Classifications

• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
  • G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
  • G01J5/48—Thermography; Techniques using wholly visual means
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
  • G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
  • G01J5/02—Constructional details
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
  • G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
  • G01J5/0044—Furnaces, ovens, kilns
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
  • G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
  • G01J5/02—Constructional details
  • G01J5/0265—Handheld, portable
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
  • G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
  • G01J5/02—Constructional details
  • G01J5/04—Casings
  • G01J5/041—Mountings in enclosures or in a particular environment
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
  • G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
  • G01J5/60—Radiation pyrometry, e.g. infrared or optical thermometry using determination of colour temperature
  • G01J5/602—Radiation pyrometry, e.g. infrared or optical thermometry using determination of colour temperature using selective, monochromatic or bandpass filtering
• • H—ELECTRICITY
  • H04—ELECTRIC COMMUNICATION TECHNIQUE
  • H04N—PICTORIAL COMMUNICATION, e.g. TELEVISION
  • H04N23/00—Cameras or camera modules comprising electronic image sensors; Control thereof
  • H04N23/20—Cameras or camera modules comprising electronic image sensors; Control thereof for generating image signals from infrared radiation only
  • H04N23/23—Cameras or camera modules comprising electronic image sensors; Control thereof for generating image signals from infrared radiation only from thermal infrared radiation
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
  • G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
  • G01J2005/0077—Imaging

Definitions

• This invention relates to an apparatus for providing thermal images in unique situations, for example the thermal imaging of the wall surface of tubes used in direct-fired, process heaters, and to such an apparatus which further allows for temperature measurements associated with conventional, predictive preventive maintenance PPM applications involved with the industrial process, or otherwise at the facility, as the user identifies and selects.
• the first method utilizes a thermocouple with direct physical contact, such as welding to the tubes in select locations.
• thermocouple installations are unreliable for extended operation because of the rapid drift in their calibration; and, deterioration of the protective materials in the furnace atmosphere.
• the number of thermocouples installed is limited due to the complexity which results in the associated wiring and instrumentation. Normally distances of 100 meters and longer are necessary to reach the control room. It is nearly impossible to identify the exact location of tube coking by the thermocouple method.
• a second method, which is widely used in many plants employs portable, single point radiation thermometers with appropriate optics, spatial resolution and infrared filtering. These instruments have the ability to correct for the effects of in-furnace conditions such as emissivity, reflected irradiance and furnace gas emission/absorptions on the indicated radiation thermometer readings (see literature for Mikron model M90D and Mikron/Quantum Logic model I, both manufactured by Mikron Infrared, Inc. of Oakland, New Jersey, (hereinafter "Mikron", “Assignee” and/or “Applicant”) for more details).
• Mikron/Quantum Logic I a novel method of using a modulated laser permits measuring the emissivity of the tube, allowing more precise temperature measurement of the tube.
• thermometers have one serious shortcoming, i.e., it is nearly impossible to expect someone to measure all the tubes across the entire length or height of the furnace.
• the number of measurements can easily reach hundreds per furnace per day. Operator fatigue and boredom will eventually result in the deterioration of the quality of the reported data. Consequently the process engineers choose only select points for measurement and ignore the rest of them. Thus, the identification of locations where coke formation takes place, becomes more a matter of chance than a certainty.
• the third method presently employed uses a thermal imaging instrument with a sufficient field of view to observe a very large portion of the interior of furnace.
• Figure 1 shows a cross section of a typical coker furnace in a refinery. The fields of view 1, 3, 5 for different imager positions 7, 9, 11 are depicted. A sufficient number of viewports 13, 15 are available in order to image a substantial if not all of the interior of the furnace.
• MWIR mid- wavelength, infrared
• MWIR infrared
• a typical infrared filter is a narrow pass band filter centered at 3.90um.
• Flame combustion by-products include gases such as H 2 0, N 2 , C0 2 , and NO x , and a small residue of ashes and other particles. These hot combustion gases emit a substantial amount of radiation toward the wall tubes 19 resulting in heating the tubes. It is known that at 3.90um there is a void in the spectrum of hot gases radiation (see Figs. 2A and 2B) that makes the hot gases very transparent. An instrument operating at this particular wavelength where the target is absorptive and thus emissive, can provide a very high quality thermal image of the interior of the furnace even in the presence of hot combustion gases.
• Modem thermal imagers have the ability to store the images taken in the field for further off-line image processing.
