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N. Serdar Erkan, Nuc. Eng. M.Sc.


An IR Imaging based Integrated System
for
Remote Real-Time Thermal Emission Monitoring of Industrial Plants
With a view to Energy Use Efficiency Enhancement

KEYWORDS: Thermal Emission, real-time, monitoring, IR-spectrum, wireless,
energy efficiency

I) Background & specific interpretation of the basis and objective of
the proposal solicitation.
As part of its solicitation for these proposals, GE Innovation initiatives task definition has
been formulated as follows:
determination and monitoring/imaging of energy use and consumption at industrial
facilities, via innovative solutions incorporating sensor, wireless and/or cellular
telephony technologies
Liberty has been taken for the following interpretation in setting the Objective and Substance
of this proposal:
i) The Subject Matter is, obviously, NOT about new power generation technologies
or development and proliferation of new energy resources.

ii) Although the above task definition could, nominally, be interpreted to refer to
energy consumption metering, this has been deemed to be too palpable and
somewhat redundant, given the availability of a developed and competitive vendor
market regarding innovative remote metering solutions, including power-line and
wireless transmission technologies. This really is not a pressing solution wanting
issue.

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N. Serdar Erkan, Nuc. Eng. M.Sc.
iii) Finally, the very wording employed in the Preamble to the above task definition
clearly points out to the urgency and relevance of energy consumption efficiency
measures, with a view to the abating the impact of the ever increasing primary
energy consumption projections, and the large fraction of industrial consumption.

iv) On the other hand, the emphasis on wireless transmission has been interpreted as a
desire for non-intrusive, non-penetrating, non-invasive modality, facilitating
retrofitting of any prospective energy efficiency enhancement system with
minimum physical disturbance, obstruction and interruption.
Hence the selection of the system proposal, as detailed herein below, which is
deliberately so configured to provide maximum synergy between available COTS
(Commercial Off The Shelf) technology hardware components. The author is of
the opinion that no singular new technology device, or gadget can provide
solutions to complex systematic problems. Especially regarding large scale
industrial processes, sometimes inefficiencies are built right into system design.
Reakpolitik of the financial environment sometimes unfortunately encourage
maximum performance, instead of optimum performance. Under the
circumstances, the best approach would be to go for existing technology
implementation and the exploitation of the same by converting the issue at hand to
one of Informatics & Calculus. This is exactly the approach favored in this
proposal, with new added-value coming from intellectual products of human
capital resources in developing new theoretical analysis methods, new
phenomenological and empirical relations, development & implementation of
innovative smart/adaptive algorithms etc.

II) Overview:
This Proposal pertains to Conceptual-Front End Engineering Design / System Architecture /
Detailed Engineering Development / Proof-of-System Test-bed Validation / Prototype System
Integration and final development of a commercial System, consisting of tangible &
intangible customer deliverables and Site TFA/TCS services for:
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N. Serdar Erkan, Nuc. Eng. M.Sc.
Real-time/Continuous monitoring of radiative & convective thermal emissions of all
critical industrial plant components (such as pumps, compressors, fans, generators, turbines,
cracking column, pressure & atmospheric vessels, steam drums, process piping, fired boilers,
HRSGs, heat-exchangers, ducts, stacks etc.) via remote I R spectrum imaging/temperature
correlation techniques, enabling the Industrial Facility Operator, to:
- Recognize, identify and analyze the energy efficiency impact of plant component
abnormal surface temperatures/thermal emission rates, indicating loci of wasted
energy
- Detect designed-for process emission/effluent discharge temperature anomalies
- Detect system fluid leaks (hot/cold water, steam, fuel-gas, process gas etc.) via
dynamic spatial/radiometric IR signature fluctuations
Equipped with the above indicators and the insight provided by the envisaged Systems
analytical software engine, The Operator is incentivized and enabled to take corrective
action to restore plant parameters back to design-basis by attending to failures,
degradations, malfunctions and/or correcting for design deficiencies alluded to and
attested by The Systems findings.
All these corrective actions are expected to naturally reflect themselves in eventual
enhanced energy use efficiency, as, any not-designed-for undue heat emission is a
parasitic loss, which will have been thus prevented.
Apart from its primary function of energy wastage prevention/mitigation, the obvious
added benefit of the system is its intrinsic diagnostic capability, as most industrial
equipment failures are preceded by temperature anomalies, before the plant DCS monitored
parameters reach their warning extremities. Moreover, several system diagnostic parameters
are not typically monitored by plant DCS, such as roto-dynamic equipment bearing or coolant
water temperatures. Hence, the system may provide invaluable early warning for impending
failures.

