Industrial Process Tomography Research Articles

Multiphase permittivity imaging using absolute value electrical capacitance tomography data and a level set algorithm.

Multiphase flow imaging is a very challenging and critical topic in industrial process tomography. In this article, simulation and experimental results of reconstructing the permittivity profile of multiphase material from data collected in electrical capacitance tomography (ECT) are presented. A multiphase narrowband level set algorithm is developed to reconstruct the interfaces between three- or four-phase permittivity values. The level set algorithm is capable of imaging multiphase permittivity by using one set of ECT measurement data, so-called absolute value ECT reconstruction, and this is tested with high-contrast and low-contrast multiphase data. Simulation and experimental results showed the superiority of this algorithm over classical pixel-based image reconstruction methods. The multiphase level set algorithm and absolute ECT reconstruction are presented for the first time, to the best of our knowledge, in this paper and critically evaluated. This article is part of the themed issue 'Supersensing through industrial process tomography'.

Sensing flame structure by process tomography.

Non-intrusive visualization of the structure of flames can offer us many advantages in studying the reaction mechanisms of combustion and observing special distributions of the parameters required for the development of equipment such as jet engines and gas turbines. Process tomography is a relatively new technique for such a task, but is useful owing to its fast speed and capability of detecting signals related to ionizations caused by chemical reactions and thermal effects. Electric capacitance tomography (ECT) is one of the process tomographic techniques. ECT usually comprises a sensor array of electrodes that detect permittivity variations in the measuring zone, a data-logging device and a computer that controls data acquisition and carries out image reconstruction. There have been studies on ECT imaging of flames; however, ECT has not been exploited sufficiently to reveal the inner structure of the flames. In this study, a sensor with planar electrodes is created, and the associated three-dimensional sensitivity map is generated by the finite-element method to detect flame structure. A series of experiments are carried out covering a range of feed rates of fuel and air. Data are collected by the ECT sensor and hardware. The results of the ECT reconstruction show good agreement with actual features, and the structure of the flame is found. This opens up a new route for the study of flames. This article is part of the themed issue 'Supersensing through industrial process tomography'.

Super-sensing technology: industrial applications and future challenges of electrical tomography.

Electrical tomography is a relatively new imaging technique that can image the distribution of the passive electrical properties of an object. Since electrical tomography technology was proposed in the 1980s, the technique has evolved rapidly because of its low cost, easy scale-up and non-invasive features. The technique itself can be sensitive to all passive electrical properties, such as conductivity, permittivity and permeability. Hence, it has a huge potential to be applied in many applications. Owing to its ill-posed nature and low image resolution, electrical tomography attracts more attention in industrial fields than biomedical fields. In the past decades, there have been many research developments and industrial implementations of electrical tomography; nevertheless, the awareness of this technology in industrial sectors is still one of the biggest limitations for technology implementation. In this paper, the authors have summarized several representative applications that use electrical tomography. Some of the current tomography research activities will also be discussed. This article is part of the themed issue 'Supersensing through industrial process tomography'.

Interface and permittivity simultaneous reconstruction in electrical capacitance tomography based on boundary and finite-elements coupling method.

Electrical capacitance tomography (ECT) is a non-destructive detection technique for imaging the permittivity distributions inside an observed domain from the capacitances measurements on its boundary. Owing to its advantages of non-contact, non-radiation, high speed and low cost, ECT is promising in the measurements of many industrial or biological processes. However, in the practical industrial or biological systems, a deposit is normally seen in the inner wall of its pipe or vessel. As the actual region of interest (ROI) of ECT is surrounded by the deposit layer, the capacitance measurements become weakly sensitive to the permittivity perturbation occurring at the ROI. When there is a major permittivity difference between the deposit and the ROI, this kind of shielding effect is significant, and the permittivity reconstruction becomes challenging. To deal with the issue, an interface and permittivity simultaneous reconstruction approach is proposed. Both the permittivity at the ROI and the geometry of the deposit layer are recovered using the block coordinate descent method. The boundary and finite-elements coupling method is employed to improve the computational efficiency. The performance of the proposed method is evaluated with the simulation tests. This article is part of the themed issue 'Supersensing through industrial process tomography'.

Reconstruction of velocity fields in electromagnetic flow tomography.