• a number of useful parameters and in particular temperature profile/time trend analysis can be readily determined.
• the trend of wall tube temperature in most cases can effectively be used as an indication of the expected life of the tubes or formation of coke inside of the tubes, either one of which having a substantial effect on the productivity of the process and the over all cost of operation of the plant.
• the existing thermal imagers designed with an appropriate infrared band pass filter of 3.9um for penetration through hot combustion gases rely on photon detectors such as Indium Antimonite (InSb), Mercury Cadmium Telluride (MCT), Platinum Suicide (PtS) or Quantum Well Infrared Photo- detector (QWIP).
• a typical detector has an array of 320H x 240V elements (pixels) to form a thermal image and are very sensitive in the spectral band of 3 to 5um.
• the main shortcoming of this class of detector is that they have to operate at very low cryogenic temperatures, such as 77K, which is equivalent to the temperature of liquid nitrogen.
• a cryocooler which operates on the same principles as a house refrigerator, except that helium gas or other very low temperature liquid gas is used as the medium of compression.
• a cryocooler compressor In addition to the initial manufacturing costs, incorporating a cryocooler compressor into a portable instrument has other shortcomings. Firstly, in order for a cryocooler to reach sufficiently low cryogenic temperatures it takes several minutes. Second of all, a cryocooler has many moving and sealing parts such as piston, cylinder, gaskets, o-rings and motor. The piston, cylinder, gaskets and o-rings seals must operate under very high pressure, in order to convert gas to liquid. The typical life of a cryocooler is about 2000 hours.
• a normal failure mode is the leaking of helium gas through the seals.
• the replacement or repair of a cryocooler can exceed 25% of the initial cost of buying the instrument.
• repairs normally are associated with long delays due either to spare parts' shortages or the limited number of repair people with the necessary level of expertise.
• the battery life is mostly consumed in keeping the detector cooled. Normally operators must carry an external high capacity battery, either strapped over the shoulder, or belted around the waist. This adds to the inconvenience and poses a threat to the safety of the operators, since operators must image the interior of these furnaces from narrow catwalks through hot view ports several stories high. Of course, the avoidance of injuries during this operation is of paramount importance to plant management.
• these photon detectors are effectively limited, again, to the spectral band of 3 to 5 urn. As such, they are not useful in detecting "lower" temperatures, for example, in the range of -40 to 200°C, and particularly outdoors, during the day, in sunlight, which, due to the influence of the sun, a powerful source of radiation energy at 3 to 5um, precludes their use. These lower temperatures can occur at other points in petrochemical-related processes and can also be very critical. Monitoring of these conditions is usually accomplished using a long wave infrared (LWIR) imaging radiometer operating in the 8-14um spectral bands. Also, ancillary furnace and other facility functions can be the subject of a comprehensive predictive and preventive maintenance (PPM) program requiring a similar low temperature, detection capability.
• LWIR long wave infrared
• PPM predictive and preventive maintenance
• UFPA focal plane array
• the infrared transmission characteristic of this window is from 6 to 14um or 8 to
• a still further object is to adapt existing UFPA thermal imaging devices so as to accomplish the purposes of the present invention, the device including built-in firmware and associated off-line software, for example, MikroSpecTM off-line software, to further enhance the degree of accuracy of the measurement, allowing for further temperature/time trend analysis which can for example prolong the life of the tubes and thus the productivity of plant operation, or provide other benefits when used with different processes.
• built-in firmware and associated off-line software for example, MikroSpecTM off-line software
• a device for thermal imaging of target surface(s) having different temperatures within a range of temperatures of interest between a high and low temperature of -40°C to 2000°C The thermal imaging takes place through intervening media having a known transmission wavelength.
• the target surface(s) have a known abso ⁇ tive wavelength.
• the device comprises a housing including an opening for admitting infrared rays including those emanating from the target surface(s).
• the rays are directed along an optical path within the housing.
• the optical path has an optical axis.
• An optical assembly is positioned within the housing and in the optical path.
• the optical assembly has an input and an output. The infrared rays are directed towards and into the input, through and out of the output of the optical assembly.
• the optical assembly includes an objective lens, a negative lens, and focusing lens means.
• each of the lenses is made of germanium.
• each lens has an anti-reflection coating with a spectral band width of 3um to 14um.
