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Real Time Facility monitoring - lessons learnedWael Badawy and Mike Macky

ACKNOWLEDGMENTSThe authors would like to Acknowledge IntelliView Technologies Inc, Alberta Ingenuity Fund, AVAC ltd., NRC-IRAP and Government of Canada - SRED for partial funding the research and development.

Leak Detection Example ClipsDiesel Leak at 50 feet

Propane Leak at 50 feet

Leak Detection Example ClipsDiesel Leak at 150 feet in heavy rainSmall Flange drip Leak at 50 feet

Typical Site Overview: Areas of Interest

Motion Inside a Region

Perimeter Crossing

Loitering

Object LeftBehind

Object Taken

Trip Wire OneDirection & BothDirectionsSecurity Analytics

Patented Standard Software

Security Analytics example clips

Gate monitoring/vehicle entryGate monitoring/vehicle exit

RequirementMobile RemoteNo local powerNo communicationNo access for service

ChallengesMobile RemoteNo local powerNo communicationNo access for service

Fixed RemoteSemi-mannedPoorly conditioned powerHPS lightingCommunicationsSafety requirements

Requirement

Proposed Solution - mobile

TrailerView - A self-contained industrial mobile video solution providing 360 o day/night coverage .Uses fuel cell and solar technology for off-grid applications (40+ days) or AC for powered locations.4 channel ruggedized DVR provides full analytic capability.Deployable in 1-2 hours when on-site and requires little or no maintenance.

Typically deployed for temporary security at shut in rig sites and O&G sites under construction, and monitored by a security company to prevent vandalism. Also deployed to active sites under construction/modification to monitor for leaks in new equipment or installations.

Proposed Solution - Fixed

Challenges Mobile SiteFuel Cell Replacement time Fuel levelsEnvironmental conditionsCellular SignalRangeBlizzards and thunders

Challenges Mobile SiteRainfall Thermal Effects

Image using auto contrast, analytic tracking objects within view. Image without using auto contrast, analytic cannot track due to lack of contrasting.

Challenges Mobile SiteOperations aspectsStatus of the systemNight time all weather

Mobile leak detection system using thermal cameras to monitor new construction for leaks.

Challenges - Fixed SiteInterference.Example of signal interference, note vertical lines across the image. Example of signal interference, note distortion at top of screen.

Challenges - Fixed SiteCommunications: QueuingAn event occur during a communications blackout, in ordinary circumstances, would result in the loss of the alert or alarms. An alarm queue was implemented that buffers alarms, with continuing retries until an acknowledgement is received Surveillance: 24 hour uptime.

Challenges - Fixed SiteSurveillance: 24 hour uptimeThe fixed site requires 24 hour surveillance, and is equipped with HPS (High Pressure Sodium) lighting. There were four challenges specific to HPS yard lighting which had to be overcome in order to provide effective coverage in what would normally be considered a straight forward environment.

Challenges - Fixed SiteChallenge 1: HPS lightingHPS cycling effect causes two potential issues:Cycles between bright and dim and, can be interpreted as a moving object by an analytic. The changing light source can cause shadows to lighten and darken, again appearing to the analytic as a moving object.Resolving this requires either a change in lighting, which is not practical for a large facility, or the use of a CCD camera core that operates at a frequency that is not affected by the HPS frequency. In this case, a number of CCD cores were tested in a lab facility with HPS lighting to determine which cores were not affected.

Challenges - Fixed SiteChallenge 2: AGC (Automatic Gain Control).Low light cameras were specified for the site, with the intention that the cameras would be more sensitive to the low light conditions and provide better images for the analytic in those conditions. The increased sensitivity of the CCD camera, the AGC was found to make large changes to the gain with relatively small changes in ambient light causes random objects to appear.Standard sensitivity cameras provided a much more gradual image gain due to lighting changes, as well as providing some longer response times. The analytic was modified to reject the frames associated with sudden changes due to lighting changes, solving issues with AGC step changes due to yard light switching or flashes. .

Challenges - Fixed Site

Pixilation at the point of AGC switching due to lighting changes.

