI might miss due to physical obstructions. |
|
Ease of Use |
Specialized training required |
Intuitive point-and-shoot simplicity |
Turns complex analysis into a standard tool for any technician. |
Conclusion: Absolute Certainty Across All Operations
For a global operator like Shell, the margin for error is zero. Fugitive emissions represent not only a financial loss but a safety and compliance risk. The HA3LX has proven in live field conditions that it can deliver what traditional tools cannot: the ability to detect, locate, and quantify gas leaks instantly, safely, and in any environment.
From moving personnel in active zones to high-altitude static assets, HA3LX provides the "absolute certainty" required to protect people, assets, and the environment.
Ready to see how HA3LX can transform your facility's leak detection program?