• UFPA detector un-cooled focal plane array, infrared ray detector
• the UFPA detector is positioned in the housing and in the optical path so as to allow the impingement of the infrared rays passing out of the optical assembly onto the detecting surface.
• Means for optimizing the spectral band width of the UFPA detector to 3um to 14 um are employed.
• this includes a spectral transmission window positioned in the optical path between the output of the optical assembly and the UFPA detecting surface, with the spectral transmission window having a spectral band width of 3um to 14um.
• the transmission window is made part of the UFPA detector.
• the UFPA detector provides an electrical output proportional to the energy of the infrared rays impinging onto the detecting surface;
• Filter means including a first and second infrared band pass filter are provided.
• the first infrared band pass filter has a spectral band width of 8 to 14um.
• the second infrared band pass filter has a respective spectral band width falling within the band of 3 to 8um.
• Each of the band pass filters is removably inte ⁇ osed in the optical path upon direction of an operator for filtering the infrared rays entering the housing so as to attenuate certain infrared rays and to pass other infrared rays of particular, respective predetermined wavelengths associated with the range of temperatures of interest, the transmission wavelength of the intervening media and the abso ⁇ tive wavelength of the target surface(s).
• Electronic means are provided which are adapted to convert the electrical output of the UFPA detector into at least one inte ⁇ retable output whereby an operator is presented with information sufficient to determine the temperature(s) of the target surface(s) within an acceptable degree of accuracy.
• the device allows for the thermal imaging of PPM type applications to occur in sunlight when said first infrared band pass filter is inte ⁇ osed in the optical path.
• the spectral band width of the second band pass filter is 3.8 to 4.0um.
• the spectral band width of the second band pass filter is 4.8 to 5.2um.
• the spectral band width of the second band pass filter is 6.7 to 6.9um.
• Figure 2A depicting in graph form, the spectral emissivity of combustion gases versus wavelength in um and wave number in cm "1 ;
• Figure 2 B depicting in graph form, the typical transmission spectra of combustion flame in percentage versus wavelength in ⁇ Figures 3, 3A and 3B showing different perspective views of a modified model 7200V thermal imager of the assignee and applicant with all necessary design changes to implement the present invention
• Figure 4 depicts in functional schematic form various elements of the thermal imager of the present invention
• Figure 5 depicting in a side elevational, partially sectional, functional view of various elements which comprise the present invention
• Figure 6 depicting a two position, IR filter assembly of the present invention
• Figure 7A depicting in front elevational view the UFPA detector used in the present invention
• Figure 7B depicting in side elevational view the UFPA detector used in the present invention
• Figure 8 depicting in a partial, plan functional view, the various components comprising the total incoming radiation to a thermal imager positioned at a viewport;
• Figure 9A showing the thermal image of the interior of a coker furnace in a refinery, as viewed through the viewfinder of the instrument of the present invention;
• Figure 9B showing the thermal image of the burner bank on the floor of a coker furnace as viewed through the viewfinder of the instrument of the present invention
• Figure 9C showing a visual image of the same burner bank shown in Figure 9B, which depicts the hot combustion gases (flame) highlighting the effectiveness of the apparatus of the present invention
• Figure 10 showing an image of a typical house hot water heater illustrating the low temperature applications of the present invention, again with the clarity of the thermal image attesting to the superior design of the present invention and its adaptability for dual pu ⁇ oses;
• Figures 11 A and 1 IB depicting in Table form the determination of the temperature, in 10°C increments, of a blackbody using Planck's law for different incident radiant energy at wavelengths of 3.8um to 4.0um;
• Figure 12 depicting in Table form the determination of the temperature, in 1°C increments between 900 and 1000°C, of a blackbody using Planck's law for different incident radiant energy at wavelengths of 3.8um to 4.0um.
• the improved device for thermal imaging of target surfaces includes a housing 12 having an opening 14 through which the infrared rays emanating from the target surface(s) are received.
• the improved device is an extremely light weight high-performance, IR camera which is designed for comfortable, one-handed point-and-shot operation. It uses an intuitive key pad located on the top of the imager which includes cursor controls 16, focus controls 18, menu selection key 20 and mode selection key 22.
• the menu selection key 20 allows the operator to identify the temperature range to be viewed.
• Memory card slot means 26 is provided to enable the storage of images and data to PCMCIA cards for subsequent review. Images can also be viewed in real time via the video outputs 28 and/or 30 (which is a RS-232C S-video output) and/or through an optional built-in IEEE 1394 Fire Wire® interface, 32. Since the camera is battery operated provision of course is made for use of an adapter at plug 34 for continuous AC operation.