Electromagnetic flow meters (EMFMs) are the gold standard in measuring flow velocity in process industry. The flow meters can measure the mean flow velocity of conductive liquids and slurries. A drawback of this approach is that the velocity field cannot be determined. Asymmetric axial flows, often encountered in multiphase flows, pipe elbows and T-junctions, are problematic and can lead to serious systematic errors. Recently, electromagnetic flow tomography (EMFT) has been proposed for measuring velocity fields using several coils and a set of electrodes attached to the surface of the pipe. In this work, a velocity field reconstruction method for EMFT is proposed. The method uses a previously developed finite-element-based computational forward model for computing boundary voltages and a Bayesian framework for inverse problems. In the approach, the vz-component of the velocity field along the longitudinal axis of the pipe is estimated on the pipe cross section. Different asymmetric velocity fields encountered near pipe elbows, solids-in-water flows in inclined pipes and in stratified or multiphase flows are tested. The results suggest that the proposed reconstruction method could be used to estimate velocity fields in complicated pipe flows in which the conventional EMFMs have limited accuracy. This article is part of the themed issue 'Supersensing through industrial process tomography'.

Characterizing the correlations between local phase fractions of gas-liquid two-phase flow with wire-mesh sensor.

Understanding of flow patterns and their transitions is significant to uncover the flow mechanics of two-phase flow. The local phase distribution and its fluctuations contain rich information regarding the flow structures. A wire-mesh sensor (WMS) was used to study the local phase fluctuations of horizontal gas-liquid two-phase flow, which was verified through comparing the reconstructed three-dimensional flow structure with photographs taken during the experiments. Each crossing point of the WMS is treated as a node, so the measurement on each node is the phase fraction in this local area. An undirected and unweighted flow pattern network was established based on connections that are formed by cross-correlating the time series of each node under different flow patterns. The structure of the flow pattern network reveals the relationship of the phase fluctuations at each node during flow pattern transition, which is then quantified by introducing the topological index of the complex network. The proposed analysis method using the WMS not only provides three-dimensional visualizations of the gas-liquid two-phase flow, but is also a thorough analysis for the structure of flow patterns and the characteristics of flow pattern transition. This article is part of the themed issue 'Supersensing through industrial process tomography'.

Arts of electrical impedance tomographic sensing.

This paper reviews governing theorems in electrical impedance sensing for analysing the relationships of boundary voltages obtained from different sensing strategies. It reports that both the boundary voltage values and the associated sensitivity matrix of an alternative sensing strategy can be derived from a set of full independent measurements and sensitivity matrix obtained from other sensing strategy. A new sensing method for regional imaging with limited measurements is reported. It also proves that the sensitivity coefficient back-projection algorithm does not always work for all sensing strategies, unless the diagonal elements of the transformed matrix, ATA, have significant values and can be approximate to a diagonal matrix. Imaging capabilities of few sensing strategies were verified with static set-ups, which suggest the adjacent electrode pair sensing strategy displays better performance compared with the diametrically opposite protocol, with both the back-projection and multi-step image reconstruction methods. An application of electrical impedance tomography for sensing gas in water two-phase flows is demonstrated.This article is part of the themed issue ‘Supersensing through industrial process tomography’.

Electronic hardware design of electrical capacitance tomography systems.

Electrical tomography techniques for process imaging are very prominent for industrial applications, such as the oil and gas industry and chemical refineries, owing to their ability to provide the flow regime of a flowing fluid within a relatively high throughput. Among the various techniques, electrical capacitance tomography (ECT) is gaining popularity due to its non-invasive nature and its capability to differentiate between different phases based on their permittivity distribution. In recent years, several hardware designs have been provided for ECT systems that have improved its resolution of measurements to be around attofarads (aF, 10(-18) F), or the number of channels, that is required to be large for some applications that require a significant amount of data. In terms of image acquisition time, some recent systems could achieve a throughput of a few hundred frames per second, while data processing time could be achieved in only a few milliseconds per frame. This paper outlines the concept and main features of the most recent front-end and back-end electronic circuits dedicated for ECT systems. In this paper, multiple-excitation capacitance polling, a front-end electronic technique, shows promising results for ECT systems to acquire fast data acquisition speeds. A highly parallel field-programmable gate array (FPGA) based architecture for a fast reconstruction algorithm is also described. This article is part of the themed issue 'Supersensing through industrial process tomography'.

A gradiometric version of contactless inductive flow tomography: theory and first applications.

