HYDROCARBON LEAK IMAGING AND QUANTIFICATION SENSOR
20170336281 · 2017-11-23
Inventors
Cpc classification
G01N21/31
PHYSICS
Y02A50/20
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
G01N21/31
PHYSICS
G01F1/66
PHYSICS
Abstract
This invention consists of sensors and algorithms to image, detect, and quantify the presence of hydrocarbon gas (for example from leaks) using a short-wave infrared radiation detector array with multiple spectral filters under natural sunlight or artificial illumination, in combination with the hydrodynamics of turbulent gas jets and buoyant plumes. Multiple embodiments are recited and address detection and quantification of methane gas leaks. Quantification includes gas column densities, gas concentration estimates, total mass, hole size estimates, and estimated emission flux (leak rate) of gas from holes and cracks in pressurized vessels, pipes, components, and general gas infrastructure, and from surface patches (for example due to gas leaks in underground pipes) under the action of buoyancy and wind. These and similar embodiments are applicable more generally to natural gas and other hydrocarbon gases, liquids, emulsions, solids, and particulates, and to emissions monitoring of greenhouse gases methane and carbon dioxide.
Claims
1. An imaging device to detect hydrocarbon compounds, comprising: a. one or more one-dimensional arrays of photo-detectors appreciably responsive to light in a wavelength range of approximately 1.0 to 2.6 microns, each said one-dimensional array having an associated electronic read-out circuit, b. at least two spectral filters associated with said one-dimensional arrays of photo-detectors, such that at least one of said spectral filters is appreciably transmissive to light of wavelengths spanned by an extended spectral feature complex of a hydrocarbon compound of interest, and such that at least one other of said spectral filters is appreciably transmissive to light of wavelengths not spanned by said spectral feature complex of said hydrocarbon compound of interest, c. a mechanical device selected from the group consisting of stationary frames, sliding frames, spinning frames, swinging blades, and rotating wheels, so that the filters can be disposed in a first position and a second position, in the first position light passes through the first filter before striking any of said one-dimensional arrays of photo-detectors, in the second position light passes through the second filter before striking any of said one-dimensional arrays of photo-detectors, and the mechanical device can move the filters between the first and second positions, d. an optical element selected from the group consisting of lenses, curved mirrors, diffractive surfaces, and combinations of said elements, to gather and focus incident illumination such that light at least in a wavelength range of approximately 1.0 to 2.6 microns is directed at said one-dimensional array(s) of photo-detectors so as to first pass through said spectral filters located in front of said one-dimensional photo-detector arrays, e. an opto-mechanical scanning device selected from the group consisting of resonant oscillating mirrors, galvanometric driven mirrors, rotating multi-faceted mirrors, and electrically actuated micro-mirror arrays, to scan a field-of-view one portion at a time relative to the one-dimensional photo-detector array(s), f. at least one electronic circuit to control the integration time of said photo-detector array(s) and to convert signals generated by said photo-detector array(s) into amplified and digitized signals, g. at least one electronic circuit to synchronize said opto-mechanical scanning device, said mechanical device to dispose said filters in said positions relative to said photo-detector array(s), and said electronic circuit to read-out and convert said signals generated by said photo-detector array(s), so as to generate two-dimensional digital multispectral imagery, h. a processor coupled to receive said multispectral imagery and a value representative of a distance to a reflective calibration target, so as to calibrate said imagery of each said spectral band relative to imagery of said spectral band associated with said spectral feature complex of said hydrocarbon compound of interest, whereby such processing determines calibration parameters consisting of a dark level offset and a relative gain for image pixels of interest between said spectral bands, and a relative absorption coefficient for each said spectral band characterizing the local atmosphere under conditions of the ambient environment, i. a processor coupled to said multispectral imagery, in combination with said calibration parameters, to generate an adaptive relative gain across spectral bands, adapted to in-scene reflectors, and a differential optical depth absorption image, so as to determine the possible presence of said hydrocarbon compound of interest in said field-of-view, employing the Beer-Lambert Law of absorption across the multiple spectral bands, j. electronic circuitry to control the operation of said photo-detector arrays, said mechanical device to dispose said filters in said positions relative to said photo-detector arrays, said opto-mechanical scanning device, said processor to calibrate said multispectral imagery, and said processor to generate said absorption image.
2. The imaging device of claim 1 in which said spectral filters includes a Core Band filter that is appreciably transmissive to light of wavelengths spanned by an extended spectral feature complex of a hydrocarbon compound of interest, and a Wings Band filter that is appreciably transmissive to light of wavelengths both shorter and longer than the Core filter, said Wings Band filter created from a broadband Surround filter that includes said Core Band, by subtracting said Core Band filter measurements from said Surround filter measurements, accounting for the relative transmission characteristics of said Core Band and Surround filters.
3. The imaging device of claim 1 in which said spectral filters includes a Core Band filter that is appreciably transmissive to light of wavelengths spanned by an extended spectral feature complex of a hydrocarbon compound of interest, and a Wings Band filter that is appreciably transmissive to light of wavelengths both shorter and longer than said Core filter, said Wings Band filter created from a broadband filter with a low-transmission notch spanning the wavelengths of said Core Band filter.
4. The imaging device of claim 1 in which said spectral filters includes a Core Band filter that is appreciably transmissive to light of wavelengths spanned by an extended spectral feature complex of a hydrocarbon compound of interest, and a Wings Band filter created from one or more filters that are appreciably transmissive to light of wavelengths either shorter or longer than those appreciably transmitted by said Core Band filter.