• the MicroScan 7200V comes standard with extensive on board image processing software. It also can be remotely controlled from a PC using optional software also available through the Assignee, which provides additional analysis and reporting capabilities. Such software is marketed by the present Assignee under its trademark MikroSpec. The
• MikroSpecTM real-time the ⁇ nal data acquisition and analysis software is a windows-based software program that offers high-speed, real-time data acquisition and image analysis capabilities. By using one or more infrared cameras connected to the software, processes can be measured accurately to insure production quality.
• the software allows the user to view thermal images in real-time as well as those that have been captured and stored to the computer's hard-disc drive.
• the software allows the creation of numerous regions of interests in various shapes so that details can be retrieved as to the temperature range within the regions of interest. Referring now to Figure 4, the thermal imaging device of the present invention is depicted functionally. Infrared radiation received at opening 14 comprises radiation emanating from target 36, radiation from other sources in the vicinity of the target and radiation reflected from the target due to other sources in its vicinity.
• the infrared radiation arrives at the opening 14 of the imaging device where it is directed along an optical path within the imaging device having an optical access 38. Positioned in the optical path and centered about the optical access is an infrared, optical assembly 40.
• the received IR radiation is directed into, through and out of the optical assembly which includes a focus control means 42 which, as noted hereafter, can be either manually or motor driven.
• the rays emanating from the optical assembly 40 are directed through a filter arrangement having at least two positions so as to inte ⁇ ose filters of different band widths consistent with the pu ⁇ oses of the invention and a respective application.
• the stepper motor 46 enables the operator to position the filter 44 at the different positions as he needs to, in response to the temperature range choice effected by key 20 and corresponding selection.
• the infrared optics assembly 40 collects the infrared energy from the target, that is the energy within the field of view of the instrument and focuses that energy onto an un-cooled focal plane array, infrared ray detector (UFPA detector) 48.
• the UFPA detector is a typical application consists of 320Hx240V elements which are sensitive to infrared energy.
• the UFPA detector 48 provides an electrical output which is proportional to the energy of the infrared rays impinging on its detecting surface. This output is supplied to a pre-amp 50 for amplification of the minute changes sensed by the UFPA detector elements in response to the impinging rays.
• a visible optic assembly 52 Parallel with the infrared optics, is a visible optic assembly 52. This collects the visible portion of the electro-magnetic spectrum originating from the target so as to create a visible image of the target which is recognizable by the user.
• the output of the visible optic assembly 52 is fed through a digital converting module 54 which in turn is fed to the CPU module 56.
• the CPU unit arranges, manages, receives or sends all necessary instruction to perform the various tasks required, for example, the change for different temperature ranges initiated by menu selection key 20.
• Some of the interactions with the CPU 56 include a microphone/speaker attachment 58 to record an operator's voice memo for playback at a latter time; the interface with the key pad keys, for example the menu select key 20; and a battery check feature 62 for monitoring the remaining capacity of the battery source to provide an early warning to the operator.
• the CPU module 56 interacts with a signal processing component 64 which receives the signal from the pre-amp 50.
• the signal processing unit 64 contains a necessary algorithm(s) and/or look up tables (see hereinafter with respect to Equations 1, 2, 3 and 4 and Figs. 11 A, HB and 12) for conversion of the incoming energy determinations to actual temperature equivalents.
• the output 66 of the signal processing unit is supplied to the IF module which converts the output of the signal processor to different types of recognizable outputs including, for example, a thermal image through the viewfinder 70 (see Figs.
• IF module can provide an output 72 for an optional color video display (not shown) attached to the imager.
• IF module 6 ⁇ can provide, through the memory card slot 26, a capability of inserting a PCMCIA which allows the detected images to be recorded for later viewing and analysis.
• the optical design plays an important role.
• the quality of the image has to be maintained over the very wide spectral band of 3 to 14 um, instead of a conventional optical assembly design used in present thermal imagers that optimizes either over the spectral band of 8 to 14um or 3 to 5um.
• the broader band width includes optics for the desirable spectral band centered at 3.9um for high temperature measurement that can see through a substantial depth of hot combustion gases encountered in furnaces, and the 8 to 14um range that allows the thermal imaging of low temperature objects in associated processes and predictive and preventive maintenance applications, even, most significantly, during daytime and outdoors when sun is present.
