Methods for performing inspections and detecting chemical leaks using an infrared camera system

• US 8,193,496 B2
• Filed: 12/10/2005
• Issued: 06/05/2012
• Est. Priority Date: 06/11/2003
• Status: Expired due to Fees

• Current Assignee: Leak Surveys Incorporated
• Original Assignee: Leak Surveys Incorporated
• Inventors: Furry, David W.
• Primary Examiner(s): Porta, David
• Assistant Examiner(s): LEE, SHUN K
• Application Number:
  US11/298,862
• Publication Number:
  US 20060091310A1
• Time in Patent Office: 2,369 Days
• Field of Search: 250/330, 250/339.03
• US Class Current: 250/330
• CPC Class Codes: G01J 1/0252 Constructional arrangements for compensating for fluctuations caused by, e.g. temperature, or using cooling or temperature stabilization of parts of the device; Controlling the atmosphere inside a photometer; Purge systems, cleaning devices protection against electromagnetic interferences G01J2001/0276
• CPC Class Codes: G01J 1/0488 with spectral filtering
• CPC Class Codes: G01J 1/4228 arrangements with two or more detectors, e.g. for sensitivity compensation
• CPC Class Codes: G01J 2005/0077 Imaging
• CPC Class Codes: G01J 3/42 Absorption spectrometry; Double beam spectrometry; Flicker spectrometry; Reflection spectrometry beam switching arrangements G01J3/08
• CPC Class Codes: G01J 5/0265 Handheld, portable ear thermometers G01J5/049
• CPC Class Codes: G01J 5/061 by controlling the temperature of the apparatus or parts thereof, e.g. using cooling means or thermostats
• CPC Class Codes: G01J 5/0802 Optical filters
• CPC Class Codes: G01J 5/0846 having multiple detectors for performing different types of detection, e.g. using radiometry and reflectometry channels
• CPC Class Codes: G01M 3/04 by detecting the presence of fluid at the leakage point
• CPC Class Codes: G01M 3/202 using mass spectrometer detection systems
• CPC Class Codes: G01N 2021/1793 Remote sensing
• CPC Class Codes: G01N 2021/3531 without instrumental source, i.e. radiometric
• CPC Class Codes: G01N 21/3518 Devices using gas filter correlation techniques; Devices using gas pressure modulation techniques
• CPC Class Codes: G01N 33/0036 specially adapted to detect a particular component physical analysis of gaseous biological material G01N33/497
• CPC Class Codes: H04N 23/20 for generating image signals from infrared radiation only
• CPC Class Codes: H04N 5/33 Transforming infrared radiation cameras or camera modules for generating image signals from infrared radiation H04N23/20; circuitry of SSIS for transforming infrared radiation into image signals H04N25/20

Abstract

A method of visually detecting a leak of a chemical emanating from a component. The method includes: aiming a passive infrared camera system towards the component; filtering an infrared image with an optical bandpass filter, the infrared image being that of the leak; after the infrared image passes through the lens and optical bandpass filter, receiving the filtered infrared image with an infrared sensor device; electronically processing the filtered infrared image received by the infrared sensor device to provide a visible image representing the filtered infrared image; and visually identifying the leak based on the visible image. The passive infrared camera system includes: a lens; a refrigerated portion including therein the infrared sensor device and the optical bandpass filter (located along an optical path between the lens and the infrared sensor device). At least part of a pass band for the optical bandpass filter is within an absorption band for the chemical.

Claims

1. A method of visually detecting a gas leak of any one or more chemicals of a group of predetermined chemicals, the gas leak emanating from a component of a group of components in different locations, the method comprising:

aiming a passive infrared camera system towards the component, wherein the passive infrared camera system comprises;

a lens,

a refrigerated portion defined by the interior of a Dewar flask, the refrigerated portion comprising therein;

an infrared sensor device; and

a single filter configuration comprising at least one fixed optical bandpass filter, each filter fixed along an optical path between the lens and the infrared sensor device, wherein at least part of the aggregate pass band for the single filter configuration is within an absorption band for each of the predetermined chemicals and wherein the aggregate pass band for the single filter configuration is at least about 200 nm; and

a refrigeration system adapted to cool the refrigerated portion, the refrigeration system comprising a closed-cycle Stirling cryocooler;

filtering an infrared image associated with the area of the gas leak under normal operating and ambient conditions for the component with the at least one optical bandpass filter;

receiving the filtered infrared image of the gas leak with the infrared sensor device;

electronically processing the filtered infrared image received by the infrared sensor device to provide a visible image of the gas leak under variable ambient conditions of the area around the leak; and

visually detecting the leak based on the visible image under the variable ambient conditions.

