Optimizing Sensor Placement for Hydrogen Leak Detection in Enclosed Infrastructure: A Comparative Study Using CFD-informed Genetic Algorithm and DeepSets Neural Surrogate
Authors: Fangnian Wang, Nicholas Tan Jerome, Thomas Jordan, Frank Simon
Abstract
Hydrogen infrastructure in enclosed environments, such as parking facilities for fuel cell vehicles, presents significant safety challenges due to hydrogen's low ignition energy and wide flammability range. Current monitoring systems are largely reactive, detecting leaks only after hazardous concentrations have formed. This study develops a computational framework for proactive sensor placement optimization by integrating computational fluid dynamics (CFD), genetic algorithm (GA) optimization, and a DeepSets neural surrogate. A CFD database of 180 scenarios was generated for a representative 50 m x 30 m x 3 m garage, covering multiple leak positions, rates (1-150 g/s), and ventilation conditions (ACH = 3-10 per hour). Sensor placement was optimized using a multi-objective GA and compared with uniform, random, and surrogate-assisted approaches. The GA achieved a detection rate of 96.1% within 60 s and reduced blind areas to 0.12%, corresponding to an approximately 5% improvement in composite fitness over a uniform baseline. The DeepSets surrogate reproduced near-optimal configurations with a fitness gap below 0.01 while reducing CFD evaluations by 89% and computational time by two orders of magnitude. Detection performance and spatial coverage remained comparable to the GA, demonstrating that surrogate-assisted optimization can retain solution quality while enabling rapid design iteration. Overall, the results show that CFD-informed optimization improves detection effectiveness and reduces sensor requirements compared to conventional layouts. The proposed framework supports scalable deployment and provides a foundation for integrating optimized sensor networks with digital twin systems for real-time monitoring and risk assessment.
The integrity of hydrogen infrastructure relies on reliable leak detection, performed almost exclusively via manual tracer gas sniffing in electrolyzer manufacturing. Although mandated by standards, the lack of spatial probe guidance instructions leaves detection reliability entirely to operator execution, further compromised by sensor signal delays. This study quantifies how sniffer trajectory kinematics affect detection reliability at small-scale pipes and fittings, a near-field regime largely neglected by macroscopic dispersion research. Using a robotically guided test bench to eliminate operator variability, static concentration fields and dynamic trajectory passes were acquired across representative geometries under standardized leak rates (5 vol% hydrogen in nitrogen) and varying scanning velocities. Results demonstrate that scanning velocity and spatial probe orientation strongly dictate detectability. Conventional linear trajectories frequently miss leaks under dynamic conditions, causing severe false negatives. Conversely, geometry-specific routing, such as circumferential plunging paths around sealing points, maintains a high safety margin. From these observations, geometry-specific routing rules and a reduction-factor model for dynamic signal loss are derived. The findings reveal that current standard operating procedures pose a tangible safety risk. To operationalize these rules, a proof-of-concept software pipeline is presented, generating validated trajectories directly from 3D models for visualization in assistance systems.
Christian Masuhr, Arne Wendt, Thorsten Schüppstuhl
Optimal sensor placement (OSP) is critical for efficient, accurate monitoring, control, and inference in complex physical systems. We propose a machine-learning-based feature attribution (FA) framework to identify OSP for target predictions. FA quantifies input contributions to a model output; however, it struggles with highly correlated input data often encountered in practical applications for OSP. To address this, we propose a Correlation-Assisted Attribution Framework (CAAF), which introduces a clustering step on the candidate sensor locations before performing FA to reduce redundancy and enhance generalizability. We first illustrate the core principles of the proposed framework through a series of validation cases, then demonstrate its effectiveness in realistic dynamical systems such as structural health monitoring, airfoil lift prediction, and wall-normal velocity estimation for turbulent channel flow. The results show that the CAAF outperforms alternative approaches that typically struggle due to the presence of nonlinear dynamics, chaotic behavior, and multi-scale interactions, and enables the effective application of FA for identifying OSP in real-world environments.
The increasing frequency and severity of global flood events highlights the need for the development of rapid and reliable flood prediction tools. This process traditionally relies on computationally expensive hydraulic simulations. This research presents a prediction tool by developing a deep-learning based surrogate model to accurately and efficiently predict the maximum water level across a grid. This was achieved by conducting a series of experiments to optimize a U-Net architecture, patch generation, and data handling for approximating a hydraulic model. This research demonstrates that a deep learning surrogate model can serve as a computationally efficient alternative to traditional hydraulic simulations. The framework was tested using hydraulic simulations of the Wupper catchment in the North-Rhein Westphalia region (Germany), obtaining comparable results.
Christian Lammers, Fernando Arévalo, Leonie Märker-Neuhaus +3