• the preferred embodiment of the present invention includes the optical assembly 40 that has a very wide-band, spectrally flat, anti-reflection coating between
• the optical assembly comprises 4 lenses.
• Lens 74 is an objective lens made from germanium material and optically coated for high transmission in the spectrum band range of 3 to 14um.
• Lens 76 is a negative lens made from germanium and optically coated for a spectral band of 3 to 14um. The bundle of rays striking the lens 76 will emerge from lens 76 more parallel to the optical axis 38. This feature allows the placement of the infrared filter assembly 44 behind the lens 76 with a minimum of shift of the critical narrow band associated with the center wavelength of the infrared filter to be inte ⁇ osed in the optical path as discussed hereinafter.
• the IR filter assembly mount 44 has in this embodiment two positions, either of which is automatically selected by the associated microprocessor CPU 56 inside the thermal imager in response to menu key 20 and the temperature range selected.
• an IR filter with a spectral band width of 8 to 14um, for low temperature thermal imaging is inserted in the optical path.
• a second infrared filter having a narrow pass band centered, in the preferred embodiment, at approximately 3.9um and having a band width of 0.2um, for high temperature thermal imaging is inserted in the optical path.
• Focusing lenses 82 and 84 combine to allow the bundle of rays emerging from the selected IR filter to be focused onto sensitive elements of the un-cooled focal plane array (UFPA) detector 48.
• the precise focusing is achieved by moving the combination of lenses 82 and 84 toward or away from lens 76.
• the focusing for example, can be achieved in the Mikron thermal imager of 7200V or 7515 manually or automatically through activation of focus keys 18.
• a protective ring 86 houses a window to protect the objective lens 74. This serves to protect the thermal imager in very harsh environments, as for example, the blowing heat and particles which may be experienced at the view port of large utility furnaces.
• the ring can be unscrewed to allow other accessories such as a telephoto or wide angle lens assembly to be attached to the front of the imager.
• an infrared filter with a spectral band width of 8 to 14um allows for low temperature thermal imaging in the range typically between -40 to 500°C. This measurement is minimally affected due to absorption by the atmosphere, and allows for long distance thermal imaging and is unaffected by the presence of sun in outdoor applications.
• the present invention introduces a very narrow band infrared filter centered at a wavelength which depends on the presence of any intervening media and/or the abso ⁇ tive wavelength range of the targeted surface.
• an infrared filter centered about the 3.9 um wavelength superimposed on spectral emissivity of hot combustion (flue) gases, avoids the abso ⁇ tion band of hot combustion gases, a by-product of fossil fuel burning. That is, the combustion gases are transparent at this wavelength.
• the band width centered at the 3.9um wavelength is 0.2um. Consequently, thermal images of wall tubes inside of petrochemical and utility furnaces can be provided. An accurate temperature profile of these wall tubes can be obtained with the application of a proper algorithm (Equations 1 and 2, see hereinafter).
• a typical temperature range for the thermal imager with this filter in place, is 400 to 2000°C.
• a stepper motor 46 under control of the microprocessor (CPU) 56 in electronics 92, will position the infrared filters 78 or 80 in front of the detector 48 as dictated by the operator via the select (menu) 20 as shown in Figure 3.
• the detector 48 is an un-cooled focal plane array (UFPA) having an active pixel array of 320 x 240. It can be purchased from DRS, Inc. of Morristown, NJ - their model number U3000AR. It is based on Vox (Vanadium oxide) microbolometer technology or amo ⁇ hous silicon (a-Si) technology. These detectors are packaged in a rugged, miniaturized assembly that inco ⁇ orates a spectral transmission infrared window 84 as shown in Figure 7B.
• UFPA un-cooled focal plane array
• the detector was optimized to work in the spectral band of 8 to 14um. In such applications, the peak infrared radiation takes place at about lOum. This is exactly in the middle of detector sensitivity and detector window spectral transmission. Since the spectral transmission band of 8 to 14 has an extra benefit of being substantially transparent to atmospheric abso ⁇ tions, this makes this spectral band one of the most used in infrared thermometry and thermal imaging.
• the present invention uses a window 84 that is spectrally coated for the very broad band of 3 to 14um instead of the conventional window in these detectors with a spectral band of 8 to 14um.