5. The imaging device of claim 1 in combination with a processor coupled to receive said absorption image, and a value of internal pressure of objects from which the detected hydrocarbons compounds being imaged originate, so as to estimate at least one quantity selected from the group consisting of the total absorption in said multispectral imagery of said hydrocarbon of interest, the total mass visible in said absorption imagery of said hydrocarbon of interest, the diameter of an approximately round hole from which said hydrocarbon of interest leaks, and the mass flow rate of said hydrocarbon of interest, by at least one method selected from the group consisting of the summation along the axis of said absorption image of said hydrocarbon gas jet of said average differential optical absorption weighted by the diameter of said imaged hydrocarbon gas jet, the scaling of total differential optical absorption of said hydrocarbon gas jet by said differential spectral absorption cross-section weighted by the mass of said hydrocarbon gas molecule, the relationship between said average differential optical depth along said hydrocarbon gas jet extrapolated back to the vertex of said hydrocarbon gas jet and said internal pressure as it relates to the diameter or area of said leak hole, and the mass flow of said hydrocarbon gas out of said leak hole of known area and said internal pressure.
6. The imaging device of claim 1 in combination with a processor coupled to receive said absorption image from a ground surface patch, and a value of near ground-level wind speed and direction, so as to estimate surface emission mass flux of said hydrocarbon of interest, by at least one method selected from the group consisting of the relationship between said mass flux and said average differential optical depth imaged across said surface patch weighted by said wind speed and the extent of said surface patch in the direction perpendicular to said wind direction, the relationship between said mass flux and said differential optical depth imaged along the downwind edges of said surface patch weighted by said wind speed and the extent of said surface patch in the direction perpendicular to said wind direction, and the relationship between said mass flux and said absorption imagery inferred rate-of-change of said average differential optical depth weighted by the area of said surface patch in combination with said average differential optical depth across said surface patch weighted by said wind speed and the extent of said surface patch in the direction perpendicular to said wind direction.
7. The imaging device of claim 1 in combination with a visible light camera such that both said imaging devices possess approximately parallel lines-of-sight and share principally overlapping fields-of-view, by which said absorption image of said hydrocarbon of interest is overlaid on the visible light image, thereby providing spatial context of where in the scene a possible hydrocarbon leak is detected.
8. The imaging device of claim 1 in combination with any of the following ancillary sensors: global positioning sensor to determine said device positional coordinates on the earth, inertial measurement unit to determine said device linear or rotational acceleration components, magnetometer to determine said device orientation with respect to the earth's magnetic field, range finder to determine range of said device from reflecting surfaces in the scene, and weather measurement unit to determine local environmental conditions in proximity to said device.
9. The imaging device of claim 1 in combination with electronic circuits capable of acting on data in ways selected from the group consisting of storing, saving, and transmitting said multispectral imagery, said absorption image, and associate with said imagery data selected from the group consisting of said estimated quantities recited in claim 5 and claim 6, said visible light camera recited in claim 7, and said sensors recited in claim 8.
10. An imaging device to detect hydrocarbon compounds, comprising: a. a two-dimensional array of photo-detectors appreciatively responsive to light in a wavelength range of approximately 1.0 to 2.6 microns, having associated electronic read-out circuitry, b. a spectral filter array organized as a set of stripes forming a two-dimensional surface that approximately covers the extent of said photo-detector array, whereby each stripe has its long dimension oriented across one dimension of said photo-detector array and the short dimension of each stripe spans one or more detectors of said photo-detector array, such that at least one of said spectral filter stripes is appreciably transmissive to light of wavelengths spanned by an extended spectral feature complex of a hydrocarbon compound of interest, and such that at least one other of said spectral filter stripes is appreciably transmissive to light of wavelengths not spanned by said spectral feature complex of said hydrocarbon compound of interest, c. a mechanical frame to hold said spectral filter array in front of said photo-detector array, such that light passes through said spectral filter array before striking said photo-detector array, d. an optical element selected from the group consisting of lenses, curved mirrors, diffractive surfaces, and combinations of said elements, to gather and focus incident illumination such that light at least in a wavelength range of approximately 1.0 to 2.6 microns is directed at said photo-detector array so as to first pass through said spectral filter array located in front of said photo-detector array, e. an opto-mechanical scanning device selected from the group consisting of resonant oscillating mirrors, galvanometric driven mirrors, rotating multi-faceted mirrors, and electrically actuated micro-mirror arrays, to scan in a direction perpendicular to the orientation of said filter array stripes, thereby establishing a two-dimensional field-of-view to be imaged by said photo-detector array, f. at least one electronic circuit to control the integration time of said photo-detector array and to convert signals generated by said photo-detector array into amplified and digitized signals, g. at least one electronic circuit by which to synchronize said opto-mechanical scanning device, and said electronic circuit to read-out and convert said signals generated by said photo-detector array, so as to generate a sequence of two-dimensional digital multispectral imagery, h. a processor coupled to receive said multispectral imagery and a value representative of a distance to a reflective calibration target, so as to calibrate said imagery of each spectral band relative to imagery of said spectral band associated with said spectral feature complex of said hydrocarbon compound of interest, whereby such processing determines calibration parameters consisting of a dark level offset and a relative gain for image pixels of interest between said spectral bands, and a relative absorption coefficient for each spectral band characterizing the local atmosphere under conditions of the ambient environment, i. a processor coupled to said multispectral imagery, in combination with said calibration parameters, to generate an adaptive relative gain across spectral bands, adapted to in-scene reflectors, and a differential optical depth absorption image, so as to determine the possible presence of said hydrocarbon compound of interest in said field-of-view, employing the Beer-Lambert Law of absorption across the multiple spectral bands, j. electronic circuitry to control the operation of said photo-detector array, said opto-mechanical scanning device, said processor to calibrate said multispectral imagery, and said processor to generate said absorption image.
