Non-contact real-time 3D mapping of surface facilities

Abstract

The systems and methods include a computer-implemented method for providing a photonic sensing system for performing an automated method for characterizing facility surface displacements and monitoring changes in real time. A three-dimensional (3D) point cloud of one or more objects is generated by an analysis and presentation system using light information collected through structured light illumination by an array of structured light sensors (SLSes) directed at the one or more objects. Generating the point cloud includes defining points of the 3D point cloud relative to reference points on the one or more objects. Real-time non-contact 3D surface measurements of the one or more objects are performed using the 3D point cloud. Changes in one or more portions of the one or more objects are identified by the analysis and presentation system by analyzing the real-time non-contact 3D surface measurements.

Description

[Technical field]

[0001] This application claims priority to U.S. Patent Application No. 17 / 328,159, filed May 24, 2021, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure applies to determining the condition of equipment. [Background technology]

[0003] Wellhead and surface structures are subject to complex forces and thermal gradients that cause structural changes or damage including, for example, anisotropic expansion, fatigue, displacement, etc. These effects can result in damage to the platform, the wellhead, or both. Conventional systems can measure structural changes manually as part of routine inspections, and measurements may be made sporadically depending on the number of wells and their locations. Summary of the Invention

[0004] This disclosure describes available techniques for using photonic sensing systems to characterize structural displacements in a wellbore. In some embodiments, a computer-implemented method includes: A three-dimensional (3D) point cloud of one or more objects is generated by an analysis and presentation system using light information collected through structured light illumination by an array of structured light sensors (SLSes) directed at the one or more objects. Generating the point cloud includes defining points of the 3D point cloud relative to reference points on the one or more objects. Real-time non-contact 3D surface measurements of the one or more objects are performed using the 3D point cloud. Changes in one or more portions of the one or more objects are identified by the analysis and presentation system by analyzing the real-time non-contact 3D surface measurements.

[0005] The foregoing embodiments can be realized using a computer-implemented method, a non-transitory computer-readable storage medium storing computer-readable instructions for performing the computer-implemented method, and a computer-implemented system including a computer memory interoperably coupled with a hardware processor configured to perform the computer-implemented method, the instructions being stored on the non-transitory computer-readable storage medium.

[0006] The subject matter described herein may be implemented in certain embodiments to achieve one or more of the following advantages: The disclosed technology using a photonic sensing system may be used to provide a high accuracy, high speed and non-contact method for characterizing deformation of surface structures in, for example, oil and gas applications. The technology may also be used to analyze absorbance or cross-polarized spectroscopy to characterize material changes or contamination. Structured light sensing may be used to characterize deformation in real time and non-contact. The term real time may correspond to events occurring within a specified time period, for example, within a few seconds or less than a minute. The technology may be used in the ongoing development of tools and methods for characterization of wellhead deformation, for example, in upstream photonics and advanced sensor programs, as well as wellhead displacement analysis. The disclosed technology may solve problems with conventional systems by improving the resolution of the results and reducing the acquisition speed. The technique is used to generate a three-dimensional (3D) point cloud (e.g., of an equipment surface) using structured light, and the technique can be used to characterize axial, radial, and azimuthal deformations, characterize mechanical tension and strain by analyzing the cross-polarized spectrum of the reflected beam (e.g., with the probe beam elliptically polarized), identify material degradation and contamination by using reflectance spectroscopy, and derive correlations between displacement, temperature, and flow rate. The technique can be extended, modified, or customized to characterize the displacement of other surface equipment. This provides an advantage over, for example, conventional systems that are typically reactive and may be slower to react to equipment-related issues.

[0007] The details of one or more embodiments of the subject matter herein are set forth in the detailed description, the accompanying drawings, and the claims. Other features, aspects, and advantages of the subject matter will become apparent from the detailed description, the claims, and the accompanying drawings. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 illustrates an example of a photonic sensing system for characterizing displacement, according to some embodiments of the present disclosure.

[0009] [Diagram 2] FIG. 1 illustrates a photonic sensing system used in the sensing and characterization process according to some embodiments of the present disclosure.

[0010] [Diagram 3] FIG. 1 illustrates an example of a location of a beacon within a wellhead, according to some embodiments of the present disclosure.

[0011] [Figure 4] 1 is a schematic diagram of an exemplary structure of a photonic sensor according to some embodiments of the present disclosure.

[0012] [Diagram 5] FIG. 1 illustrates an example of a photonic sensing system for use on a wellhead structure, according to some embodiments of the present disclosure.

[0013] [Figure 6A] 1A-1C illustrate an exemplary top view and photonic sensing system according to some embodiments of the present disclosure. [Figure 6B] 1A-1C illustrate an exemplary top view and photonic sensing system according to some embodiments of the present disclosure.

[0014] [Figure 7] 1 is a flowchart illustrating an example of a method for determining changes in one or more portions of one or more objects using real-time non-contact three-dimensional (3D) surface measurement according to some embodiments of the present disclosure.

[0015] [Figure 8]FIG. 1 is a block diagram illustrating an example computer system that may be used to provide computational functionality associated with the described algorithms, methods, functions, processes, flows and procedures as described in this disclosure, in accordance with some embodiments of the present disclosure.