2. The method of claim 1, further comprising recording the visible image representing the filtered infrared image provided by the infrared camera system, wherein the visual identification of the leak is performed at another location remote from the component while viewing the recorded visual image.

3. The method of claim 1, further comprising:

transmitting the visible image representing the filtered infrared image provided by the infrared camera system to another location remote from the component, wherein the visual identification of the leak is performed at the remote location; and

recording the visible image representing the filtered infrared image provided by the infrared camera system at the remote location.

4. The method of claim 1, further comprising recording the visible image representing the filtered infrared image along with inspection information, wherein the inspection information is selected from a group consisting of inspection location name, inspection location address, component name, component identification information, global positioning coordinates, a date, a time of day, an inspector'"'"'s name, an inspection company'"'"'s name, one or more camera system setting values, and combinations thereof.

5. The method of claim 1, wherein the aiming of the infrared camera system towards the component is performed from a moving vehicle selected from a group consisting of a truck, a car, a motorcycle, a bicycle, a boat, a ship, a personal watercraft, a fixed-wing airplane, a rotary wing vehicle, a powered paraglider, an ultralight aircraft, a powered glider, a glider, a balloon, a blimp, a remotely controlled vehicle, an unmanned aerial vehicle, and combinations thereof.

6. The method of claim 5, wherein the vehicle is a helicopter and the component is a pipeline, wherein the pipeline is at least partially buried in the ground.

7. The method of claim 1, wherein the infrared camera system is portable, wherein the infrared camera system further comprises a frame, a shoulder-rest portion extending from the frame, and a handle extending from the frame, and wherein the aiming of the infrared camera system towards the component is performed by a person holding the infrared camera system.

8. The method of claim 1, wherein the aiming of the infrared camera system towards the component is performed from a satellite, and wherein the component is located on Earth.

9. The method of claim 1, wherein the aiming of the infrared camera system towards the component is performed from outside of a boundary defined by a fence, and wherein the component is located within the boundary.

10. The method of claim 1, wherein the component is located on a ship, wherein the aiming of the infrared camera system towards the component is performed from a location not on the ship.

11. The method of claim 1, wherein the component is selected from the group consisting of a component within a building, a component located at a processing plant, a component located on a ship, a component located on an offshore rig, a component located at least 10 feet from the infrared camera system, a component located above a majority of a structure, a component located on a vehicle, a pipe, a compressor, an engine, a valve, a container, a tank, a switch, a reservoir, a fitting, a connector, a hose, a flare, an exhaust outlet, a machine, a vent for a blow-off valve, and combinations thereof.

12. The method of claim 1, wherein the refrigeration system is adapted to cool the infrared sensor device and the optical bandpass filter to a temperature below about 100 K.

13. The method of claim 1, wherein the infrared camera system is non-radiometric.

14. The method of claim 1, wherein the infrared sensor device comprises an Indium Antimonide focal plane array of at least 81,920 sensor elements.

15. The method of claim 1, wherein the aggregate pass band for the single filter configuration has a center wavelength located within the absorbance band for the chemical emanating from the component.

16. The method of claim 1, wherein the any one or more chemicals comprises any one or more substance selected from the group consisting of refrigerant, fuel, water vapor, methane, ethane, propane, butane, hexane, ethylene, propylene, acetylene, alcohol, ethanol, methanol, xylene, benzene, butadiene, acetone, gasoline, diesel fuel, petroleum, petroleum by-product, volatile organic compound, volatile inorganic compound, a hydrocarbon, and combinations thereof.