11. The imaging device of claim 10 in which said spectral filters includes a Core Band filter that is appreciably transmissive to light of wavelengths spanned by an extended spectral feature complex of a hydrocarbon compound of interest, and a Wings Band filter that is appreciably transmissive to light of wavelengths both shorter and longer than the Core filter, said Wings Band filter created from a broadband Surround filter that includes said Core Band, by subtracting said Core Band filter measurements from said Surround filter measurements, accounting for the relative transmission characteristics of said Core Band and Surround filters.
12. The imaging device of claim 10 in which said spectral filters includes a Core Band filter that is appreciably transmissive to light of wavelengths spanned by an extended spectral feature complex of a hydrocarbon compound of interest, and a Wings Band filter that is appreciably transmissive to light of wavelengths both shorter and longer than said Core filter, said Wings Band filter created from a broadband filter with a low-transmission notch spanning the wavelengths of said Core Band filter.
13. The imaging device of claim 10 in which said spectral filters includes a Core Band filter that is appreciably transmissive to light of wavelengths spanned by an extended spectral feature complex of a hydrocarbon compound of interest, and a Wings Band filter created from one or more filters that are appreciably transmissive to light of wavelengths either shorter or longer than those appreciably transmitted by said Core Band filter.
14. The imaging device of claim 10 in combination with a processor coupled to receive said absorption image, and a value of internal pressure of objects from which the detected hydrocarbons compounds being imaged originate, so as to estimate at least one quantity selected from the group consisting of the total absorption in said multispectral imagery of said hydrocarbon of interest, the total mass visible in said absorption imagery of said hydrocarbon of interest, the diameter of an approximately round hole from which said hydrocarbon of interest leaks, and the mass flow rate of said hydrocarbon of interest, by at least one method selected from the group consisting of the summation along the axis of said absorption image of said hydrocarbon gas jet of said average differential optical absorption weighted by the diameter of said imaged hydrocarbon gas jet, the scaling of total differential optical absorption of said hydrocarbon gas jet by said differential spectral absorption cross-section weighted by the mass of said hydrocarbon gas molecule, the relationship between said average differential optical depth along said hydrocarbon gas jet extrapolated back to the vertex of said hydrocarbon gas jet and said internal pressure as it relates to the diameter or area of said leak hole, and the mass flow of said hydrocarbon gas out of said leak hole of known area and said internal pressure.
15. The imaging device of claim 10 in combination with a processor coupled to receive said absorption image from a ground surface patch, and a value of near ground-level wind speed and direction, so as to estimate surface emission mass flux of said hydrocarbon of interest, by at least one method selected from the group consisting of the relationship between said mass flux and said average differential optical depth imaged across said surface patch weighted by said wind speed and the extent of said surface patch in the direction perpendicular to said wind direction, the relationship between said mass flux and said differential optical depth imaged along the downwind edges of said surface patch weighted by said wind speed and the extent of said surface patch in the direction perpendicular to said wind direction, and the relationship between said mass flux and said absorption imagery inferred rate-of-change of said average differential optical depth weighted by the area of said surface patch in combination with said average differential optical depth across said surface patch weighted by said wind speed and the extent of said surface patch in the direction perpendicular to said wind direction.
16. The imaging device of claim 10 in combination with a visible light camera such that both said imaging devices possess approximately parallel lines-of-sight and share principally overlapping fields-of-view, by which said absorption image of said hydrocarbon of interest is overlaid on the visible light image, thereby providing spatial context of where in the scene a possible hydrocarbon leak is detected.
17. The imaging device of claim 10 in combination with any of the following ancillary sensors: global positioning sensor to determine said device positional coordinates on the earth, inertial measurement unit to determine said device linear or rotational acceleration components, magnetometer to determine said device orientation with respect to the earth's magnetic field, range finder to determine range of said device from reflecting surfaces in the scene, and weather measurement unit to determine local environmental conditions in proximity to said device.
18. The imaging device of claim 10 in combination with electronic circuits capable of acting on data in ways selected from the group consisting of storing, saving, and transmitting said multispectral imagery, said absorption image, and associate with said imagery data selected from the group consisting of said estimated quantities recited in claim 14 or claim 15, said visible light camera recited in claim 16, and said sensors recited in claim 17.