[0016] Like reference numbers and designations in the various drawings indicate like elements. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] In the following detailed description, techniques are described for providing a photonic sensing system that performs an automated method of characterizing the displacement of equipment surfaces and monitoring changes in real time. For example, a method and system for non-contact three-dimensional (3D) surface measurement based on structured light illumination can be used. Laser pattern illumination can be used to obtain a real-time three-dimensional map of surface equipment (e.g., wellheads, production tubing, and manifolds). The term real-time can correspond to events occurring within a specified period of time, e.g., within a few seconds or less than a minute. The real-time map can be used to track relative changes in the positions of known markers on the object surface. This process generates a point cloud that can be used to derive structural properties and changes, such as displacement, deformation, stress / strain state, etc. Additionally, the use of different laser wavelengths and hyperspectral structured light illumination allows for real-time monitoring of material deposition (contamination) and degradation. The present technique can be incorporated into or used with monitoring systems used in the petrochemical industry, such as gas operations, including offshore gas wells.

[0018] Various modifications, changes and substitutions of the disclosed embodiments are permissible, and the defined general principles, which may be readily apparent to those skilled in the art, may be applied to other embodiments and applications without departing from the scope of the present disclosure. In some cases, details unnecessary for obtaining an understanding of the described subject matter may be omitted so as not to obscure one or more described embodiments with such unnecessary details, and insofar as such details are within the skill of those skilled in the art. The present disclosure is not intended to be limited to the embodiments described or illustrated, but is intended to be accorded the widest scope consistent with the described principles and features.

[0019] FIG. 1 illustrates an example of a photonic sensing system 100 for characterizing displacement, according to some embodiments of the present disclosure. The photonic sensing system 100 can provide remote sensing, for example, using a workflow that allows for real-time and non-contact monitoring of growth 102 at a wellhead 104. The photonic sensing system 100 can include a single sensor 106 or an array (or group) of sensors 106, a data transmission system, a computerized data collection system, and a toolbox (e.g., a user interface 108) for visualization and data analysis. The user interface 108 used by a user can present, for example, one or more graphs showing the wellhead growth 102 (e.g., in inches (in.)) over time 114 (e.g., in weeks, months, or years) and the change in production rate 110 (e.g., in thousands of cubic feet per day (MMSCFD)).

[0020] Photonic sensing system 100 can include an array of structured-light sensors (SLSes) (e.g., sensors 106) that are directed at one or more objects, such as equipment at a wellhead 104. A computerized data collection system is configured to collect light information from the array of SLSes. The light information collected from the array of SLSes can be used by an analysis and presentation system to provide analysis and visualization of the light information. A data transmission system can transmit information between the array of SLSes, the computerized data collection system, and the analysis and presentation system.

[0021] The spatial resolution of the sensor may be, for example, 100×10^(-6)m (or 100 μm), or 100 micrometers, and the repetition rate may be, for example, on the order of ≧60 Hz. Data communication may be achieved using mobile networks (e.g., Global System For Mobile Communications (GSM) or 4th or 5th generation), meshed wireless networks, or optical fibers.

[0022] FIG. 2 illustrates a photonic sensing system 200 used in the sensing and characterization process, according to some embodiments of the present disclosure. The photonic sensing system 200 can generate a point cloud, for example, of a wellhead 104. Generating the point cloud 102 can include system features 204 including a structured light sensor system, signal processing, point cloud generation and storage, transformation using optical flow (e.g., using artificial intelligence (AI)), and transmission to a supervisory control and data acquisition (SCADA) system. This process can be performed prior to integration with the SCADA system. The process can use post-analysis routines and machine learning engines. The photonic sensing system 200 can use structured light, multi-laser ranging, laser array ranging, or laser patterned beam array ranging to obtain a point cloud P of n points whose coordinates can be, for example, Equation (1).

number

number

[0023] The photonic sensing system 200 can provide the point cloud capture process, analysis and transmission. Basic analysis can be performed at the edge by incorporating a neural engine that calculates the optical flow of the point cloud between two subsequent acquisitions. Alternatively, the data can be sent to a central processing authority. This information can provide the transient changes in position / displacement. The data can be further utilized in other analytical toolboxes to correlate and predict flow using data available through the SCADA system.

[0024] 3 is a diagram illustrating an example location of a beacon 302 within a wellhead 300, according to some embodiments of the present disclosure. The beacon 302 may be used, for example, in the photonic sensing system 200. In some embodiments, the beacon 302 (or tracer), shown as a white square in FIG. 3, may be placed at a known location in the wellhead 300 to serve as a reference or anchor in calculations related to FIG.

[0025] FIG. 4 is a schematic diagram of an example structure of a photonic sensor 400 according to some embodiments of the present disclosure. The photonic sensor 400 includes field housing components 402a-g ("S1"-"S7"). The sensor 402 can be a patterned (e.g., commercially available) optical sensor and receiver. The lens 404 can be made of titanium dioxide / silicon dioxide (TiO2 / SiO2), TiO2 / diamond, titanium dioxide TiO2 / IRFS (infrared fused silica glass), or a hierarchical diamond / diamond window, where the TiO2 layer is used for self-cleaning. The beam 406 can be a beam projected onto and reflected from the measurement target. The cooler 408 can be a heat sink with a thermoelectric cooler and air circulation to maintain the operation of the device below a threshold temperature, e.g., 50 degrees Celsius (C). The air component 410 can include an air pump and conduits. The circulating air can serve at least two purposes, including cooling the photonic sensor 400 and cleaning the window using the ionized air nozzle 412. The power components 414 can include a power source and a battery (e.g., Lithium (Li)-ion or hydrogen batteries). The housing 416 can house a high gain, high temperature photovoltaic cell, for example using Gallium Nitride (GaN).

