Infrared Detector Thermal Imaging for Process Conduit Anomaly Detection
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Solution Overview
Problem
Industrial process conduits degrade due to excessive temperatures, leading to temperature gradients that require manual monitoring with handheld thermal imaging cameras, which is time-consuming and lacks continuous monitoring, potentially causing premature plant shutdowns.
Innovation Solution
A diagnostic field device using an infrared detector with multiple pixels to capture thermal images of process conduits, a microprocessor to identify anomalies based on pixel outputs and thermal profile information, and output circuitry to provide diagnostic outputs indicative of non-linear relationships between pixel outputs, enabling automated monitoring without operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual monitoring with handheld thermal imaging cameras is used, then temperature measurements can be obtained, but continuous monitoring is not provided and the process is time-consuming
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical detection system. An infrared detector captures thermal radiation from the process conduit, and a microprocessor automatically analyzes the thermal images to detect temperature gradients and anomalies, eliminating the need for manual handheld camera operation and providing continuous automated monitoring.
Solution Approach 2:
The system performs self-monitoring by automatically capturing thermal images, processing the data through algorithms that detect non-linear temperature relationships, and generating anomaly detections without requiring operator intervention. The device autonomously identifies potential degradation issues in the process conduit.
2Reliability
If automated thermal monitoring is implemented, then continuous monitoring is achieved, but device complexity increases
Solution Approach 1:
The system segments the thermal monitoring task into distinct functional modules: an infrared detector for capturing thermal radiation, a microprocessor for processing images, memory for storing thermal profile data, and output circuitry for reporting anomalies. This modular segmentation manages complexity while enabling continuous automated monitoring.
Solution Approach 2:
The patent introduces a microprocessor as an intermediary between the infrared detector and the monitoring system. The microprocessor automatically processes thermal images, compares them against stored thermal profiles, and detects anomalies based on non-linear temperature relationships, reducing the complexity burden on the overall system architecture.
3Measurement precision
If physical inspection by operators is used, then temperature ranges can be assessed, but the process is time-consuming and does not provide continuous monitoring
Solution Approach 1:
The patent replaces manual visual inspection with automated infrared thermal imaging. The infrared detector captures precise temperature distribution data across the process conduit surface, and the microprocessor analyzes this data to detect temperature gradients and anomalies, providing both precision and continuous monitoring capability.
Solution Approach 2:
The system implements continuous thermal monitoring by continuously capturing thermal images of the process conduit and automatically analyzing them for anomalies. This continuous action eliminates the intermittent nature of manual inspections while maintaining measurement precision through consistent thermal data collection.
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 device allows for continuous, automated monitoring of process conduits, detecting anomalies and predicting potential failures, thereby preventing premature shutdowns and extending equipment lifespan.
Implementation Method 1
an infrared detector comprising a plurality of pixels configured to receive infrared radiation from the process conduit and responsively provide a plurality of pixel outputs
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A diagnostic field device (12) for detecting a condition of a process conduit (32) includes an infrared detector (100) comprising a plurality of pixels (120) configured to receive infrared radiation from the process conduit and responsively provide a plurality of pixel outputs. A first pixel of the plurality of pixels is configured to receive infrared radiation from a first location on the process conduit (32). A second pixel of the plurality of pixels is configured to receive infrared radiation from a second location on the process conduit (32). A memory (26) contains thermal profile information which relates an output from the first pixel to a first temperature at the first location and relates an output from the second pixel to a second temperature at the second location. A microprocessor (24) identifies a process anomaly based upon outputs from the first and second pixels. Output circuitry (30) provides a diagnostic output indicative of the identified process anomaly.