19. An imaging device to detect hydrocarbon compounds, comprising: a. An array of at least two discrete photo-detectors, each responsive to light in a wavelength range of approximately 1.0 to 2.6 microns, each having an associated electronic read-out circuit, b. a spectral filter mosaic organized as a set of filter islands that approximately covers the extent of said array of discrete photo-detectors, whereby each said filter island covers only one discrete photo-detector, such that at least one of said filter islands is appreciably transmissive to light of wavelengths spanned by an extended spectral feature complex of a hydrocarbon compound of interest, and such that at least one other of said spectral filter islands is appreciably transmissive to light of wavelengths not spanned by said extended spectral feature complex of said hydrocarbon compound of interest, c. a mechanical frame to hold said spectral filter mosaic in front of said array of discrete photo-detectors, such that light passes through said spectral filter array before striking said array of discrete photo-detectors, d. an optical element selected from the group consisting of lenses, curved mirrors, diffractive surfaces, and combinations of said elements, to gather and focus incident illumination such that light at least in a wavelength range of approximately 1.0 to 2.6 microns is directed at said array of discrete photo-detectors so as to first pass through said spectral filters located in front of said array of discrete photo-detectors, e. a mechanical scanning device selected from the group consisting of resonant oscillating mirrors, galvanometric driven mirrors, rotating multi-faceted mirrors, electrically actuated micro-mirror arrays, and dual-axis pan-tilt unit, to scan in two perpendicular directions, thereby establishing an optical field-of-regard to be imaged by said array of discrete photo-detectors, f. at least one electronic circuit to control the integration time of said array of discrete photo-detectors and to convert signals generated by said array of discrete photo-detectors into amplified and digitized signals, g. at least one electronic circuit to synchronize said mechanical scanning device, and said electronic means to read-out and convert said signals generated by said array of discrete photo-detectors, so as to generate a sequence of two-dimensional digital imagery of multiple spectral bands, h. a processor coupled to receive said multispectral imagery and a value representative of a distance to a reflective calibration target, so as to calibrate said imagery of each spectral band relative to imagery of said spectral band associated with said spectral feature complex of said hydrocarbon compound of interest, whereby such processing determines calibration parameters consisting of a dark level offset and a relative gain for image pixels of interest between said spectral bands, and a relative absorption coefficient for each spectral band characterizing the local atmosphere under conditions of the ambient environment, i. a processor coupled to said multispectral imagery, in combination with said calibration parameters, to generate an adaptive relative gain across spectral bands, adapted to in-scene reflectors, and a differential optical depth absorption image, so as to determine the possible presence of said hydrocarbon compound of interest in said field-of-regard, employing the Beer-Lambert Law of absorption across the multiple spectral bands, j. electronic circuitry to control the operation of said discrete photo-detectors, said mechanical scanning device, said processor to calibrate said multispectral imagery, and said processor to generate said absorption image.
20. The imaging device of claim 19 in which said spectral filter islands includes a Core Band filter that is appreciably transmissive to light of wavelengths spanned by an extended spectral feature complex of a hydrocarbon compound of interest, and a Wings Band filter that is appreciably transmissive to light of wavelengths both shorter and longer than the Core filter, said Wings Band filter created from a broadband Surround filter that includes said Core Band, by subtracting said Core Band filter measurements from said Surround filter measurements, accounting for the relative transmission characteristics of said Core Band and Surround filters.
21. The imaging device of claim 19 in which said spectral filter islands includes a Core Band filter that is appreciably transmissive to light of wavelengths spanned by an extended spectral feature complex of a hydrocarbon compound of interest, and a Wings Band filter that is appreciably transmissive to light of wavelengths both shorter and longer than said Core filter, said Wings Band filter created from a broadband filter with a low-transmission notch spanning the wavelengths of said Core Band filter.
22. The imaging device of claim 19 in which said spectral filter islands includes a Core Band filter that is appreciably transmissive to light of wavelengths spanned by an extended spectral feature complex of a hydrocarbon compound of interest, and a Wings Band filter created from one or more filters that are appreciably transmissive to light of wavelengths either shorter or longer than those appreciably transmitted by said Core Band filter.
23. The imaging device of claim 19 in combination with a processor coupled to receive said absorption image, and a value of internal pressure of objects from which the detected hydrocarbons compounds being imaged originate, so as to estimate at least one quantity selected from the group consisting of the total absorption in said multispectral imagery of said hydrocarbon of interest, the total mass visible in said absorption imagery of said hydrocarbon of interest, the diameter of an approximately round hole from which said hydrocarbon of interest leaks, and the mass flow rate of said hydrocarbon of interest, by at least one method selected from the group consisting of the summation along the axis of said absorption image of said hydrocarbon gas jet of said average differential optical absorption weighted by the diameter of said imaged hydrocarbon gas jet, the scaling of total differential optical absorption of said hydrocarbon gas jet by said differential spectral absorption cross-section weighted by the mass of said hydrocarbon gas molecule, the relationship between said average differential optical depth along said hydrocarbon gas jet extrapolated back to the vertex of said hydrocarbon gas jet and said internal pressure as it relates to the diameter or area of said leak hole, and the mass flow of said hydrocarbon gas out of said leak hole of known area and said internal pressure.
24. The imaging device of claim 19 in combination with a processor coupled to receive said absorption image from a ground surface patch, and a value of near ground-level wind speed and direction, so as to estimate surface emission mass flux of said hydrocarbon of interest, by at least one method selected from the group consisting of the relationship between said mass flux and said average differential optical depth imaged across said surface patch weighted by said wind speed and the extent of said surface patch in the direction perpendicular to said wind direction, the relationship between said mass flux and said differential optical depth imaged along the downwind edges of said surface patch weighted by said wind speed and the extent of said surface patch in the direction perpendicular to said wind direction, and the relationship between said mass flux and said absorption imagery inferred rate-of-change of said average differential optical depth weighted by the area of said surface patch in combination with said average differential optical depth across said surface patch weighted by said wind speed and the extent of said surface patch in the direction perpendicular to said wind direction.