[0026] The photonic sensor 400 of FIG. 4 can be implemented with an integrated sensing head or structured light sensor (SLS) system and field housing. The photonic sensor 400 can use several structured light sensors and laser ranging sensors available on the market, such as, for example, Ladimo, Blackrock, or Velodyne, in various combinations. In most cases, the number of devices used can vary depending on the axial or longitudinal resolution requirements. In some embodiments, one sensor can be placed and used every 30 centimeters (cm) to 50 cm for axial resolution better than 0.1 millimeters (mm). This ratio can depend on the characteristics of the sensors used. The use of an array of sensors can depend on the location of each SLS, for example, since each beam 406 may not be able to see some parts of the wellhead. The on-board edge computing system can use all-optical or ASIC processing. The photonic sensor 400 can include self-cleaning and anti-fog windows that help ensure long-term maintenance-free optical monitoring. Two mutually non-exclusive routes can be used to achieve the following two examples.

[0027] A first example involves modifying a surface to exhibit at least one of the following atypical behaviors: hydrophobic, hydrophilic, oleophobic, superhydrophobic and superoleophobic. This allows the surface to either completely repel liquids and particles (hydrophobic or superhydrophobic / hydrophobic surfaces) or to allow liquids to spread evenly across the entire surface to avoid lensing and diffusion effects while washing away contaminants (e.g., hydrophilic or superhydrophilic surfaces). An embodiment using diamond windows can include deposition of tailored diamond nanofilms or diamond-like carbon structures to exhibit long-lasting self-cleaning and anti-fogging effects while maintaining high light transmission.

[0028] A second example involves the use of TiO2-based photocatalytic surfaces. When ambient UV light interacts with TiO2, the surface releases reactive oxygen species. The oxygen radicals burn organic matter attached to the surface, thus cleaning the surface. Photocatalytic surfaces can exhibit anti-fog, self-cleaning properties, antibacterial and anti-fouling properties.

[0029] 5 is a diagram illustrating an example of a photonic sensing system 500 used on a wellhead structure 502, according to some embodiments of the present disclosure. The photonic sensing system 500 includes an SLS array and a projection 504. The SLS array may be mounted on a rack. Each SLS 506 may incorporate a laser meter to determine the distance between each SLS 506 and the ground. These features allow the photonic sensing system 500 to measure absolute displacement relative to the ground. The SLS array reference / beacon markers 508 are shown as open circles on the wellhead structure 502. The photonic sensing system 500 generates a point cloud 510 representing points on the wellhead structure 502.

[0030] The SLSes can each be mounted on a rack. Each SLS can monitor the distance to the next measurement device (e.g., underneath the SLS) using a laser ranging system located at the bottom of the SLS. This allows the process to know the relative position of each measurement device and therefore improve axial / longitudinal displacement characterization.

[0031] The horizontal (H) and vertical (V) resolution of a structured light sensor can vary depending on the configuration of the photonic sensing system used. Thus, the resolution Δ h、v is the distance r from the circumscribing cylinder to the light output sls and angular resolution φ H / V As a function of, for example, it can be expressed as shown in the following equation (3).

number

[0032] The field of view (FOV) of an SLS typically spans, for example, 170-360 degrees horizontally and 5-30 degrees vertically. These spans and the distance to the target may dictate the number of SLSes required in an array configuration.

[0033] 6A and 6B show top views 600 and 602 of a photonic sensing system according to some embodiments of the present disclosure. The top views 600 and 602 show a wellhead structure 604 and an SLS array 606, illustrating examples of suggested locations for a remote structured light sensor (RSLS) from above. The wellhead structure 604 has a maximum wellhead radius 608 including the wellhead arms. The major and minor axes of the parabola can be selected such that the pattern projected by each beam on the structure covers a given area, for example a 30 centimeter (cm) to 50 cm wide plane tangent to a cylinder circumscribing the wellhead structure 604. The proposed locations can be selected to maximize field of view and characterization.

[0034] The photonic sensing system may also be used to characterize stress along a structure (e.g., wellhead structure 604). In this case, the photonic sensing system may be modified to perform photonic stress analysis tomography. In this setup, the output beam of the analyzer may be elliptically polarized using a variable or permanent wavelength retarder. Polarization may also be incorporated into the laser system that delivers the beam. This polarization step is performed before the creation of the pattern. All or part of the structure is covered with a birefringent film (e.g., an epoxy or oil that is transparent to the wavelengths used by the light source). The reflected beam is then split into its base polarizations and the intensity patterns of each polarization are compared. The resulting polarizations and spectral distributions can be used to derive a stress map according to strain / stress-optical laws.

[0035] 7 is a flow chart illustrating an example of a method 700 for identifying changes in one or more portions of one or more objects using real-time non-contact 3D surface measurements, according to some embodiments of the present disclosure. For clarity of presentation, the following description generally describes the method 700 in the context of other figures herein. However, it will be understood that the method 700 may be performed by, for example, any suitable system, environment, software, and hardware, or combination of systems, environments, software, and hardware, as appropriate. In some embodiments, various steps of the method 700 may be performed in parallel, in combination, in a loop, or in any order.

[0036] At 702, a 3D point cloud of one or more objects is generated by the analysis and presentation system using light information collected through structured light illumination by an array of SLSes directed at the one or more objects. The SLSes can include, for example, laser patterned lighting devices. Generating the point cloud includes defining points of the 3D point cloud relative to reference points on the one or more objects. The one or more objects can include equipment used in petrochemical industry operations. The equipment can include one or more of a wellhead, a production tubing, and a manifold. The reference points can be markers placed at specific locations on the equipment. The SLSes can provide, for example, a spatial resolution of 100 micrometers and a repetition rate of, for example, 60 Hertz (Hz) or greater. The SLSes can identify x, y, z, lambda values ​​for each point in the point cloud, where x, y, z are 3D spatial coordinates and lambda is the illumination wavelength in the 3D spatial coordinates. In some embodiments, the analysis and presentation system can include analysis tools to correlate and predict flows using data available through a supervisory control and data acquisition (SCADA) system. From 702, method 700 proceeds to 704.