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N. Serdar Erkan, Nuc. Eng. M.Sc.
III) Brief Description of the Proposed System

a) The System, essentially, consists of;
COTS suite of Plant-wide Strategically distributed, wireless transmission capable, DATA
ACQUISITION elements (IR spectrum Imagers, ambient air parameter sensors and insolation
sensors, etc.)
COTS Data Logging INTERFACE HARDWARE ADAPTER Elements
COTS Central Processing Unit / Operator Console Hardware (Work Stations and relevant
peripherals)
PROPRI ETARY System Software, consisting of a system core engine (OS, GUI &
Interface adapter software modules) and several autonomous, scalable, functional / analytical
sub-systems, collectively dubbed the analytical engine.
(In addition to the above System deliverables, the initial system configuration/Implementation
at prospective Customer Sites shall require the temporary deployment of LIDAR/LADAR
Laser scanning Equipment for 3D modelling, which shall remain the property of the Vendor)
b) STEM (Science, Technology, Engineering, Maths) proficiencies relevant to the
development and implementation of the System, are as follows:

- Optronics (Passive IR Sensors)
- Science of Black/Gray Body Radiation (Stefan Boltzmann Phenomenological Laws)
- Science of convective heat transfer (phenomenological & empirical formulations)
- Image Processing-Cat1 (Scene matching, correlation, fusion)
- Image Processing-Cat2 (feature/event detection, recognition and identification)
- Image Processing-Cat3 (3D Object Extraction & Mensuration)
- Algorithm Design Smart/Adaptive Systems, Fuzzy Logic, AI, evolutionary source
code generation.
- Computer Coding conventional
- Software Application Proficiency (3D CAD, manual & semi-automatic processing of
Laser Scan generated Cloud Point data)
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N. Serdar Erkan, Nuc. Eng. M.Sc.
- General Large Scale Industrial Plant Process Design knowledge and System
Commissioning Expertize (notably refineries, fossil fuel power generation plants, steel
foundries, aluminum smelters, fertilizer plants, cement plants etc.)
- General System Integration Expertize

c) The System, once fully developed on the basis of above proficiencies, shall
basically function as follows:
Incoming IR imagery (and auxiliary support ambient air parameter data) streams are
logged, parsed, reduced and fed as input to the analytical engine transfer functions,
resulting in the calculated object surface temperatures, with proper real-world
coordinate mapping.
Based on 3D object mensuration and surface emissivity relational database files
generated during initial site configuration, temperature values are converted to heat
emission rates for each and every target surface area or the total rate for the target
object in the field of view of the sensors (radiative & convective emissions).
Other analytical engine modules calculate process emission/effluent temperatures,
again based on emission/effluent IR signature and real world mapped process
effluent source coordinate databases developed during initial site configuration.
Finally, anomalous IR signatures (based on combined spatial and radiometric vector
space) are detected and identified by the relevant smart modules, again with real
world coordinate mapping, providing indication of undesired leakages or severe
component integrity breach warnings/alarms.
All the information thus generated is displayed, stored, archived and also sent to
further analysis and reporting modules, as relevant, for comparison with ideal plant
parameters, raising of warnings & alarms, or simply reported as is.
Calculated component object heat emission rates, process effluent temp data and
anomalous event detections can be exported (real-time or off-line/historical) to
external applications.

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N. Serdar Erkan, Nuc. Eng. M.Sc.
IV) System Architecture & Primary Hardware/Software subsystem
functions:

A) Commercially Delivered System hardware components:
- IR Imaging Staring Cameras, utilizing either SWIR spectrum (3-5 micron for high
temp facilities) or MWIR spectrum (7-12 micron for more conventional applications)
(wireless transmission)
- Ambient Air Temperature, Pressure, velocity & humidity sensors (wireless
transmission)
- Incident Insolation Sensors (wireless transmission)
- Wireless Reception/Data Logging Interface Hardware
- Work Stations (operator consoles), working and rolling-buffer archive Mass-
Storage, Printers
B) Commercially Delivered System Essential Software Components:
- GUI Sub-system
- Real-Time Data Logging/Reduction Interface Adaptor Sub-system
- Data Export & Reporting Sub-system: (Graphical and textual reporting functions and
data interface to external applications)
- Analytical Engine Subsystem:
i) Multiple IR image data fusion Sub-module: Fuses pixel rosters generated by
different imagers for selection of best-representative pixel set for
subsequent analysis, to mitigate against occlusions and blurring that may
primarily be caused by positioning and viewing angle issues, in addition to
more troublesome factors as convective current distortions. Several Multiple
Sensor Pixel Roster Matching and Pixel Selection Key Look-up Tables
(static)* are initially generated as a once-only effort for each critical target
object. Dynamically changing conditions may dictate frequent real-time
update of those tables.
ii) Temperature Correlation Sub-Module: Maps IR image pixel intensity
metrics to temperature metrics, based on black/graybody radiation laws,
Surface Emissivity Database (static)* and acquired ambient air & surface
insolation data for compensation, as required by relevant formulae.
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N. Serdar Erkan, Nuc. Eng. M.Sc.
iii) Target Object Spatial Mapping Heat Emission Rate Calculation Sub-
module: Maps real-time IR image pixel roster index coordinates to 3D
Object Model (static)* Space Real World Surface Coordinates, and
calculates radiative & convective heat emission rates based on target 3D
object areas and above correlated temperatures. Process emission/effluent
fluid temperatures are also determined by this module, relying not on any 3D
object model space (not applicable), but on Emission/Effluent Source Real-
world Coordinate Data-Base (static)*
iv) IR signature Anomaly detection sub-module: Detects undesired system fluid
leaks by detecting anomalous spatial & radiometric
fluctuations/aberrations in imagery and correlates the same to Real-World
Space coordinates. Needs to be an adaptive/smart algorithm to filter out
image artifacts and transient spurious signals, likely requiring
development of anomaly signature libraries via training the algorithm by
subjecting it to several deliberately arranged and calibrated real world
anomalies, leading to an Anomalous Signature Database (static)*
v) 3D Object manual/semi-automatic object extraction & database merger-
fusion sub-module: All critical target plant components may, and most likely
will, need to be modelled from scratch via Laser Scanning
(LIDAR/LADAR) and subsequent manual or semi-automatic extraction and
mensuration of objects from the generated point cloud model. Any existing
AutoCAD 3D models will be of help. However, for one, such models typically
represent as-designed status as opposed to as-built, and moreover, several
critical components may have never been modelled at all. Hence, during Initial
Site Configuration, Facility Ties Points (benchmarks) may need to be
established and a high resolution Laser Scanning of the facility may be
required. Fusion of the generated cloud model with existing 3D models may
require the conversion of AutoCAD type file formats to STL (STereo
Lithography) format as it is an open-source standard and mapping to the
spherical coordinate system of the Laser Scanner. Once these tasks are
completed, a static 3D Object Model Database (static)* is created and
may only need to be updated occasionally, depending on the magnitude and
frequency of physical changes at the Site, post initial configuration. This is a
commercial intangible item and part of the initial site configuration
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N. Serdar Erkan, Nuc. Eng. M.Sc.
service. Hence, any laser scanning equipment that is temporarily
deployed to site remains the property of the Vendor.