25. The imaging device of claim 19 in combination with a visible light camera such that both said imaging devices possess approximately parallel lines-of-sight and share overlapping fields-of-view, by which said absorption image of said hydrocarbon of interest is overlaid on the visible light image, thereby providing spatial context of where in the scene a possible hydrocarbon leak is detected.
26. The imaging device of claim 19 in combination with any of the following ancillary sensors: global positioning sensor to determine said device positional coordinates on the earth, inertial measurement unit to determine said device linear or rotational acceleration components, magnetometer to determine said device orientation with respect to the earth's magnetic field, range finder to determine range of said device from reflecting surfaces in the scene, and weather measurement unit to determine local environmental conditions in proximity to said device.
27. The imaging device of claim 19 in combination with electronic circuits capable of acting on data in ways selected from the group consisting of storing, saving, and transmitting said multispectral imagery, said absorption image, and associate with said imagery data selected from the group consisting of said estimated quantities recited in claim 23 and claim 24, said visible light camera recited in claim 25, and said sensors recited in claim 26.
28. A method for characterizing the mass flow of a hydrocarbon gas jet leaking from a leak hole in an object: a. whereby the internal pressure of said object is approximately known, b. obtaining a differential absorption image of said hydrocarbon gas jet leaking from said object utilizing a multispectral imaging sensor sensitive to two or more spectral bands in which at least one of said spectral bands is appreciably transmissive to light of wavelengths spanned by one or more spectral features of said hydrocarbon compound of interest, and at least one other of said spectral bands is highly transmissive of light of wavelengths not spanned by said one or more spectral features of said hydrocarbon compound of interest, and c. estimating at least one quantity selected from the group consisting of the total absorption in said multispectral imagery of said hydrocarbon of interest, the total mass visible in said absorption imagery of said hydrocarbon of interest, the diameter of an approximately round hole from which said hydrocarbon of interest leaks, and the mass flow rate of said hydrocarbon of interest by at least one method selected from the group consisting of the summation along the axis of said absorption image of said hydrocarbon gas jet of said average differential optical absorption weighted by the diameter of said imaged hydrocarbon gas jet, the scaling of total differential optical absorption of said hydrocarbon gas jet by said differential spectral absorption cross-section weighted by the mass of said hydrocarbon gas molecule, the relationship between said average differential optical depth along said hydrocarbon gas jet extrapolated back to the vertex of said hydrocarbon gas jet and said internal pressure as it relates to the diameter or area of said leak hole, and the mass flow of said hydrocarbon gas out of said leak hole of known area and said internal pressure.
Description
DRAWINGS
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DETAILED DESCRIPTION OF THE INVENTION
Principals of Gas Absorption Imaging
[0048] This invention detects gas leaks via differential absorption imaging spectroscopy in the range 1.0 to 2.6 microns, exploiting spectral features of hydrocarbons in the short-wave infrared (SWIR) region, primarily in the wavelength range of 2.0 to 2.5 microns. These wavelengths are not typically associated with those in the thermal emission regions of the mid-wave infrared (MWIR) and long-wave infrared (LWIR) for objects at terrestrial temperatures. Appreciable thermal emission at around 2.0 microns requires objects at temperatures of around 1000° C. Instead, this invention relies on illumination sources like natural sunlight and lamps of color temperature near 1000° C. Thus, the invention can detect hydrocarbons at the same temperatures as their backgrounds by using external illumination instead of thermally emitted light.
[0049] The principals underlying non-thermal infrared multispectral imaging of a gas leak are shown in
[0050] When imaging methane and other hydrocarbons, it is common to exploit their strong features in the MWIR and LWIR, as the absorption in those spectral regions is greater than in the SWIR. However, it is important to consider the effects of water vapor absorption by the intervening atmosphere. In most applications, the physical extent of a gas jet, plume or cloud is small compared to the length of atmosphere that the light will propagate through on its way to the sensor. Thus, appreciable absorption may occur at wavelengths characteristic of water vapor, depending on the humidity of the air or the presence of fog or steam in optical field-of-view. It is therefore important to consider the relative absorption of methane to water vapor at the wavelengths that characterize methane.
[0051]
[0052] In order to detect and quantify the hydrocarbons present in natural gas, it is advantageous to use multiple spectral bands in the SWIR. This can be accomplished using spectral filters designed to selectively transmit preferred wavelength bands while rejecting other SWIR radiation. Such spectral filters can be narrow bandpass filters, broadband filters, notched filters, edge filters, and combinations of such filters. For example, to preferentially detect methane, the primary constituent of natural gas, the invention utilizes a minimum of two spectral bands; one called the Core Band which spans the spectral feature complex from approximately 2.25 to 2.45 microns (200 nm bandwidth), and the other called the Wings Band (serving as a reference band) which spans an interval of approximately 100 nm to either side of the Core Band. These spectral intervals are shown as the rectangular boxes in
Prototype Gas Imaging Sensor
[0053] The invention described here has been reduced to practice by building functional prototypes of a multispectral video imager and a scan imager for methane imaging, detection and quantification The prototype dual-band video sensor images at 20 frames per second and displays gas absorption imagery overlaid on color visible imagery of the scene on a touch-screen user display. The prototype system is hand-portable and interfaces to external networks via both wireless and wired interfaces. The prototype 6-band scan sensor creates imagery of gas over a programmable and variable field-of-regard, by combining raster scanning with super-resolution image processing. The flexibility of switching among a variety of scan patterns enables this sensor to support both gas safety applications and emissions monitoring applications, in a cost-effective manner. This scan imager is suitable for mast-mounting to overlook wide-area installations, using a programmable pan-tilt unit to effect scanning. An alternative embodiment replaces the pan-tilt unit with scanning mirrors or a combination of scanning mirror and rotating optics, to enable compact packaging for a hand-portable gas imaging and quantification camera.