[0037] At 704, real-time non-contact 3D surface measurement of one or more objects is performed using the 3D point cloud. From 704, method 700 proceeds to 706.

[0038] At 706, changes in one or more portions of the one or more objects are identified by the analysis and presentation system by analyzing the real-time non-contact 3D surface measurements. As an example, identifying changes in one or more portions of the one or more objects may include deriving changes in structural properties including displacement, deformation, stress / strain state, and material deposition / contamination and degradation. After 706, method 700 may stop.

[0039] 8 is a block diagram of an exemplary computer system 800 used to provide computational capabilities associated with the algorithms, methods, functions, processes, flows, and procedures described in this disclosure, according to some embodiments of the disclosure. The illustrated computer 802 is intended to encompass any computing device, such as a server, desktop computer, laptop / notebook computer, wireless data port, smartphone, personal digital assistant (PDA), tablet computing device, or one or more processors within these devices, including physical instances, virtual instances, or both. The computer 802 can include input devices, such as a keypad, keyboard, and touch screen, that can accept user information. The computer 802 can also include output devices that can communicate information related to the operation of the computer 802. The information can include digital data, video data, audio information, or a combination of information. The information can be presented in a graphical user interface (UI) (or GUI).

[0040] The computer 802 may act as a client, a network component, a server, a database, a persistence, or a component of a computer system for implementing the subject matter described in this disclosure. The illustrated computer 802 is communicatively coupled to a network 830. In some embodiments, one or more components of the computer 802 may be configured to operate in different environments, including a cloud computing based environment, a local environment, a global environment, and a combination of environments.

[0041] At a top level, computer 802 is an electronic computing device operable to receive, transmit, process, store, and manage data and information related to the described subject matter. According to some embodiments, computer 802 may also include or be communicatively coupled to an application server, an email server, a web server, a caching server, a streaming data server, or a combination of servers.

[0042] The computer 802 can receive requests from a client application (e.g., running on another computer 802) over the network 830. The computer 802 can respond to the received requests by processing the received requests using a software application. Requests can also be sent to the computer 802 from internal users (e.g., from a command console), external (or third parties), automated applications, entities, individuals, systems and computers.

[0043] Each component of the computer 802 can communicate using a system bus 803. In some embodiments, any or all of the components of the computer 802, including hardware or software components, can be coupled to each other or to an interface 804 (or a combination of both) via the system bus 803. The interface can use an application programming interface (API) 812, a service layer 813, or a combination of the API 812 and the service layer 813. The API 812 can include specifications of routines, data structures, and object classes. The API 812 can be computer language independent or computer language dependent. The API 812 can refer to a complete interface, a single function, or a set of APIs.

[0044] The service layer 813 can provide software services to the computer 802 and other components communicatively coupled to the computer 802 (whether shown or not). The functionality of the computer 802 can be accessible to all service consumers using this service layer. Software services such as those provided by the service layer 813 can provide reusable defined functionality through defined interfaces. For example, the interface can be software written in JAVA, C++, or a language that provides data in Extensible Markup Language (XML) format. Although shown as an integrated component of the computer 802, in alternative embodiments, the API 812 or the service layer 813 can be a stand-alone component associated with other components of the computer 802 and other components communicatively coupled to the computer 802. Additionally, any or all portions of the API 812 or the service layer 813 can be implemented as a child module or sub-module of another software module, enterprise application, or hardware module without departing from the scope of the present disclosure.

[0045] The computer 802 includes an interface 804. Although shown as a single interface 804 in FIG. 8, two or more interfaces 804 may be used according to the particular needs, desires, or particular embodiment of the computer 802 and the described functionality. The interface 804 may be used by the computer 802 to communicate with other systems (whether shown or not) connected to the network 830 in a distributed environment. In general, the interface 804 may include or be implemented using logic encoded in software or hardware (or a combination of software and hardware) operable to communicate with the network 830. More specifically, the interface 804 may include software supporting one or more communication protocols associated with the communication. Thus, the network 830 or interface hardware may be operable to communicate physical signals in and out of the illustrated computer 802.

[0046] Computer 802 includes a processor 805. Although shown in Figure 8 as a single processor 805, two or more processors 805 may be used according to the particular needs, desires, or particular embodiment and described functionality of computer 802. Generally, processor 805 may execute instructions and manipulate data to perform the operations of computer 802, including operations using the algorithms, methods, functions, processes, flows, and procedures described in this disclosure.

[0047] Computer 802 also includes a database 806 capable of holding data for computer 802 and other components (whether shown or not) connected to network 830. For example, database 806 may be an in-memory, conventional, or database that stores data consistent with the present disclosure. In some embodiments, database 806 may be a combination of two or more different database types (e.g., a hybrid in-memory and conventional database) according to the particular needs, desires, or particular embodiment and described functionality of computer 802. Although shown in FIG. 8 as a single database 806, two or more databases (same, different, or a combination of types) may be used according to the particular needs, desires, or particular embodiment and described functionality of computer 802. Although database 806 is shown as an internal component of computer 802, in alternative embodiments, database 806 may be external to computer 802.