The contactless inductive flow tomography (CIFT) is a measurement technique that allows reconstructing the flow of electrically conducting fluids by measuring the flow-induced perturbations of one or various applied magnetic fields and solving the underlying inverse problem. One of the most promising application fields of CIFT is the continuous casting of steel, for which the online monitoring of the flow in the mould would be highly desirable. In previous experiments at a small-scale model of continuous casting, CIFT has been applied to various industrially relevant problems, including the sudden changes of flow structures in case of argon injection and the influence of a magnetic stirrer at the submerged entry nozzle. The application of CIFT in the presence of electromagnetic brakes, which are widely used to stabilize the flow in the mould, has turned out to be more challenging due to the extreme dynamic range between the strong applied brake field and the weak flow-induced perturbations of the measuring field. In this paper, we present a gradiometric version of CIFT, relying on gradiometric field measurements, that is capable to overcome those problems and which seems, therefore, a promising candidate for applying CIFT in the steel casting industry. This article is part of the themed issue 'Supersensing through industrial process tomography'.

ITS Reconstruction Tool-Suite: An inverse algorithm package for industrial process tomography

Electrical resistance tomography (ERT) and electrical capacitance tomography (ECT) are two established process tomography techniques that can be applied into various indsutries. ERT can monitor the electrical conductivity changes in the process whereas ECT can detect the electrical dielectric materials. Due to their high-speed and low cost features, they are particularly attractive to industrial applications which require real time conditional monitoring. For the past decades, 2D linear back projection (LBP) has been the standard technique for both commercialised ERT and ECT systems because of its simplicity and fast reconstruction speed. In this paper, ITS Plc has released a 'Reconstruction Tool-Suite' software that allows industrial users to utilise different reconstruction algorithms to further understand their processes. Different algorithms are integrated into this software package including the single step Tikhonov method and the iterative Landweber method. In the latest version of the software, the full-field 3D tomography reconstruction scheme is also included, which allows the users to perform 3D reconstruction for their processes. A series of experiments are conducted to validate the pros and cons of different methods.

Imaging floating metals and dielectric objects using electrical capacitance tomography

Electrical capacitance tomography (ECT) is a well-established industrial process tomography technique. The application of ECT is generally limited to imaging insulating objects with permittivity contrast. Although ECT imaging for grounded conductors are studied earlier, there is not a systematic study of imaging floating metals using ECT. To broaden the application of the ECT, imaging of suspended metallic samples is studied in this paper. Placing a metallic conductor between electrodes has an effect of shortening the spacing between the electrodes, thus the capacitances are increased. This increment in capacitances can be regarded as placing a dielectric sample with higher permittivity than the reference data. An ECT image of the floating metallic samples can be reconstructed using traditional sensitivity based image reconstruction, which is in the same way as imaging dielectric permittivity. In this paper, both metallic and dielectric samples are tested, and the results show the feasibility of ECT imaging for floating metals.

Dual modality ECT–MIT multi-phase flow imaging

Three-phase flow imaging is a very challenging problem in industrial process tomography. A particular interest here is three phase flow including both conductive and non-conductive phases. Currently there is no robust solution to this problem. Electrical capacitance tomography (ECT) has been applied to visualize the permittivity distribution by measuring inter-capacitance between electrodes around sensing area. Magnetic inductance tomography (MIT) is a technique to image the conductivity distribution through the inductance measurements over the coils around the sensing area. In this paper, the three-phase flow is classified into two scenarios: air background and water background. A dual-modality method of ECT and MIT is proposed to image both the conductive and dielectric components under test. As a result of this experiment, the dual-modality method is able to solve air-background three-phase flow imaging, but a problem has been raised in the water-background scenario. The static experiment results are promising for such contactless three phase flow imaging.

Experimental evaluation of conductive flow imaging using magnetic induction tomography

Multi-phase flow imaging is a challenging topic in industrial process tomography. In this paper, we present a non-invasive imaging technique for the electrically conductive phase of a multi-phase flow problem. Magnetic induction tomography (MIT) is sensitive to the conductivity of the target, and as such has the potential to be used as an imaging technique to visualise the conductive components in a multi-phase flow application. A 16 channel MIT system is used for this study, among which eight excitation coils are supplied with a 15V peak, 13MHz sinusoidal signal in sequence from a signal generator, while the remaining eight coils are floated as receivers. The imaging region of this MIT system has an inner and outer diameter of 190mm and 200mm respectively. Static fluid distribution patterns are produced using several fluids with different conductivities and placed inside the imaging region to form conductivity phase contrasts. Experimental results show within our hardware and software capability, a conductivity contrast of 0.06S/m for an inclusion that occupies 8.69% of the imaging region can be imaged. An in-depth experimental evaluation of the system response towards various fluid measurements is shown for the first time, as are results for quasi-static fluid experiments showing that a non-homogenous flow of gas bubbles can be imaged in various conductive backgrounds. In sum, the analyses presented investigate the feasibility and capability of MIT for this application, while also reporting some of the first flow rig tests in this field.