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Imaging Sensor Embodiments
[0055] Several different embodiments of SWIR imaging sensors for hydrocarbon imaging are described next. There are several different semiconductor materials that can be used to fabricate the basic photo-detector sensitive to the SWIR spectrum of light from approximately 1.0 to 2.6 microns, with a dark-current that can be suitably reduced by thermo-electric cooling. These include so-called extended-response indium gallium arsenide (extended-InGaAs) commonly grown on an indium phosphide (InP) lattice-mismatched substrate, and the recently developed type-II quantum wells made from alternating layers of InGaAs and gallium arsenide antiminide (GaAsSb) grown on an InP lattice-matched substrate. These two materials have different spectral response characteristics, but both can be used for detecting the hydrocarbons that comprise natural gas, and in particular, methane as well as VOCs. They also have different manufacturing yields due to their lattice structures. Thus, extended-InGaAs photo-detectors are only available as discrete photo-detectors and one-dimensional arrays but not as two-dimensional arrays, while type-II InGaAs/GaAsSb photo-detectors have been successfully fabricated and demonstrated as two-dimensional arrays. Mercury cadmium telluride (MCT) is a common infrared detector material that can also be used for imaging in the extended SWIR; however, its high dark-current requires cryogenic cooling with, for example, a Stirling engine to achieve useful signal-to-noise ratios.
[0056] There are several embodiments of photo-detector arrays in combination with multiple spectral filters that yield a suitable sensor for use in a gas leak imaging and quantification system.
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[0060] All of the multi-spectral SWIR detector configurations described and shown in
Gas Imaging Sensor Systems
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[0063] Each imaging sensor system of
[0064] As shown in
Operation of All Sensor Embodiments
[0073] The various sensor embodiments described above can be operated in many different modes. In one mode the data gathered from the sensor is analyzed by a processor and used for automatic analysis and decisions (such as triggering of an alarm signal or different operating mode, because a certain limit of gas detection is exceeded) by the processor without being displayed in real-time or near real-time on a display. In another mode an image of the received data can be shown on a display (for example for monitoring by a human operator) however no real-time analysis like gas quantification is performed. In a third mode an image is displayed and automatic gas quantification is performed, and significant results are automatically stored or sent to remote locations. Other combinations and modes of operation are possible as well, for example in conjunction with the use of low-bandwidth sensors like range and weather sensors.
Imaging Turbulent Gas Jets and Absorption Profiles
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[0075] The geometry of the gas jet, as shown in
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[0078] The maximum of the absorption on each profile should occur on axis of the jet, if the imaging line-of-sight is perpendicular to the jet axis, as this is where the path length through the jet is a maximum and the gas concentration is largest. Based on the self-similar solution for turbulent round jets, the gas concentration on axis will decrease linearly along the jet as it expands, while the diameter increases linearly along the axis, and so the product of axial gas concentration with diameter should remain a constant, suggesting the column density along the jet axis should remain constant. However, due to the turbulent fluctuations, these profiles change over time, and so individual pixel values fluctuate. To cope with these turbulent fluctuations, it is suggested to use spatial averages of quantities across the jet, and then calculate the total absorption of a slice of jet, as it is due to the total mass of gas in that slice and not sensitive to the exact distribution of mass throughout the slice. Each row of pixels along consecutive cross-sections through the jet corresponds to a constant thickness slice, and since the jet diameter varies linearly with axial distance, hence, the slice volume increases as the square of the axial distance. But since the gas concentration dilutes linearly with axial distance in a self-similar round jet, the mass of gas in constant thickness slices is expected to increase linearly with axial distance along the jet. That is, the gas at the front of a jet slice flows slower than the gas at the rear of the jet slice, causing mass to build up between slices of constant thickness. And since the mass of gas in slices increases linearly along the jet axis, so should the absorption due to that mass. Thus, the integrated differential optical depth across each cross-section of the jet image should increase linearly along the jet. Similarly, the jet width in the absorption image should increase linearly along the jet, where the jet boundary is determined by the noise in the background image. Integrating the absorption across jet cross-sections acts to smooth out the effect of turbulent fluctuations on gas concentration in the jet.
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[0081] Absorption and Mass Flow Across a Range of Pressures and Orifice Sizes
[0082] Experiments have been conducted to image the release of methane gas under a range of pressures (50-1400 psig) exiting from round orifices (diameters of 0.75 mm and 1.0 mm). Gas jet boundaries are automatically extracted from the imagery, and the average differential optical depth (Avg-dOD) along the jet axis is computed. Fitting a least-squares regression line to this data determines the intercept of this regression line, which indicates the degree of absorption of the methane at the effective orifice.
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[0085] Next, the mathematical formulation of absorption imaging and quantification of gas leaks is described, using methane or natural gas as a specific example.
Defining the SWIR Spectral Bands
[0086] Spectral imagery is taken through at least two filters with transmission exceeding about 5% over wavelength regions that cover the 2350 nm methane feature complex. One filter is narrow (bandwidth approximately 200 nm) and centered at about 2350 nm; call this the Core Filter with transmission F.sub.C (λ) and integrated transmission F.sub.C. The other filter is broad (bandwidth approximately 400 nm), transmitting between approximately 2100-2500 nm; call this the Surround Filter with transmission F.sub.S (λ) and integrated transmission F.sub.S.