[0048] Computer 802 also includes memory 807 that can hold data for computer 802 or a combination of components connected to network 830 (whether shown or not). Memory 807 can store any data consistent with this disclosure. In some embodiments, memory 807 can be a combination of two or more different types of memory (e.g., a combination of solid-state and magnetic storage devices) according to the particular needs, desires, or particular embodiment and described functionality of computer 802. Although shown in FIG. 8 as a single memory 807, two or more memories 807 (of the same, different, or combination of types) can be used according to the particular needs, desires, or particular embodiment and described functionality of computer 802. Although memory 807 is shown as an internal component of computer 802, in alternative embodiments, memory 807 can be external to computer 802.

[0049] The application 808 may be an algorithmic software engine that provides functionality according to the particular needs, desires, or particular embodiment and described functionality of the computer 802. For example, the application 808 may function as one or more components, modules, or applications. Further, while shown as a single application 808, the application 808 may be implemented as multiple applications 808 on the computer 802. Additionally, while shown as internal to the computer 802, in alternative embodiments, the application 808 may be external to the computer 802.

[0050] The computer 802 can also include a power source 814. The power source 814 can include a rechargeable or non-rechargeable battery that can be configured to be either user-replaceable or non-user-replaceable. In some embodiments, the power source 814 can include power conversion and management circuitry, including recharge, standby, and power management functions. In some embodiments, the power source 814 can include a power plug to allow the computer 802 to be plugged into a wall outlet or power source, for example, to power the computer 802 or to recharge a rechargeable battery.

[0051] Associated with or external to the computer system that includes computer 802 may be any number of computers 802, with each computer 802 communicating via network 830. Additionally, the terms "client," "user," and other appropriate terms may be used interchangeably, as appropriate, without departing from the scope of this disclosure. Additionally, this disclosure contemplates that many users may use one computer 802, and that one user may use multiple computers 802.

[0052] The described embodiments of the present subject matter may include one or more features, either alone or in combination.

[0053] For example, in a first embodiment, a computer-implemented method includes: A three-dimensional (3D) point cloud of one or more objects is generated by an analysis and presentation system using light information collected through structured light illumination by an array of structured light sensors (SLSes) directed at the one or more objects. Generating the point cloud includes defining points of the 3D point cloud relative to reference points on the one or more objects. Real-time non-contact 3D surface measurements of the one or more objects are performed using the 3D point cloud. Changes in one or more portions of the one or more objects are identified by the analysis and presentation system by analyzing the real-time non-contact 3D surface measurements.

[0054] Each of the above and other described embodiments can optionally include one or more of the following features.

[0055] The first feature may be combined with any of the latter features, wherein the one or more objects include equipment used in petrochemical industry operations, the equipment including one or more of a wellhead, a production tubing, and a manifold, and the reference point is a marker positioned at a particular location on the equipment.

[0056] A second feature may be combined with any of the preceding or following features, wherein the SLSes comprises a laser patterned illumination device.

[0057] A third feature, which may be combined with any of the preceding or following features, includes determining changes in one or more portions of one or more objects including deriving changes in structural properties including displacement, deformation, stress / strain state, and material deposition / contamination and degradation.

[0058] A fourth feature, which can be combined with any of the preceding or following features, provides the SLSes with a spatial resolution of 100 micrometers and a repetition rate of 60 Hertz (Hz) or greater.

[0059] A fifth feature, which can be combined with any of the previous or subsequent features, is that the SLSes identifies x, y, z, and λ values ​​for each point in the point cloud, where x, y, and z are 3D spatial coordinates and λ is the illumination wavelength in the 3D spatial coordinates.

[0060] A sixth feature, which may be combined with any of the preceding or following features, wherein the analysis and presentation system includes analytical tools for correlating and forecasting flows using data available through a supervisory control and data acquisition (SCADA) system.

[0061] In a second embodiment, a non-transitory computer-readable storage medium stores one or more instructions executable by a computer system to perform operations including: A three-dimensional (3D) point cloud of one or more objects is generated by an analysis and presentation system using light information collected through structured light illumination by an array of structured light sensors (SLSes) directed at the one or more objects. Generating the point cloud includes defining points of the 3D point cloud relative to reference points on the one or more objects. Real-time non-contact 3D surface measurements of the one or more objects are performed using the 3D point cloud. Changes in one or more portions of the one or more objects are identified by the analysis and presentation system by analyzing the real-time non-contact 3D surface measurements.

[0062] Each of the above and other described embodiments can optionally include one or more of the following features.

[0063] The first feature may be combined with any of the latter features, wherein the one or more objects include equipment used in petrochemical industry operations, the equipment including one or more of a wellhead, a production tubing, and a manifold, and the reference point is a marker positioned at a particular location on the equipment.

[0064] A second feature may be combined with any of the preceding or following features, wherein the SLSes comprises a laser patterned illumination device.

[0065] A third feature, which may be combined with any of the preceding or following features, is that identifying changes in one or more portions of the one or more objects includes deriving changes in structural properties including displacement, deformation, stress / strain state, and material deposition / contamination and degradation.

[0066] A fourth feature, which can be combined with any of the preceding or following features, provides the SLSes with a spatial resolution of 100 micrometers and a repetition rate of 60 Hertz (Hz) or greater.

[0067] A fifth feature, which can be combined with any of the previous or subsequent features, is that the SLSes identifies x, y, z, and λ values ​​for each point in the point cloud, where x, y, and z are 3D spatial coordinates and λ is the illumination wavelength in the 3D spatial coordinates.

[0068] A sixth feature, which may be combined with any of the preceding or following features, wherein the analysis and presentation system includes analytical tools for correlating and forecasting flows using data available through a supervisory control and data acquisition (SCADA) system.