Challenges - Fixed SiteChallenge 3: Yard light switching.Yard lights used for security within yard perimeters are usually switched on using photo sensors, turning on at dusk. The sudden switching of large yard lights can cause shadows to appear similar to the HPS issues mentioned earlier. Lightning can cause the yard lights to switch off as well, and then switching on again. The analytic can possibly see these shadows as changes in the area of interest and cause false alarms. This can also occur with improperly aimed cameras that have a light directly within view of the camera.The solution to the issue is the same as for AGC changes, to associate the video input change with lighting and therefore reject those few frames in real time to prevent the analytic from creating false objects.

Challenges - Fixed SiteHPS yard lighting cycling or switching on and off can cause shadows to appear.

Challenges - Fixed SiteChallenge 4: IR Switching.Similar to AGC changes, when the camera switches from normal daylight mode to night mode there is an abrupt change as IR LEDs (Light Emitting Diodes) switch on and the image typically changes from color to black and white. This can cause an alarm condition due to objects forming due to the large number of pixel changes in image. Similar to AGC and light switching, the analytic is programmed to reject frames related to IR switching while it re-learns the new background.

Other Challenges: Conditional security alarms.The system at one point generated high volumes of alarms over a 6 hour period. These were caused by a combination of 4 factors: Warm winds, melting snow, analytic positioning, and yard light location (reflection). In this condition, wind blows across a pool of water melted by warm winds, where the reflection of the yard light crosses the analytic tripwire (see image). The effect of the wind blowing across the water causes the reflected yard light to move back and forth across the tripwire, causing high volumes of alarms. In the following image, the object identified by the analytic (light reflected in water), is shown by the green box. The solution was moving the virtual analytic tripwire slightly, providing the same security coverage while resolving the reflection issue.

Perfect Combinationperfect combination of season, wind, light, and analytic location to create security alarm conditions.

Other Challenges: HPS lighting color and age.HPS lighting is widespread in industrial facilities. Another issue related to this type of lighting is the color of the light, it has an extremely yellow hue and with certain CCD camera cores the image the operator sees appears as if it is filtered by a yellow lens. This can result in a darker overall image at night, and incorrect colors being displayed, making identification of vehicle colors difficult.

A second issue with HPS lighting is that, when nearing the end of their life, the bulbs turn off when they get hot and turn on again when they cool down. This cycling on and off of the lighting can cause issues with analytics in many different ways.

Installation: Masts.The light masts on site cannot normally be utilized for mounting cameras to run analytics. These masts are designed to be lowered and due to this, allow some movement at the base. The masts also have flexibility, and are prone to movement in windy conditions due to the large amount of wind loading from the large yard lights mounted at the top. As video analytics operate on movement within the view of the camera, camera movement will result in false alarms.To resolve the issue, a square pole mounted on a screw pile specifically for camera mounting is recommended. The square pole has the added feature of allowing the cameras to be mounted using a wall mount on a flat surface, with power and signal then able to be run through the mount itself.In over two years of operation, there has been no issue with camera movement with this type of install.

Installation: CameraMounting cameras at height is an important factor in both security and leak detection. The height provides better angles for the analytic to detect leak pooling, to see over equipment, and prevent the horizon from being in the camera view.In cases where the horizon is within the camera view, or the downward angle is not high, it is possible for sunlight to glare on the camera lens and possibly create false alarms or blind spots at certain times of the day. It may not be at time of installation, but seasonal changes in sunrise and sunset can cause the issue.Downward angles are also important to minimize the possibility of background interference. An example of this may be the monitoring of a fence line with a road in the background. If the camera is mounted at a low angle, vehicles in the far background can interfere with the analytic in the foreground.

Thermal Leak Detection: OutdoorsThe three outdoor thermal cameras were directed to monitor valves and headers. The thermal cameras can be used for detection day and night, and are not impacted by environmental factors such as rain, fog, or snow.The leak detection analytic and thermal cameras use for detection is the difference in temperature between the background and the leaking liquid, and its movement characteristics. However, the thermal camera also detects other forms of energy, resulting in the detection for example of reflections in flat metal and glass surfaces.There are two ways to prevent these reflections from creating false objects. Using analytic tools, create an area of interest that operates without the reflective surface in it. The other option is to use the analytic tools to create an analytic mask in the affected area, thereby preventing the analytic from operating in the region.

Color Cameras: Verification.

Color cameras are paired with thermal cameras in order to provide operators with a color view of the area of interest. With thermal cameras typically displaying in grayscale, it can be difficult to see detail in the image. Color cameras provide the additional information needed to make informed decisions. In addition, security analytics can be run on these color cameras if required.