[0087] Remove the overlapping Core Band spectral transmission from the Surround Filter, in order to image the intensity in the spectral Wings Band of methane. Alternatively, use two separate filters that transmit in bands on either side of the Core Band, and combine them into a Wings Band filter. Or use a single broadband filter that spans both sides of the Core Band with a low-transmission notch in the region of the Core Band. It is recommended to use Core Band and Wings Band filters with approximately equal transmission-bandwidth product to balance the dynamic range of the signal in both spectral bands.
[0088] Define the core integrated transmission of the Surround Filter as F.sub.SC and of the Core Filter as F.sub.C, and the imaged intensities in the core and surround pass-bands as I.sub.C and I.sub.S, then the intensity in the Wings Band I.sub.W is obtained as
[0089] Calibrating the Sensor in the Ambient Environment
[0090] Define the optical depth in the Core Band as τ.sup.(a).sub.c and the optical depth in the Wings Band as τ.sup.(a).sub.w Each is the product of the respective absorptivity and path length through the environment (approximating integrals across wavelength bands). Noting the superscript (a) to connote the ambient atmosphere, and using the symbols defined previously and shown in
I.sup.(a).sub.c=S.sub.c.sup.(r)Q.sub.cF.sub.CR.sub.c.sup.exp−[τ.sup.(a).sub.c] (Eq. 2a)
I.sup.(a).sub.w=S.sub.w.sup.(r)Q.sub.wF.sub.wR.sub.w.sup.exp−[τ.sup.(a).sub.w] (Eq. 2b)
[0091] Next form the ratio of these spectral intensities, and note the spectral illumination source function ratio S.sub.C/S.sub.W is independent of distance and only a function of wavelength. Then define the cross-channel Core-to-Wings gain G.sub.CW as the ratio of bracketed terms in Eq. 3a, the atmospheric differential absorption coefficient δα.sup.(a), and path length from sensor to the reflector panel L.sub.R. The ratio of Core to Wing intensities is then
[0092] To adaptively calibrate the sensor in the ambient atmosphere, first measure the SWIR illumination bouncing off a reflector panel at two or more distances, calculate the image average intensities, and form the log of their ratio to solve for the unknowns G.sub.CW and δα.sup.(a) (if using more than two distances, solve for the two unknowns via method of least-squares). The resulting value for the gain G.sub.CWincorporates the ratio of Core-to-Wings reflectivities of the calibration panel. When the sensor is sufficiently close to the potential leak site, it is not required to account for absorption by the ambient atmosphere, therefore one can forego measurement of reflected light from calibration panels at measured distances, and instead adopt a value of zero distance to such panels. Practical application for methane sensing suggests that distances from 5 to 15 meters are sufficiently close under conditions of a fair atmosphere, however, under foggy conditions, even distances below 5 meters might require the above process to compensate for atmospheric absorption.
[0093] Next, rescale the gain G.sub.CW using in-scene reflector materials (i.e., background materials). Use a pair of Core and Wings Band images of the in-scene reflector materials (concrete, wood, asphalt, dirt, grass, etc.) together with Eq. 3b to determine an adaptive gain G.sub.CWfor each reflecting material. It is also possible to generate a library of these gain values for a variety of background materials, and have the user select from a menu the appropriate gain value, or have the sensor system automatically select the appropriate gain value to use while conducting a leak inspection. For direct transmission of sunlight through gas, as in
Imaging Possible Gas Leaks (Detection Mode)
[0094] To inspect for a possible gas leak, image in the direction of interest. Using the symbols of
[0095] Core and Wings Bands are given by
I.sup.(g).sub.c=S.sub.c.sup.(r)Q.sub.cF.sub.cR.sub.c.sup.exp−[τ.sup.(g+a).sub.c] (Eq. 4a)
I.sup.(g).sub.w=S.sub.w.sup.(r)Q.sub.wF.sub.wR.sub.w.sup.exp−[τ.sup.(g+a).sub.w] (Eq. 4b)
[0096] Form the ratio of Core to Wings Bands from equations (4), substitute the expression for the cross-channel gain G.sub.CW (appropriate for the background surface reflector), define the differential spectral absorption coefficient δα(.sub.g) of methane or natural gas, and rearrange terms (the superscript “(g)” connotes gas may be present),
[0097] Define the Excess Differential Spectral Absorptivity of the gas jet (diluted methane or natural gas) over that of the ambient atmospheric environment as
Δ.sub.CW.sup.g-a≡δα.sup.(g)−δα.sup.(a)=[α.sup.(g).sub.c−α.sup.(g).sub.w]−[α.sup.(a).sub.c−α.sup.(a).sub.w] (Eq. 6)
[0098] Therefore, the Differential Optical Depth (dOD) image due to the gas jet is obtained from the measured spectral intensities and calibration parameters via equations (5) and (6) as
[0099] In the case of negligible atmospheric absorption as compared to the gas leak (e.g., imaging sufficiently close to a potential leak), the second term on the right can be eliminated by setting L.sub.R to zero, thus
[0100] The factor of ½ in equation (7b) comes from the double path length through the gas due to reflection of incident light from near or behind the sensor, off the background surface, and back to the sensor. In the case of single pass transmission (e.g., sunlight ahead of the gas leak, passing directly through the gas to the sensor), this factor is simply dropped.
