Gas and/or flame imaging system with explosion proof housing

• US 7,687,776 B2
• Filed: 01/09/2008
• Issued: 03/30/2010
• Est. Priority Date: 04/11/2007
• Status: Active Grant

• Current Assignee: MSA Technology, LLC (MSA Safety, Inc.)
• Original Assignee: General Monitors, Inc. (MSA Safety, Inc.)
• Inventors: Park, John H., Romero, John G., Baliga, Shankar B.
• Primary Examiner(s): Porta; David P
• Assistant Examiner(s): BOOSALIS, FANI POLYZOS
• Application Number:
  US11/971,413
• Publication Number:
  US 20080251724A1
• Time in Patent Office: 811 Days
• Field of Search: 250/338.5, 250/338.3, 250/338.2, 250/339.02, 250/339.03, 250/338.1, 356/437
• US Class Current: 250/338.5
• CPC Class Codes: G01J 3/02 Details
• CPC Class Codes: G01J 3/0235 using means for replacing an element by another, for replacing a filter or a grating
• CPC Class Codes: G01J 3/2823 Imaging spectrometer
• CPC Class Codes: G01J 3/443 Emission spectrometry
• CPC Class Codes: G01J 5/0018 Flames, plasma or welding
• CPC Class Codes: G01N 2021/1795 Atmospheric mapping of gases
• CPC Class Codes: G01N 21/3504 for analysing gases, e.g. multi-gas analysis
• CPC Class Codes: G01N 2201/0221 Portable; cableless; compact; hand-held

Abstract

A gas imaging system for remotely detecting gas emissions by passive images of infrared radiation includes an optical system having a field of view. The optical system has a lens, an optical filter system for filtering light passed through the lens, and a photosensitive array located at the focal plane of the optical system to produce multi-spectral infrared image data of a scene under observation. A multi-spectral image processing system is configured for processing the image data produced by the photosensitive array to detect hazardous gas emissions and to discriminate against infrared radiation emitted by false alarm sources. Some embodiments may be configured for flame detection. Other embodiments may be configured for gas and flame detection.

Claims

1. A gas imaging system for remotely detecting gas emissions by passive images of infrared radiation, comprising:

an explosion proof housing structure configured to contain explosive conditions within the housing structure so as to not ignite a surrounding environment in which the gas imaging system is installed, the housing structure including an optical window fabricated of a mechanically strong, infrared transmissive material mounted on the housing structure to pass infrared radiation into the housing structure;

an optical system having a field of view and including a lens, an optical filter system for filtering light passed through the lens, and a photosensitive array located in a fixed position at the focal plane of the optical system to produce multi-spectral infrared image data of a scene under observation;

a multi-spectral image processing system configured for processing the image data produced by the photosensitive array to detect hazardous gas emissions and to discriminate against infrared radiation emitted by false alarm sources; and

wherein the optical system and image processing system are disposed within the explosion proof housing structure.

2. The system of claim 1, wherein the photosensitive array is an uncooled, microbolometer array, at the focal plane of the optical system to form an infrared image.

3. The system of claim 2, wherein the microbolometer array is fabricated from an oxide of vanadium or from amorphous silicon.

4. The system of claim 1, wherein the photosensitive array is an uncooled ferroelectric or pyroelectric array.

5. The system of claim 1, wherein the photosensitive array is a cooled semiconductor array.

6. The system of claim 1, wherein the photosensitive array comprises a two dimensional array of photosensitive elements, producing successive frames of image data for processing by the image processing system.

7. The system of claim 1, wherein the focal plane array has a Noise Equivalent Temperature Difference (NETD) measure of sensitivity value of less than 100 milliKelvins.

8. The system of claim 1, wherein said image processing system is configured to process image data over one or more sets of active and reference wavelengths.

9. The system of claim 8, wherein said filter system includes a filter wheel housing multiple filter elements configured to be moved in a sequence across the imaging array by rotation about a center axis, and wherein the multiple filter elements include a first narrowband infrared filter having a passband for passing infrared energy in an active wavelength band of a gas whose presence is to be detected by the system, and a second filter having a passband for passing energy in a reference wavelength band of a false alarm or thermal background source.

