A Wavelength Modulation Spectroscopy-Based Methane Flux Sensor for Quantification of Venting Sources at Oil and Gas Sites

An optical sensor employing tunable diode laser absorption spectroscopy with wavelength modulation and 2f harmonic detection was designed, prototyped, and tested for applications in quantifying methane emissions from vent sources in the oil and gas sector. The methane absorption line at 6026.23 cm(–1) (1659.41 nm) was used to measure both flow velocity and methane volume fraction, enabling direct measurement of the methane emission rate. Two configurations of the sensor were designed, tested, and compared; the first used a fully fiber-coupled cell with multimode fibers to re-collimate the laser beams, while the second used directly irradiated photodetectors protected by Zener barriers. Importantly, both configurations were designed to enable measurements within regulated Class I / Zone 0 hazardous locations, in which explosive gases are expected during normal operations. Controlled flows with methane volume fractions of 0 to 100% and a velocity range of 0 to 4 m/s were used to characterize sensor performance at a 1 Hz sampling rate. The measurement error in the methane volume fraction was less than 10,000 ppm (1%) across the studied range for both configurations. The short-term velocity measurement error with pure methane was <0.3 m/s with a standard deviation of 0.14 m/s for the fiber-coupled configuration and <0.15 m/s with a standard deviation of 0.07 m/s for the directly irradiated detector configuration. However, modal noise in the multimode fibers of the first configuration contributed to an unstable performance that was highly sensitive to mechanical disturbances. The second configuration showed good potential for an industrial sensor, successfully quantifying methane flow rates up to 11 kg/h within ±2.1 kg/h at 95% confidence over a range of methane fractions from 25–100%, and as low as ±0.85 kg/h in scenarios where the source methane fraction is initially unknown within this range and otherwise invariant.