Color Leak Detection: Indoors.

Indoor leak detection can be accomplished with relatively inexpensive color cameras. In this application, the analytic monitors the area of interest for the color(s) of the product(s). Lighting in these cases must be consistent in order for the analytic to properly see the color of the product correctly.

The following factors were discovered to impact the system:

Building windows:

During certain times of year, sunlight can slant through the windows and create very bright areas on the floor areas being monitored. This can cause the color camera to automatically compensate by darkening the image, which can then potentially trigger the analytic if it is monitoring for a dark colored liquid.

Building doors:

Personnel entering and leaving the building during the day and opening doors can allow in enough light to trigger the camera compensation and cause alarms.

HPS light cycling:

Once HPS lights near the end of their lifecycle, they go through a process of cycling on and off. This can cause alarms as the lighting within the building fluctuates.

System Monitoring Considerations.

With customers expecting to deploy the system with a potential of hundreds of cameras, the monitoring system must be scalable to effectively manage over 1000 devices. In addition, the monitoring station must be designed to receive alarms only on an exception basis rather than constant live video, as most pump stations are remotely located with limited bandwidth and operators cannot manage that volume of information. This allows for large numbers of DVRs to be deployed into the field with a single monitoring station capable of managing them all.

Monitoring Considerations: Modbus TCP.

Most remote pump facilities are controlled via a SCADA interface, many of which are currently based on MODBUS TCP. In order to work within the current control systems, a MODBUS module was programmed so the DVR would be capable of sending alarm notifications and monitoring certain pieces of customer equipment.This allows limited connectivity and control as a slave or master device, and the ability of the customer to use a familiar interface.

Monitoring Considerations: Recertification program

It is common in the Oil and Gas industry to provide a test program or service to ensure equipment is operating to specification. In order to facilitate this, a solution is required to simulate leaks at the customer site. The system should be portable and can be towed to any location, and hoses can be used to transport water into any hazardous location where leaks need to be monitored. A heater can optionally be used to bring the water temperature up to process fluid temperature, and pressure can be controlled to simulate various types of leaks. This ensures that the settings in the analytic are optimal for leak detection for that installation, as well as verifying proper operation on a regular basis.

Color Cameras: VerificationColor cameras are paired with thermal cameras in order to provide operators with a color view of the area of interest. With thermal cameras typically displaying in grayscale, it can be difficult to see detail in the image. Color cameras provide the additional information needed to make informed decisions. In addition, security analytics can be run on these color cameras if required.

Color Leak Detection: Indoors.Indoor leak detection can be accomplished with relatively inexpensive color cameras. In this application, the analytic monitors the area of interest for the color(s) of the product(s). Lighting in these cases must be consistent in order for the analytic to properly see the color of the product correctly.

The following factors were discovered to impact the systemBuilding windows: During certain times of year, sunlight can slant through the windows and create very bright areas on the floor areas being monitored. This can cause the color camera to automatically compensate by darkening the image, which can then potentially trigger the analytic if it is monitoring for a dark colored liquid.

Building doors:Personnel entering and leaving the building during the day and opening doors can allow in enough light to trigger the camera compensation and cause alarms.

HPS light cycling:

Once HPS lights near the end of their lifecycle, they go through a process of cycling on and off. This can cause alarms as the lighting within the building fluctuates.

System Monitoring Considerations.

With customers expecting to deploy the system with a potential of hundreds of cameras, the monitoring system must be scalable to effectively manage over 1000 devices. In addition, the monitoring station must be designed to receive alarms only on an exception basis rather than constant live video, as most pump stations are remotely located with limited bandwidth and operators cannot manage that volume of information. This allows for large numbers of DVRs to be deployed into the field with a single monitoring station capable of managing them all.

Monitoring Considerations: Modbus TCP.

Most remote pump facilities are controlled via a SCADA interface, many of which are currently based on MODBUS TCP. In order to work within the current control systems, a MODBUS module was programmed so the DVR would be capable of sending alarm notifications and monitoring certain pieces of customer equipment.This allows limited connectivity and control as a slave or master device, and the ability of the customer to use a familiar interface.