10. The system of claim 9, wherein the image processing system includes image processing algorithms for processing the image data, and wherein the location of the filter wheel is synchronized with the image processing algorithms in real-time.

11. The system of claim 9, wherein a frame of image data is obtained each time a filter element crosses the photosensitive array.

12. The system of claim 1, wherein the lens is configured to produce a collimated beam of energy, and the system further includes:

a two dimensional array of microlenses disposed in an optical path between the lens and the photosensitive array, each microlens of the array configured to direct light destined for an inactive region around an element of the photosensitive array to a photosensitive area of the element of the photosensitive array.

13. The system of claim 12, wherein the microlens array is fabricated from an infrared transmissive material.

14. The system of claim 12, wherein the microlens array is configured so that different parts of the microlens array focus different infrared wavelengths on the detector array, using diffractive optical techniques.

15. The system of claim 12, wherein the microlens array is positioned one focal distance from the photosensitive array.

16. The system of claim 1, wherein the filtering system includes one or more active wavelength band filters and one or more reference wavelength band filters, the one or more active wavelength band filters for passing infrared energy in corresponding one or more wavelength bands of one or more gases whose presence is to be detected by the system, and the one or more reference wavelength band filters for passing energy in one or more wavelength bands of one or more false alarm or thermal background sources.

17. The system of claim 16, wherein the system is configured for hydrocarbon gas detection, and the one or more active wavelength band filters includes an active filter band centered at 3.335 micron, and the one or more reference wavelength band filters includes reference filters centered respectively at 2.2 microns, 3.16 microns and 4.90 microns.

18. The system of claim 16, wherein the system is configured for gas detection and to discriminate against emissions from steam and water vapor, and the one or more reference wavelength band filters includes a filter centered at 2.95 microns sensitive to water vapor emissions.

19. The system of claim 16, wherein the system is further configured for imaging of hydrocarbon flame emissions, and the one or more active wavelength band filters includes filters centered at 4.30 microns and 4.45 microns, and the one or more reference wavelength band filters includes reference filters centered respectively at 2.2 microns, 3.16 microns and 4.90 microns.

20. The system of claim 16, wherein the system is configured for imaging of flames generating hot water vapor from combustion of hydrogen, methane or other alkanes, and the one or more active wavelength band filters includes a filter centered at 2.95 microns.

21. The system of claim 1, wherein the window is an annealed sapphire window.

22. The system of claim 1, wherein the lens includes said window.

23. A stationary gas imaging system for remotely detecting gas emissions by passive images of infrared radiation, comprising:

an explosion proof housing structure including an optical window fabricated of a mechanically strong, infrared transmissive material to pass infrared radiation into the housing structure;

an optical system having a field of view and including a lens, an optical filter system for filtering light passed through the lens, and a photosensitive array located at the focal plane of the optical system to produce multi-spectral infrared image data of a scene under observation;

a multi-spectral image processing system configured for processing the image data produced by the photosensitive array to detect hazardous gas emissions and to discriminate against infrared radiation emitted by false alarm sources; and

wherein the optical system and image processing system are disposed within the explosion proof housing structure; and

wherein the system operates in a fixed installation in a hazardous environment.

24. The system of claim 23, wherein the photosensitive array is an uncooled array.

25. The system of claim 23, wherein the photosensitive array is a cooled array.

26. The system of claim 23, wherein the photosensitive array comprises a two dimensional array of photosensitive elements, producing successive frames of image data for processing by the image processing system.

27. The system of claim 23, wherein said image processing system is configured to process image data over one or more sets of active and reference wavelengths.

28. The system of claim 27, wherein said filter system includes a filter wheel housing multiple filter elements configured to be moved in a sequence across the imaging array by rotation about a center axis, and wherein the multiple filter elements include a first narrowband infrared filter having a passband for passing infrared energy in an active wavelength band of a gas whose presence is to be detected by the system, and a second filter having a passband for passing energy in a reference wavelength band of a false alarm or thermal background source.