[0069] In a third embodiment, a computer-implemented system includes an array of structured light sensors (SLSes) directed at one or more objects, a computerized data collection system configured to collect light information from the array of SLSes, an analysis and presentation system configured to provide analysis and visualization of the light information collected from the array of SLSes, and a data transmission system for transmitting information between the array of SLSes, the computerized data collection system, and the analysis and presentation system. The computer-implemented system includes one or more processors and a non-transitory computer-readable storage medium coupled to the one or more processors and storing programming instructions for execution by the one or more processors. The programming instructions direct the one or more processors to perform operations including: A three-dimensional (3D) point cloud of the one or more objects is generated by the analysis and presentation system using light information collected through structured light illumination by the array of structured light sensors (SLSes) directed at the one or more objects. Generating the point cloud includes defining points of the 3D point cloud relative to reference points on the one or more objects. A real-time non-contact 3D surface measurement of the one or more objects is performed using the 3D point clouds. Changes in one or more portions of the one or more objects are identified by an analysis and presentation system by analyzing the real-time non-contact 3D surface measurement.

[0070] Each of the above and other described embodiments can optionally include one or more of the following features.

[0071] The first feature may be combined with any of the latter features, wherein the one or more objects include equipment used in petrochemical industry operations, the equipment including one or more of a wellhead, a production tubing, and a manifold, and the reference point is a marker positioned at a particular location on the equipment.

[0072] A second feature may be combined with any of the preceding or following features, wherein the SLSes comprises a laser patterned illumination device.

[0073] A third feature, which may be combined with any of the preceding or following features, includes determining changes in one or more portions of one or more objects including deriving changes in structural properties including displacement, deformation, stress / strain state, and material deposition / contamination and degradation.

[0074] A fourth feature, which can be combined with any of the preceding or following features, provides the SLSes with a spatial resolution of 100 micrometers and a repetition rate of 60 Hertz (Hz) or greater.

[0075] A fifth feature, which can be combined with any of the previous or subsequent features, is that the SLSes identifies x, y, z, and λ values ​​for each point in the point cloud, where x, y, and z are 3D spatial coordinates and λ is the illumination wavelength in the 3D spatial coordinates.

[0076] Implementations of the subject matter and functional operations described herein may be realized in digital electronic circuitry, tangibly embodied computer software or firmware, computer hardware including the structures disclosed herein and their structural equivalents, or a combination of one or more of them. Software implementations of the described subject matter may be realized as one or more computer programs. Each computer program may include one or more modules of computer program instructions encoded on a tangible, non-transitory computer-readable storage medium for execution by or to control the operation of a data processing device. Alternatively or additionally, the program instructions may be encoded in / on an artificially generated propagated signal. For example, the signal may be a machine-generated electrical, optical, or electromagnetic signal generated to encode information for transmission to an appropriate receiving device for execution by a data processing device. The computer storage medium may be a machine-readable storage device, a machine-readable storage substrate, a random access memory device or a serial access memory device, or a combination of computer storage media.

[0077] The terms "data processing device", "computer" and "electronic computing device" (or equivalents understood by those skilled in the art) refer to data processing hardware. For example, a data processing device can encompass any type of apparatus, device and machine for processing data, including, for example, a programmable processor, a computer, or multiple processors or computers. An apparatus can also include special purpose logic circuitry, including, for example, a central processing unit (CPU), a field programmable gate array (FPGA), or an application specific integrated circuit (ASIC). In some embodiments, the data processing device or special purpose logic circuitry (or a combination of data processing devices or special purpose logic circuitry) can be hardware-based or software-based (or a combination of both hardware-based and software-based). An apparatus can optionally include code that creates an execution environment for a computer program, such as code that constitutes a processor firmware, a protocol stack, a database management system, an operating system, or a combination of execution environments. The present disclosure contemplates the use of a data processing device with or without a conventional operating system, such as LINUX, UNIX, WINDOWS, MAC OS, ANDROID, or IOS.

[0078] A computer program may also be referred to or described as a program, software, software application, module, software module, script or code, and may be written in any form of programming language. Programming languages ​​may include, for example, compiled, interpreted, declarative, or procedural languages. A program may be deployed in any form, including a standalone program, module, component, subroutine, or unit for use in a computing environment. A computer program may correspond to a file in a file system, but need not correspond to a file. A program may be stored as part of a file that holds other programs or data, for example one or more scripts stored in a markup language document, a single file dedicated to the program in question, or multiple cooperating files that store one or more modules, subprograms, or code portions. A computer program may be deployed for execution on one computer or multiple computers, for example located at one site or distributed across multiple sites interconnected by a communication network. While some of the programs shown in the various figures may be shown as individual modules that implement various features and functions through various objects, methods, or processes, a program may instead include several sub-modules, third party services, components, and libraries. Conversely, the features and functions of the various components may be combined into a single component as desired. The thresholds used to perform the calculations may be specified statically, dynamically, or both statically and dynamically.

[0079] The methods, processes, or logic flows described herein may be performed by one or more programmable computers executing one or more computer programs to perform functions by operating on input data and generating output. The methods, processes, or logic flows may also be performed by, and an apparatus may be implemented as, special purpose logic circuitry, such as a CPU, FPGA, or ASIC.

[0080] A computer suitable for executing a computer program may be based on one or more general-purpose and special-purpose microprocessors, as well as other types of CPUs. The elements of a computer are a CPU for executing or executing instructions and one or more memory devices for storing instructions and data. In general, a CPU can receive instructions and data from (and write data to) memory.

[0081] A graphics processing unit (GPU) may also be used in combination with a CPU. The GPU may provide specialized processing that occurs in parallel with processing performed by the CPU. The specialized processing may include, for example, artificial intelligence (AI) applications and processing. The GPU may be used in a GPU cluster or in multi-GPU computing.

