Flare Burner Smoke Detection via Image Segmentation
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Solution Overview
Problem
Current flare monitoring systems in the petrochemical and oil industries face challenges in accurately detecting smoke presence and adjusting process conditions to comply with environmental regulations, leading to potential fines and increased operational costs due to inefficient combustion and excessive fuel usage.
Innovation Solution
A method and system utilizing video cameras to analyze images of flare burners by segmenting regions of interest, calculating a smoke index based on pixel intensity, and adjusting process conditions such as assist fuel gas, purge gas, steam, and air to maintain compliance with regulatory requirements, incorporating additional sensors for reliability and atmospheric data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If existing flare monitoring systems use simple sensors (thermocouples, IR sensors) to detect smoke presence, then the device complexity is reduced, but the measurement precision and reliability of smoke detection deteriorates
Solution Approach 1:
The visual image of the flare burner is segmented into multiple regions of interest, and each region is analyzed independently to calculate a smoke index. This segmentation allows for more precise local smoke detection while using a standard video camera system, resolving the contradiction between simple device complexity and measurement precision.
Solution Approach 2:
The patent replaces specialized mechanical sensors (thermocouples, IR sensors) with a video camera system that uses optical imaging and image processing algorithms. This substitution maintains device simplicity while improving measurement precision through digital image analysis and smoke index calculation based on pixel intensity variations.
2Extent of automation
If operators manually monitor and adjust flare operation to ensure compliance, then the extent of automation is reduced, but the manufacturing precision of smoke control improves
Solution Approach 1:
The system continuously monitors smoke presence using video imaging, calculates smoke indices in real-time, and provides feedback to automatically adjust flare operation parameters. This closed-loop feedback mechanism achieves both high automation and precise smoke control by using visual information to drive control actions.
Solution Approach 2:
The flare monitoring and control system performs self-service by automatically detecting smoke conditions, determining compliance status, and adjusting operation parameters without requiring continuous manual operator intervention. The system serves itself by using its own visual measurements to control its own operation.
3Reliability
If excessive assist fuel gas, purge gas, steam, or air is used to control smoke, then the reliability of smoke control improves, but the loss of energy increases
Solution Approach 1:
Instead of using excessive assist media continuously, the system applies partial action by only introducing assist fuel gas, purge gas, steam, or air when smoke is actually detected. The automated control system modulates the amount of assist media based on real-time smoke measurements, achieving reliable smoke control while minimizing energy waste from unnecessary media injection.
4Reliability
If conservative operation with excessive assist media is used to ensure compliance, then the reliability of regulatory compliance improves, but the loss of substance increases
Solution Approach 1:
The system avoids conservative over-use of assist media by implementing partial action control. Assist fuel gas, purge gas, steam, and air are introduced only at the minimum necessary levels to achieve smoke control and regulatory compliance, as determined by real-time visual monitoring and smoke index calculations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively determines the presence or absence of smoke and adjusts process conditions to ensure compliance with environmental regulations, reducing the risk of fines and operational costs by optimizing combustion efficiency.
Implementation Method 1
obtaining a visual image of the flare burner and an area surrounding the flare burner
Implementation Method 2
calculating a smoke index for each of the regions of interest based on a historical intensity of a plurality of pixels within each of the regions of interest
Data Source
AI summary
Methods and systems for monitoring a flare burner with a camera. The methods and systems which may indicate to operators the presence or absence of one or more of smoke, flare flame, and steam plume and record those indications or measurements. Additionally, the methods and systems may confirm whether compliance with local regulations on visual emissions, smoke plume is achieved. The methods and systems automatically adjust the delivery rate of key inputs including measures assist fuel gas, purge gas, steam and/or air simultaneously to maintain or attain compliance with said local regulatory requirements. Also, methods for a machine learning process for using controller inputs to identify normal and abnormal flare states and provide visual indications and flare operation recommendations.