V) Proposed Prototype Development Road-Map, Business Plan
Highlights & Marketing Tips/Gimmicks:

- Select a Collaboration Customer: Ideally an Oil refinery with site power generation
facilities (preferably an NG CCPP or an oil fired steam plant). This is THE TEST-
BED. Customer incentive? Install System-1 for free!

- Most important development resource is engineering humanpower. The real R & D
component of the system pertains to the science of informatics and signal processing
on one hand and thermodynamic science on the one hand. This shall require earnest
innovative development. Partner with a scientifically/technologically motivated and
competent entity as opposed to a commercial oriented one no matter what
competences they may have.

- Directly assume overall Project Management, COTS component
selection/procurement, System Integration and System Commissioning/Start-up duties
and responsibilities.

- Informatics, Thermodynamics, algorithm development and coding works shall likely
require around 20,000 25,000 engineer/scientist hours. Overall program/project
management and all other works shall likely equal this figure. Hence, plan for around
40000 50000 direct person-hours.

- Aim for 18 to 24 months from conception to commissioning of System-1. That
translates to around 15 highly competent key professionals to lead the effort,
excluding all other support staff (administration, accounts, comptrollers, procurement,
shipment etc.) and direct-staff (field engineers and technicians, support labor)

SOME HUMBLE THOUGHTS:

- As soon as possible, coin a catchy nomer for the System. What about:
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N. Serdar Erkan, Nuc. Eng. M.Sc.

STA-R (System Thermal Awareness Realtime)?

Alright Another suggestion:

STEE-R (System Thermal Efficiency Enhancement-Realtime)?

US corporations have always been extremely creative in coining Acronyms anyway.
Hence, rise up to the occasion and coin the coolest / catchiest one. THIS IS REALLY
IMPORTANT!

- DO NOT START active promotion of the system until proof-of-concept validation of
all critical elements. However, DO PROVIDE ample and frequent coverage of the
development program in technical media circles in and outside of GE world. Raise
curiosity and interest.

- When marketing & sales activity earnestly begins, pricing strategy shall be critical.
The system must be scalable enough with direct cost reduction implications, to also
attracts a myriad of small scale industrial facility owner / operators. A meagre 0.2%
thermodynamic cycle efficiency increase promise thanks to the implementation
increase would roughly translate into 0.5 0.6 % additionally exportable power for a
1000 MW installed capacity fossil fuel fired steam plant. Based on a modest 5000
hour/year availability, that would translate to an additional export of close to 25 - 30
million kwhours and would probably mean an additional operating margin of several
hundred thousand dollars. Just for the sake of argument a price tag of 2M USD would
pose no problem for such a customer. The same doesnt go for a smaller capacity
customer. Therefore, must reach to a sufficient number of big customers to
recuperate the development non-recurrents at the soonest, so that smaller, lesser
capability system cost advantages could be comfortably reflected to SME scale
customers.

An anecdotal account of conversation between a GE sales Rep and a
prospective STA-R customer, who happens to be the owner of a small
scale steel foundry:
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N. Serdar Erkan, Nuc. Eng. M.Sc.

- GE Rep: Good Morning Sir, what would you say if I were to offer you a totally non-
penetrating, non-invasive, real-time, continuous medical check-up system that would
give you a health status update once every second and you wont even know that the
system is there and watching you all the time?
- Awed Customer: Are you kidding? Sure, how soon can I get it?
- GE Rep: Err Sir, actually.. Unfortunately we cant provide this system for your
personal health (YET!). However, what about one for your Plant?

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