[0082] A computer may include or be operatively connected to one or more mass storage devices for storing data. In some embodiments, a computer may receive data from and transfer data to a mass storage device, including, for example, a magnetic disk, a magneto-optical disk, or an optical disk. Additionally, a computer may be incorporated into another device, for example, a mobile phone, a personal digital assistant (PDA), a mobile audio or video player, a game console, a global positioning system (GPS) receiver, or a portable storage device, such as a universal serial bus (USB) flash drive.

[0083] Computer readable storage media suitable for storing computer program instructions and data (transient or non-transient, as appropriate) can include all forms of persistent / non-persistent and volatile / non-volatile memory, media, and memory devices. Computer readable storage media can include semiconductor memory devices such as random access memory (RAM), read only memory (ROM), phase change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), erasable programmable read only memory (EPROM), electrically erasable programmable read only memory (EEPROM), and flash memory devices. Computer readable storage media can also include magnetic devices such as tapes, cartridges, cassettes, and internal / removable disks. Computer readable storage media can also include magneto-optical disks and optical memory devices and technologies, including, for example, digital video disks (DVDs), CD-ROMs, DVD+ / -R, DVD-RAM, DVD-ROM, HD-DVD, and BLU-RAY®. The memory may store a variety of objects or data, including caches, classes, frameworks, applications, modules, backup data, jobs, web pages, web page templates, data structures, database tables, repositories, and dynamic information. The types of objects and data stored in the memory may include parameters, variables, algorithms, instructions, rules, constraints, and references. Additionally, the memory may include logs, policies, security or access data, and report files. The processor and the memory may be supplemented by, or incorporated in, special purpose logic circuitry.

[0084] Embodiments of the subject matter described in this disclosure may be implemented on a computer having a display device for providing interaction with a user, including displaying information to (and receiving input from) the user. Types of display devices may include, for example, cathode ray tubes (CRTs), liquid crystal displays (LCDs), light emitting diodes (LEDs), and plasma monitors. Display devices may include, for example, keyboards and pointing devices, including mice, trackballs, or trackpads. User input may also be provided to the computer through the use of a touch screen, for example, a tablet computer surface having pressure sensitivity, or a multi-touch screen using capacitive or electrical sensing. Other types of devices may be used to provide interaction with a user, including receiving user feedback, including, for example, sensory feedback, including visual feedback, auditory feedback, or haptic feedback. Input from a user may be received in the form of acoustic input, voice input, or tactile input. Additionally, a computer may interact with a user by sending documents to and receiving documents from a device used by the user. For example, a computer may send a web page to a web browser on a user's client device in response to a request received from the web browser.

[0085] The terms "graphical user interface" or "GUI" may be used in the singular or plural to describe one or more graphical user interfaces and each of the displays of a particular graphical user interface. Thus, a GUI may represent any graphical user interface, including but not limited to a web browser, a touch screen, or a command line interface (CLI), that processes information and efficiently presents information results to a user. In general, a GUI may include some or all of the user interface (UI) elements associated with a web browser, such as interactive fields, pull-down lists, and buttons. These and other UI elements may relate to or represent the functionality of a web browser.

[0086] Embodiments of the subject matter described herein may be implemented in a computing system including a back-end component, e.g., as a data server, or in a computing system including a middleware component, e.g., an application server. Additionally, the computing system may include a front-end component, e.g., a client computer having one or both of a graphical user interface or a web browser through which a user can interact with the computer. The components of the system may be interconnected by any form or medium of wired or wireless digital data communication (or combination of data communication) in a communication network. Examples of communication networks include a local area network (LAN), a radio access network (RAN), a metropolitan area network (MAN), a wide area network (WAN), Worldwide Interoperability for Microwave Access (WIMAX), a wireless local area network (WLAN) (e.g., using 802.11a / b / g / n or 802.20 or a combination of protocols), all or part of the Internet, or any other communication system or systems in one or more locations (or combination of communication networks). A network may communicate, for example, Internet Protocol (IP) packets, Frame Relay frames, Asynchronous Transfer Mode (ATM) cells, voice, video, data, or a combination of communication types between network addresses.

[0087] A computing system may include clients and servers. Clients and servers may generally be remote from each other and typically interact through a communication network. The relationship of client and server may arise by virtue of computer programs running on the respective computers and having a client-server relationship.

[0088] A cluster file system can be any type of file system that is accessible from multiple servers for reads and updates. Locking or consistency tracking may not be required for an Exchange file system because locking can be done at the application layer. Additionally, Unicode data files may differ from non-Unicode data files.

[0089] Although the present specification contains many details of specific embodiments, these should not be construed as limitations on the scope of the claims, but rather as descriptions of features that may be specific to certain embodiments. Some features described in the present specification in the context of separate embodiments may also be realized in a single embodiment in combination. Conversely, various features described in the context of a single embodiment may also be implemented in multiple embodiments, separately or in any suitable subcombination. Furthermore, although the features described above may be described as acting in a particular combination and may be initially claimed, one or more features from a claimed combination may, in some cases, be deleted from the combination, and the claimed combination may be directed to a subcombination or a variation of the subcombination.

[0090] Specific embodiments of the present subject matter have been described. As will be apparent to those skilled in the art, other embodiments, modifications, and permutations of the described embodiments are within the scope of the following claims. Although operations are shown in the drawings or claims in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown, or in sequential order, or that all of the shown operations be performed, to achieve desirable results (some operations may be considered optional). In certain situations, multitasking or parallel processing (or a combination of multitasking and parallel processing) may be advantageous and may be performed where deemed appropriate.