Estimating Jet Mass, Orifice Size, and Methane Mass Flux
[0101] From the differential optical depth (dOD) image for a detected jet (or plume or cloud), compute the average-dOD across the jet profiles along its axis, and sum along the axis to obtain the total optical depth of the visible jet according to
dOD.sub.jet=Σ.sub.axisD.sub.J(z)
[0102] Relating dOD to the methane molecular column density via the absorption cross-sections σ.sub.C σ.sub.W in the Core and Wings Bands (see
[0103] From the differential optical depth (dOD) image for a detected jet, derive the Avg-dOD intercept
Solve for (an approximately round) orifice diameter D.sub.o and substitute for the scale factor and exponent as obtained from the experimental data as shown in
Use this orifice diameter D.sub.o to estimate the methane mass flow rate from the orifice flow formula using the linear regression formula shown in
[0104] This mass flow estimate is valid for internal pressures P greater than approximately 1.8 bar (26 psi), such that chocked flow occurs at the leak orifice, with outflow speed at the local sound speed and adiabatic expansion of the gas. The units for the physical quantities in equations (8) through (11) are: optical depth intercept dOD.sub.0 is dimensionless, diameter D.sub.0 in millimeters, pressure P in psig, and methane mass flux Q.sub.m in grams/min.
Surface Emission Mass Flux Under Steady Winds
[0105] To estimate surface emission mass flux under conditions of buoyancy and ground-level winds, we consider the imaging geometry shown in
[0106] As illustrated in
[0107] Measure the wind speed V and direction near ground/surface level, and assume it is representative of the wind at the emitting surface patch. Also measure range from the sensor to the surface patch, so that pixel dimensions of the patch can be converted to linear dimensions. The steady wind V (cm/sec) blows methane across the patch and away, as it diffuses out of the ground into the air above the patch, and an equilibrium is established in which the surface emission mass flux Q.sub.m (grams/sec) is balanced by the windblown mass crossing the downwind boundary of the patch. The methane layer above the surface patch has a characteristic thickness D and concentration c which give rise to the measured differential optical depth dOD at each pixel. By adjusting the threshold on the optical depth to a low level above the noise floor, the spatial extent of an emitting patch is defined. Construct the bounding rectangle around that patch such that one axis of the rectangle aligns with the wind direction, as illustrated in
Q.sub.m=cρ.sub.CH.sub.
Expressing cρ.sub.CH.sub.
[0108] As the imaging geometry shown in
Surface Emission Mass Flux Under Gusting Winds
[0109] Similar to the formulation for steady winds, gas diffuses out of the ground into the air above the surface patch and builds up a gas layer as the wind blows it away. However, when a gust occurs, the wind rapidly blows the entire layer of methane away. In gusting winds, the methane layer alternates between building itself up (in steady winds of speed V) and being rapidly destroyed by a sudden gust. This allows the build-up of a methane layer to be observed over time. The build-up of methane mass above the patch is the surface emission mass flux Q.sub.m minus the mass flux due to steady wind Vas in Eq.12B,
However, direct observation of the accumulation of methane is possible by imaging the time-varying differential optical depth over the patch, since
[0110] Here A.sub.p is the area of the patch observed before the gust, D is the changing thickness of the methane layer above the patch, and c is the increasing concentration of methane as the layer grows until the next gust. Equating expressions Eq. 13a and Eq. 13b, we obtain an estimate of the methane mass flux Q.sub.m (grams/time) from a surface patch in gusting wind by observing the time-varying differential optical depth as the methane layer is reestablished under steady wind conditions;
CONCLUSION, RAMIFICATIONS AND SCOPE
[0111] The embodiments as described above consist of both multispectral SWIR sensors for imaging, detecting and localizing methane and other hydrocarbon gases, and methods to estimate the leak rate or mass flux. Multiple embodiments of sensor systems have been described to enable imaging of gas leaks, and multiple methods have been disclosed for estimating methane mass flux from holes in pressurized lines, and from surface patch emissions due to underground gas pipe leaks. Example imagery and leak rate estimates across a wide variety of conditions illustrate the viability of the sensors and methods.
[0112] Summarizing the advantages of the invention over existing alternative gas imaging technologies, we note the ability to image and quantify gas leaks using natural sunlight without the need for any thermal contrast between the gas and the background, the ability to image and quantify methane in the presence of water vapor and fog, and the ability to quantify leak rates and surface emission flux in order to assess leak severity and prioritize repairs. These capabilities have application in gas safety, gas leak inspection, and greenhouse gas emissions monitoring.
[0113] While the above description contains much specificity, these should not be construed as limitations on the scope, but rather as exemplification of several embodiments thereof. Many other variations are possible. For example, by selecting the appropriate spectral filters in the SWIR, the invention can be used for detecting and quantifying other gases, liquids, emulsions, powders, and solids, in addition to the ones cited above and discussed in detail. Thus, multiple spectral filters can be selected to detect ammonia gas, which is both combustible and toxic. Also fertilizers can be detected and quantified, as can soil wetness and general plant health, thus other embodiments may be well suited for agricultural assessments. Yet other embodiments can be constructed that are well suited for detection of ammonium nitrate and its variants as used in the making of homemade explosives. Additionally, the methods developed for leak rate quantification of gases can be utilized for detecting gases and other substances in other spectral bands, in addition to the SWIR band. Accordingly, the scope should be determined not by the embodiments illustrated, but by the appended claims and legal equivalents.