• the detector can be used for the dual purposes envisioned by the invention: 8 to 14um for low temperature thermal imaging; and 3 to Sum for specialized high temperature thermal imaging, all within the same unit.
• the interior of the detector is vacuum-sealed for maximum sensitivity of sensing elements in the detector sensitive area 86 (Fig. 7A).
• the shutter 88 is a mechanical flag that operates either by a command from the operator, or automatically, to periodically shield the incoming infrared radiation from the target. This time period may last from a fraction of a second to a few seconds. Since the temperature of the shutter is uniform by the virtue of the design, and also is known due to the placement of a suitable temperature sensor, not shown, this becomes a way to do a quick test of the integrity of the detector. Also, the non-uniformity of each individual pixel of the detector is tested and all off-sets associated with drifts can be eliminated. During the time the shutter is closed, the instrument, of course, is "blind" and not taking any images.
• the motor 90 actuates the shutter 88 to block momentarily incoming radiation from the target.
• the housing 12 is the same as used with Mikron's standard the ⁇ nal imager models, # 7102, 7200V and 7515. It is a precision die cast, made from aluminum by an injected molding process.
• the viewfinder 70 is the same as used on Mikron's models, # 7102, 7200V and 7515 and is used for seeing thermal images in indoor or outdoor environments, such as Figures 9A and 9B (both with filter 80 in place) and 10 (with filter 78 placed in the optical path).
• Figure 9C is an image taken with visible spectrum of a built-in CCD camera inside the thermal imager.
• the electronics 92 is substantially the same as that used in Mikron's thermal imager models, # 7102, 7200V and 7515. However, some changes in the firmware allows for the selection of the different temperature ranges required by the invention, positioning of infrared filters, and includes different menu selections.
• the electronics includes a new algorithm for high temperature range with the ability to cancel the influence of background radiation, as discussed hereinafter.
• the battery 94 is a high capacity lithium ion rechargeable battery, and is also the same type as used in thermal imager models # 7102, 7200V, and 7515.
• a thermal imager for the purposes of this embodiment is a modified version of Mikron's model # 7200V. It is a radiometer calibrated to indicate correctly the temperature of a blackbody source. The procedure to obtain the temperature of the blackbody, from the spectral radiance W ⁇ T (watts per um 2 ) reaching one pixel of the thermal imager, involves only the use of Planck's law. It is stated as follows:
• ⁇ eff is the effective wavelength of the thermal imager, i.e., 3.90um
• C and C 2 are constants with values of 3.741 x 10 "4 watts um 2 and 14388 um degree respectively
• T is the temperature of the blackbody expressed in K.
• UFPA detector 48 which is comprised of several radiation components. Determining the actual tube wall temperature from an indicated apparent temperature is difficult.
• Figure 8 shows schematically, incoming radiation to the thermal imager from different sources including the unwanted radiation from the surrounding background including radiation from hot combustion gases.
• the tube surroundings are comprised of a refractory wall 96, with a temperature of
• T w opposite side tube banks 98 with a temperature of T hl ; and hot combustion gases 100
• IF filter 80 With IF filter 80 in place in the imager' s optical path, irradiance originating from the surroundings incident on a furnace tube is reflected into the instantaneous field of view (IFOV) of the imager or a single element
• W a ( ⁇ ,T a ) 101 is the sum of the radiance due to emission from the various sources and the reflection from the tube (see equation 2) and is expressed by the following equation
• W a (T a ) t g [e t W, ⁇ T, )+ W r ( ⁇ bg ) ⁇ + e g W g (T g ) , where: W a (T a ) is the total energy received within the IFOV of a single pixel of the imager detector 48 producing an apparent temperature of T a for tube 102; W t (T t ) is the equivalent radiated energy from a tube at a tube temperature of T t , and having an emissivity of 1.0; W,.(T hg ) is the total reflected energy received due to the background influence of the surrounding tube bank, 98, refractory walls 96 and hot combustion gases 100; W (T ) is the total radiance energy from the hot combustion gases at gas temperature of T g ; t g is the transmission coefficient of the hot combustion gases; e, is the emissivity of the wall tubes; e g is the emissivity of the hot combustion
• T hg (1 - e t )[F l e,W bl (T bl ) + G w v W w (T w ) + K g e g W g (T g )J, where W bl (T ht ) and W W (T W ) are energy levels emitted by the background tube banks
• 98 and refractory walls 96 and W g (T ) is an energy level, at an effective length, of the hot combustion gases, all at their respective temperatures; and e w is the emissivity of the refractory wall.