[0091] Furthermore, the separation or integration of various system modules and components in the foregoing embodiments should not be understood as requiring such separation or integration in all embodiments, and it should be understood that the described program components and systems may generally be integrated together in a single software product or packaged into multiple software products.

[0092] Accordingly, the foregoing exemplary embodiments do not define or limit the disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of the disclosure.

[0093] Furthermore, any of the claimed embodiments are deemed applicable to a computer system including at least a computer-implemented method, a non-transitory computer-readable storage medium storing computer-readable instructions for performing the computer-implemented method, and a computer memory interoperably coupled with a hardware processor configured to execute the computer-implemented method or the instructions stored in the non-transitory computer-readable storage medium.

Claims

1. An array of structured light sensors (SLSes) directed at one or more objects, A computerized data collection system configured to collect optical information from the array of SLSes, An analysis and presentation system configured to provide analysis and visualization of the optical information collected from the array of SLSes, A data transmission system for transmitting information between the array of SLSes, the computerized data collection system, and the analysis and presentation system, One or more processors, A non-transitory computer-readable storage medium coupled to the one or more processors and storing programming instructions executed by the one or more processors, the programming instructions causing the one or more processors to, Generating, by the analysis and presentation system using optical information collected through structured light illumination by the array of SLSes, a three-dimensional (3D) point cloud of the one or more objects, the step including defining points of the 3D point cloud relative to reference points on the one or more objects, Performing real-time non-contact 3D surface measurement of the one or more objects using the 3D point cloud, Identifying, by analyzing the real-time non-contact 3D surface measurement by the analysis and presentation system, correlations between changes in material, damage, deformation, mechanical stress and strain, material degradation and contamination, and displacement, temperature, and flow rate of one or more parts of the one or more objects, the non-transitory computer-readable storage medium instructing to perform, System.

2. The one or more objects include equipment used in petrochemical industry operations, the equipment including one or more of a wellhead, production tubes, and manifolds, and the reference points are markers positioned at specific locations on the equipment. The system according to claim 1.

3. The SLSes include laser-patterned illumination devices. The system according to claim 1.

4. The SLSes provide a spatial resolution of 100 micrometers and a repetition rate of 60 Hertz (Hz) or more. The system according to claim 1.

5. The SLSes identify x, y, z, and λ values for each point within the point cloud, where x, y, and z are 3D spatial coordinates and λ is the illumination wavelength at the 3D spatial coordinates. The system according to claim 1.

6. The analysis and presentation system includes analysis tools for correlating and predicting flows using data available through a Supervisory Control and Data Acquisition (SCADA) system. The system according to claim 1.

7. A step of generating a three-dimensional (3D) point cloud of one or more objects, including defining points of the 3D point cloud relative to reference points on the one or more objects by an analysis and presentation system using light information collected through structured light illumination by an array of structured light sensors (SLSes) directed at the one or more objects. A step of performing real-time non-contact 3D surface measurement of one or more objects using the 3D point cloud. A step of identifying correlations between changes in material, damage, deformation, mechanical stress and strain, material degradation and contamination, and displacement, temperature, and flow rate in one or more parts of the one or more objects by analyzing the real-time non-contact 3D surface measurement by the analysis and presentation system. A computer-implemented method.

8. The one or more objects include equipment used in petrochemical industry operations, the equipment includes one or more of a wellhead, production tubes, and manifolds, and the reference points are markers positioned at specific locations on the equipment. The computer-implemented method according to claim 7.

9. The SLSes include laser-patterned lighting devices. The computer-implemented method according to claim 7.

10. The SLSes provide a spatial resolution of 100 micrometers and a repetition rate of 60 Hertz (Hz) or more. The computer-implemented method according to claim 7.

11. The SLSes identify x, y, z, and λ values for each point within the point cloud, where x, y, and z are 3D spatial coordinates and λ is the illumination wavelength at the 3D spatial coordinates. The computer-implemented method according to claim 7.

12. The analysis and presentation system includes analysis tools for correlating and predicting flows using data available through a Supervisory Control And Data Acquisition (SCADA) system. The computer-implemented method according to claim 7.

13. A non-transitory computer-readable storage medium storing one or more instructions executable by a computer system to perform a number of operations, the operations including: generating a three-dimensional (3D) point cloud of one or more objects, including defining points of the 3D point cloud relative to reference points on the one or more objects using light information collected through structured light illumination by an array of structured light sensors (SLSes) directed at the one or more objects, by an analysis and presentation system; performing real-time non-contact 3D surface measurements of the one or more objects using the 3D point cloud; identifying correlations between changes in material, damage, deformation, mechanical stress and strain, material degradation and contamination, and displacement, temperature and flow rate in one or more portions of the one or more objects by analyzing the real-time non-contact 3D surface measurements by the analysis and presentation system. Non-transitory computer-readable storage medium.

14. The one or more objects include equipment used in petrochemical industry operations, the equipment including one or more of a wellhead, production tubes and a manifold, and the reference points are markers positioned at specific locations on the equipment. The non-transitory computer-readable storage medium according to claim 13.

15. The SLSes include a laser-patterned lighting device. The non-transitory computer-readable storage medium according to claim 13.

16. The SLSes provide a spatial resolution of 100 micrometers and a repetition rate of 60 Hertz (Hz) or more. The non-transitory computer-readable storage medium according to claim 13.

17. The SLSes identify x, y, z, λ values for each point in the point cloud, where x, y, z are 3D spatial coordinates and λ is the illumination wavelength at the 3D spatial coordinates. The non-transitory computer-readable storage medium according to claim 13.

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