29. The system of claim 28, wherein the image processing system includes image processing algorithms for processing the image data, and wherein the location of the filter wheel is synchronized with the image processing algorithms in real-time.

30. The system of claim 28, wherein a frame of image data is obtained each time a filter element crosses the photosensitive array.

31. The system of claim 23, including a two dimensional array of microlenses disposed in an optical path between the lens and the photosensitive array.

32. The system of claim 31, wherein each microlens of the array is configured to direct light destined for an inactive region around an element of the photosensitive array to a photosensitive area of the element of the photosensitive array.

33. The system of claim 31, wherein the microlens array is fabricated from an infrared transmissive material.

34. The system of claim 31, wherein the microlens array is configured so that different parts of the microlens array focus different infrared wavelengths on the detector array, using diffractive optical techniques.

35. The system of claim 31, wherein the microlens array is positioned one focal distance from the photosensitive array.

36. The system of claim 23, wherein the filtering system includes one or more active wavelength band filters and one or more reference wavelength band filters, the one or more active wavelength band filters for passing infrared energy in corresponding one or more wavelength bands of one or more gases whose presence is to be detected by the system, and the one or more reference wavelength band filters for passing energy in one or more wavelength bands of one or more false alarm or thermal background sources.

37. The system of claim 36, wherein the system is configured for hydrocarbon gas detection, and the one or more active wavelength band filters includes an active filter band centered at 3.335 micron, and the one or more reference wavelength band filters includes reference filters centered respectively at 2.2 microns, 3.16 microns and 4.90 microns.

38. The system of claim 36, wherein the system is configured for gas detection and to discriminate against emissions from steam and water vapor, and the one or more reference wavelength band filters includes a filter centered at 2.95 microns sensitive to water vapor emissions.

39. The system of claim 36, wherein the system is further configured for imaging of hydrocarbon flame emissions, and the one or more active wavelength band filters includes filters centered at 4.30 microns and 4.45 microns, and the one or more reference wavelength band filters includes reference filters centered respectively at 2.2 microns, 3.16 microns and 4.90 microns.

40. The system of claim 36, wherein the system is configured for imaging of flames generating hot water vapor from combustion of hydrogen, methane or other alkanes, and the one or more active wavelength band filters includes a filter centered at 2.95 microns.

41. The system of claim 23, wherein the lens includes said window.

42. A gas or flame imaging system for remotely detecting gas or flame emissions by passive images of infrared radiation, comprising:

an explosion proof housing structure configured to contain explosive conditions within the housing structure so as to not ignite a surrounding environment in which the gas imaging system is installed, the housing structure including an optical window fabricated of a mechanically strong, infrared transmissive material mounted on the housing structure to pass infrared radiation into the housing structure;

an optical system having a field of view and including a lens, an optical filter system for filtering light passed through the lens, and a photosensitive array located in a fixed position at the focal plane of the optical system to produce multi-spectral infrared image data of a scene under observation; and

a multi-spectral image processing system configured for processing the image data produced by the photosensitive array to detect hazardous gas or flame emissions and to discriminate against infrared radiation emitted by false alarm sources; and

wherein the optical system and image processing system are disposed within the explosion proof housing structure.

43. The system of claim 42, wherein the filter system includes one or more active wavelength band filters and one or more reference wavelength band filters, the one or more active wavelength band filters for passing infrared energy in corresponding one or more wavelength bands of one or more hazardous gases or flames whose presence is to be detected by the system, and the one or more reference wavelength band filters for passing energy in one or more wavelength bands of one or more false alarm or thermal background sources.

44. The system of claim 43, wherein the system is configured for imaging of hydrocarbon flame emissions, and the one or more active wavelength band filters includes filters centered at 4.30 microns and 4.45 microns, and the one or more reference wavelength band filters includes reference filters centered respectively at 2.2 microns, 3.16 microns and 4.90 microns.

45. The system of claim 43, wherein the system is configured for imaging of flames generating hot water vapor from combustion of hydrogen, methane or other alkanes, and the one or more active wavelength band filters includes a filter centered at 2.95 microns.