17. The method of claim 1, wherein the infrared sensor device includes an Indium Antimonide focal plane array, wherein the aggregate pass band for the single filter configuration is between 3250 nm and 3510 nm, and further including cooling the infrared sensor device and the optical bandpass filter to a temperature below about 100°

K with the refrigeration system.

18. A method of visually detecting a gas leak of any one or more chemicals of a group of predetermined chemicals, the gas leak emanating from a component of a group of components in different locations, the method comprising:

aiming a passive infrared camera system towards the component, wherein the passive infrared camera system comprises;

a lens,

a refrigerated portion defined by the interior of a Dewar flask, the refrigerated portion comprising therein;

an infrared sensor device; and

a single filter configuration comprising at least one fixed optical bandpass filter, each filter fixed along an optical path between the lens and the infrared sensor device, the single filter configuration comprising an aggregate pass band with a full width at half maximum transmittance being less than about 600 mn, wherein at least part of the aggregate pass band for the single filter configuration is within an absorption band for each of the predetermined chemicals and wherein the aggregate pass band for the at least one optical bandpass filter is at least about 200 mn; and

a refrigeration system adapted to cool the refrigerated portion, the refrigeration system comprising a closed-cycle Stirling cryocooler;

receiving an infrared image with the infrared sensor device of the gas leak under normal operating and ambient conditions for the component, after the infrared image passes through the lens and the at least one optical bandpass filter, and after the infrared image is filtered by the at least one optical bandpass filter;

electronically processing the filtered infrared image received by the infrared sensor device to provide a visible image of the gas leak under variable ambient conditions of the area around the leak; and

visually detecting the leak based on the visible image under the variable ambient conditions.

19. A method of visually detecting a gas leak of any one or more chemicals of a group of predetermined chemicals, the gas leak emanating from a component of a group of components in different locations, the method comprising:

aiming a passive infrared camera system towards the component, wherein the passive infrared camera system comprises;

a lens,

a refrigerated portion defined by the interior of a Dewar flask, the refrigerated portion comprising therein;

an infrared sensor device; and

a single filter configuration comprising at least one fixed optical bandpass filter, each filter fixed along an optical path between the lens and the infrared sensor device, wherein the aggregate pass band for the single filter configuration is at least from about 3100 nm to about 3600 nm and at least about 200 nn and wherein at least part of the aggregate pass band for single filter configuration is within the absorption band for each of the predetermined chemicals; and

a refrigeration system adapted to cool the refrigerated portion, the refrigeration system comprising a closed-cycle Stirling ciyocooler;

receiving an infrared image with the infrared sensor device of the gas leak under normal operating and ambient conditions for the component, after the infrared image passes through the lens and the at least one optical bandpass filter, and after the infrared image is filtered by the at least one optical bandpass filter;

electronically processing the filtered infrared image received by the infrared sensor device to provide a visible image of the gas leak under variable ambient conditions of the area around the leak; and

visually detecting the leak based on the visible image under the variable ambient conditions.

20. A method of visually detecting a gas leak of any one or more chemicals of a group of predetermined chemicals, the gas leak emanating from a component of a group of components in different locations, the method comprising:

aiming a passive infrared camera system towards the component, wherein the passive infrared camera system comprises;

a lens,

a refrigerated portion defined by the interior of a Dewar flask, the refrigerated portion comprising therein;

an infrared sensor device; and

a single filter configuration comprising at least one fixed optical bandpass filter, each filter fixed along an optical path between the lens and the infrared sensor device, wherein the aggregate pass band for the single filter configuration is at least from about 3200 nm to about 3500 nm, is at least 200 nm, and has a center wavelength located between about 3320 nm and about 3440 nm, and wherein at least part of the aggregate pass band for the single filter configuration is within the absorption band for each of the predetermined chemicals; and

a refrigeration system adapted to cool the refrigerated portion, the refrigeration system comprising a closed-cycle Stirling cryocooler;

receiving an infrared image with the infrared sensor device of the gas leak under normal operating and ambient conditions for the component, after the infrared image passes through the lens and is filtered by the single filter configuration;

electronically processing the filtered infrared image received by the infrared sensor device to provide a visible image of the gas leak under variable ambient conditions of the area around the leak; and

visually detecting the leak based on the visible image under the variable ambient conditions.