Ultrasonic Sonic Imaging for a Two Phase System Based on Support Vector Machine Classifier

Multiphase flow characterization is an important task for monitoring, measuring or controlling industrial processes. This can be done by means of process tomography. The use of tomographic techniques has been used within the oil industry. One of the potential applications is flow visualization and measurement in producing wells. Research on industrial process tomography consists in obtaining estimated images of a cross section of a pipe or vessel containing or carrying the substances of the process. One category of process tomography is ultrasonic tomography technique. A simple tomography can be built by mounting a number of sensors around the circumference of a horizontal pipe. This includes acquiring and processing ultrasonic signals from the transducers to obtain the information of the spatial distributions of liquid and gas in an experimental column. Analysis on the transducers’ signals will be carrying out to distinguish between the observation time and the Lamb waves. The information obtained from the observation time is useful for further development of the image reconstruction. To obtain the time easily, the time will be calculated from the starting pulse of transmitter signal until the starting peak of receiver signal. Finally Support Vector Machine (SVM) was employed to distinguish of each phase between water and gas.

Magnetic induction tomography guided electrical capacitance tomography imaging with grounded conductors

Electrical capacitance tomography (ECT) is an imaging technique commonly used for imaging dielectric permittivity of insulating objects. In applications such industrial process tomography and non-destructive testing (NDT), the objects under test may exhibit variations in both dielectric permittivity and electrical conductivity. In particular, a sample that includes high conductivity, such as metal, can cause a large change in electrical field in ECT. The metal sample in imaging area will cause a large change in the sensitivity map of ECT compared to free space, which will make the ECT image reconstruction inaccurate. This effect is more severe in grounded conductor than floating conductors, so this paper focuses on grounded conductor. In order to update the sensitivity map, one needs to gain information about the conductivity distribution in ECT problem. Magnetic induction tomography (MIT) is sensitive to electrical conductivity and not sensitive to permittivity variations; therefore, it can be used to visualize the conductivity distribution of the target under test. In this paper, a dual-modality MIT and ECT system is proposed to image a medium including conductors and dielectrics. Both simulated and experimental results are presented, which demonstrate the feasibility of the proposed method.

HIGH DEFINITION ELECTRICAL CAPACITANCE TOMOGRAPHY FOR PIPELINE INSPECTION

Pipelines made of dielectric materials such as Polyethylene (PE) are becoming increasingly popular. With no suitable inspection technique for dielectric pipes, there is an urgent need to develop new technology for their inspection. This paper presents a novel pipe inspection technique using Electrical Capacitance Tomography (ECT) imaging. Traditionally ECT is used for industrial process tomography as a low resolution but fast tomographic imaging technique. Typically commercial ECT can provide a resolution of approximately 10 percent of the imaging region. In this paper a limited region tomography technique is developed take into account prior knowledge about the geometry of the pipe. This has signiflcantly enhanced the imaging resolution of the ECT system, making it a viable pipe inspection solution. The experimental results in this study demonstrate an interior wall loss area as small as 0.195 percent of the ECT cross sectional imaging region is repeatable and can be reliably detected. A narrowband pass fllter method (NPFM) is used as a means to limit the region for the ECT algorithm. This results in an unprecedented resolution, making ECT a viable non-destructive evaluation (NDE) technique for plastic pipes. The NDE application of the ECT for PE pipes is demonstrated in this paper with several experimental results. A wall loss of depth of 1.5mm could be detected for an ECT sensor array of 150mm in diameter, showing a high resolution and high deflnition ECT (HD-ECT) imaging that has not been reported before.

Theoretical and Experimental Evaluation of Rotational Magnetic Induction Tomography

Magnetic induction tomography (MIT) is a new and emerging tomographic imaging technique, which has found applications in industrial process tomography and material inspection, particularly for imaging metallic objects. In this paper, a rotational MIT (RMIT) system has been developed, in which a coil array is rotated with respect to a central axis perpendicular to the plane of the coil array. The RMIT is capable of producing images with better quality as a result of increasing the number of independent measurements. An eight-coil MIT system has been developed to generate the experimental data required in this paper. To show the proof of principle, a manual rotational scheme has been implemented. The advantages of the RMIT system have been established using theoretical analysis and comparison of the underlying inverse problem in MIT and RMIT. The effectiveness of RMIT has been shown using both synthetic and experimental data. Several image quality measures have been used to critically evaluate RMIT against the traditional MIT system.