Monitoring Considerations: Recertification program

It is common in the Oil and Gas industry to provide a test program or service to ensure equipment is operating to specification. In order to facilitate this, a solution is required to simulate leaks at the customer site. The system should be portable and can be towed to any location, and hoses can be used to transport water into any hazardous location where leaks need to be monitored. A heater can optionally be used to bring the water temperature up to process fluid temperature, and pressure can be controlled to simulate various types of leaks. This ensures that the settings in the analytic are optimal for leak detection for that installation, as well as verifying proper operation on a regular basis.

The following factors were discovered to impact the systemHPS light cycling:Once HPS lights near the end of their lifecycle, they go through a process of cycling on and off. This can cause alarms as the lighting within the building fluctuates.System Monitoring Considerations.With customers expecting to deploy the system with a potential of hundreds of cameras, the monitoring system must be scalable to effectively manage over 1000 devices. In addition, the monitoring station must be designed to receive alarms only on an exception basis rather than constant live video, as most pump stations are remotely located with limited bandwidth and operators cannot manage that volume of information. This allows for large numbers of DVRs to be deployed into the field with a single monitoring station capable of managing them all.

Monitoring Considerations: Modbus TCP.

Most remote pump facilities are controlled via a SCADA interface, many of which are currently based on MODBUS TCP. In order to work within the current control systems, a MODBUS module was programmed so the DVR would be capable of sending alarm notifications and monitoring certain pieces of customer equipment.This allows limited connectivity and control as a slave or master device, and the ability of the customer to use a familiar interface.

Monitoring Considerations: Recertification program

It is common in the Oil and Gas industry to provide a test program or service to ensure equipment is operating to specification. In order to facilitate this, a solution is required to simulate leaks at the customer site. The system should be portable and can be towed to any location, and hoses can be used to transport water into any hazardous location where leaks need to be monitored. A heater can optionally be used to bring the water temperature up to process fluid temperature, and pressure can be controlled to simulate various types of leaks. This ensures that the settings in the analytic are optimal for leak detection for that installation, as well as verifying proper operation on a regular basis.

The following factors were discovered to impact the systemMonitoring Considerations: Modbus TCP.Most remote pump facilities are controlled via a SCADA interface, many of which are currently based on MODBUS TCP. In order to work within the current control systems, a MODBUS module was programmed so the DVR would be capable of sending alarm notifications and monitoring certain pieces of customer equipment.This allows limited connectivity and control as a slave or master device, and the ability of the customer to use a familiar interface.

The following factors were discovered to impact the systemMonitoring Considerations: Recertification program

It is common in the Oil and Gas industry to provide a test program or service to ensure equipment is operating to specification. In order to facilitate this, a solution is required to simulate leaks at the customer site. The system should be portable and can be towed to any location, and hoses can be used to transport water into any hazardous location where leaks need to be monitored. A heater can optionally be used to bring the water temperature up to process fluid temperature, and pressure can be controlled to simulate various types of leaks. This ensures that the settings in the analytic are optimal for leak detection for that installation, as well as verifying proper operation on a regular basis.

Performance Analysis:Color Outdoor Security: The installed systems generate an average of 0.08 Alarms/Day/Analytic. In actuality, these alarms tend to occur in clusters. As an example, 20 consecutive tripwire alarms due to an environmental condition, followed by no alarms for 10 days, followed by 5 alarms in an afternoon due to animals, and so on. These are well below the industry average of 10 alarms/day/camera reported by our security monitoring partner.

Performance Analysis:Color Outdoor Security: The installed systems generate an average of 0.08 Alarms/Day/Analytic. In actuality, these alarms tend to occur in clusters. As an example, 20 consecutive tripwire alarms due to an environmental condition, followed by no alarms for 10 days, followed by 5 alarms in an afternoon due to animals, and so on. These are well below the industry average of 10 alarms/day/camera reported by our security monitoring partner.

Performance Analysis:Outdoor Thermal Leak Detection: The installed systems generate an average of 0.02 Alarms/Day/Analytic. These alarms were specifically caused by animals in the analytic area.Color indoor Leak Detection: The installed systems generate an average of 0 false alarms over the duration of the experiment.

Performance Analysis:Valid Security Alarms: The installed systems generate an average of 99.9% (Note this comprises of personnel on site that have triggered alarms when the system has not been disabled). A detailed statistics is illustrated in Annex A, where performance at 7, 15 and 30 days is shown. The performance is reported within four categories of performance and four acceptance criteria of the operators

Alarm tracking statisticS