FOUR DIMENSIONAL RECONSTRUCTION USING MAGNETIC INDUCTION TOMOGRAPHY: EXPERIMENTAL STUDY

Magnetic Induction Tomography (MIT) is a relatively new and emerging type of tomography techniques that is able to map the distribution of all three passive electrical properties (PEPs). Its non-invasive and contactless features make it an attractive technique for many applications compared to the traditional contact electrode based electrical impedance tomography. Recently, MIT has become a promising monitoring technique in industrial process tomography, and the area of the research interest has moved from 2D to 3D because of the volumetric nature of electromagnetic field. Three dimensional MIT images provide more information on the conductivity distribution, especially in the axial direction. However, it has been reported that the reconstructed 3D images can be distorted when the imaging object is located at a less sensitive region. Although this distortion can be compensated by adjusting the regularisation criteria, this is not practical in real life applications as the prior information about the object's location is often unavailable. This paper presents a memory efficient 4D MIT algorithm which can maintain the image quality under the same regularisation circumstances. Instead of solving each set of measurement individually, the 4D algorithm takes advantage of the correlations between the image and its neighboring data frames to reconstruct 4D of conductivity movements. The 4D algorithm improves the image qualities by increasing the temporal resolution. It also overcomes some sensitivity issues of 3D MIT algorithms and can provide a more stable result in terms of the size consistency of the reconstructed image. Several experimental results using real laboratory data are presented for validating the proposed algorithms.

TWO-PHASE LOW CONDUCTIVITY FLOW IMAGING USING MAGNETIC INDUCTION TOMOGRAPHY

Magnetic Induction Tomography (MIT) is a new and emerging type of tomography technique that is able to map the distribution of all three passive electromagnetic properties, however most of the current interests are focusing on the conductivity and permeability imaging. In an MIT system, coils are used as separate transmitters or sensors, which can generate the background magnetic fleld and detect the perturbed magnetic fleld respectively. Through switching technique the same coil can work as transceiver which can generate fleld at a time and detect the fleld at another time. Because magnetic fleld can easily penetrate through the non-conductive barrier, the sensors do not need direct contact with the imaging object. These non-invasive and contactless features make it an attractive technique for many applications compared to the traditional contact electrode based electrical impedance tomography. Recently, MIT has become a promising monitoring technique in industrial process tomography, for example MIT has been used to determine the distribution of liquidised metal and gas (high conductivity two phase ∞ow monitoring) for metal casting applications. In this paper, a low conductivity two phase ∞ow MIT imaging is proposed so the reconstruction of the low contrast samples (< 6S/m) can be realised, e.g., gas/ionised liquid. An MIT system is developed to test the feasibility. The system utilises 16 coils (8 transmitters and 8 receivers) and an operating frequency of 13MHz. Three difierent experiments were conducted to evaluate all possible situations of two phase ∞ow imaging: 1) conducting objects inside a non-conducting background, 2) conducting objects inside a conducting background (low contrast) and 3) non-conducting objects inside a conducting background. Images are reconstructed using the linearised inverse method with regularisation. An experiment was designed to image the non-conductive samples inside a conducting

THREE-DIMENSIONAL NONLINEAR INVERSION OF ELECTRICAL CAPACITANCE TOMOGRAPHY DATA USING A COMPLETE SENSOR MODEL

Electrical Capacitance Tomography (ECT) is a non- invasive and non-destructive imaging technique that uses electrical capacitance measurements at the periphery of an object to generate map of dielectric permittivity of the object. This visualization method is a relatively mature industrial process tomography technique, especially in 2D imaging mode. Volumetric ECT is a new method that poses major computational challenges in image reconstruction and new challenges in sensor design. This paper shows a nonlinear image reconstruction method for 3D ECT based on a validated forward model. The method is based on the flnite element approximation for the complete sensor model and the solution of the inverse problem with nonlinear iterative reconstruction. The nonlinear algorithm has been tested against some complicated experimental test cases, and it has been demonstrated that by using an improved forward model and nonlinear inversion method, very complex shaped samples can be reconstructed. The reconstruction of very complex geometry with objects in the shape of letters H, A, L and T is extremely promising for the applications of 3D ECT.