• F lM , G w t and K are what could be called view factor coefficients. These attempt to provide a weighing of each contributing element of the surrounding background. They vary between 0.0 to 1.0 depending principally on the geometry of the furnace and view port location with respect to the exact location of the measurement area of IFOV of the detector.
• Equations 1 and 2 are considered generalized measurement equations, since the parameters of the equations are different from pixel to pixel.
• An intimate knowledge of geometry of the furnace, background temperatures and view factors, from spot to spot, fuel transmission and emissivity for different fuel types, and dependency of the tube emissivity with angle should be available, in order to obtain the final tube, true temperature.
• true temperature of tube T, ,is 1173K or 900 °C (104 in fig. 1 IB)
• background refractory wall temperature, T w is 1373K or 1100° C (106 in Fig. 11B)
• combustion gases temperature T g ,is 1973K or 1700°C (108 in Fig.
• emissivity of tube e, is 0.88; emissivity of refractory wall, e w is 0.90; emissivity coefficient of combustion gases, e g , is 0.004/(meter of gas depth) at 3.90um (see
• Table 1 is a conversion table reflecting the relationship between radiance energy and temperature. It is generated by integrating Planck's Law over the interval of 3.8um to 4.0um, which corresponds to the spectral bandwidth of the infrared filter 80. It is further assumed that the central pixel of the thermal imager has a distance, or gas depth, of 5.0 meters from the tube. Inserting these assumed numbers in equation 2 and solving for W r (T b g),Xh& total spectral reflected energy from tube 102 in Figure 8 is, or,
• the apparent temperature, T a , 110 would be approximately 923°C, or about 23° C above actual temperature with an instrument emissivity setting at 1.0; and the influence of the background is not cancelled.
• the temperature would appear to be 971 °C , about 71 °C above actual temperature.
• the total energy used for the calculation of the actual tube temperature is, W t (T t ) W a (T a ) ⁇ e t .
• each of the unwanted components of the incoming energy can be accounted for and subtracted by the use of a proper algorithm, in order to achieve absolute temperature readings.
• the user can ignore some of the less important components of unwanted incoming energy and still be able to get accurate readings.
• Implicit in this analysis is an assumption that the surrounding background can be approximated as two different blackbodies at two different temperatures, and that the surfaces are diffuse and follow Lambert's law.
• One blackbody represents wall tubes of the opposite side and the other blackbody represents the opposite refractory walls.
• the equations 3 and 4 can be considered as simplified measurement equations, which could be programmed into the instrument's firmware.
• the operator can easily input the parameters such as tube emissivity, view factors for the background tube bank and refractory wall, and hot combustion gases' emissivity depending on the fuel type, and average distance measurements.
• the present invention provides a new thermal imager design having a UFPA detector which includes a new, spectral transmission window which allows the incoming radiation from a given target reaching the sensitive elements (pixels) of the detector to include the radiation spectrum from 3 to 14um.
• the invention allows for the placement of a narrow pass band infrared filter centered at a particular wavelength in the range generally between 3 to 8um, in front of the detector window only when the requirement for the thermal imager is for high temperature thermal imaging and temperature profiling through an abso ⁇ tive media such as combustion gases. The transparency of this media will only take place at a narrow band wavelength centered at 3.9um.
• a specially designed mechanism adaptable for use in the Mikron thermal imager model 7200V allows for automatic placement of this infrared filter in or out of the optical path by the operator.
• the design of the optical lens assembly and its infrared coating is optimized, in a standard thermal imager, for example, the Mikron 7200V, a 4 element germanium lens assembly is optimized for acceptance of the much wider spectrum of radiation. Instead of the traditional 8 to 14um, it is optimized for the range from 3 to 14um.
• a standard thermal imager for example, Mikron's model 7200V series
• Mikron's model 7200V series is enhanced so as to produce a new class of infrared thermal imagers with the following features heretofore unavailable to industrial users in a single device.
• a thermal imager using an un-cooled focal plane array (UFPA) detector which is able to see through an abso ⁇ tive media such as hot combustion gases by using an appropriately centered, infrared narrow pass band filter.
• UFPA focal plane array
• Mikron for use with its thermal imagers may be used for a comprehensive image manipulation, trend analysis and maintenance scheduling and report generation, for management review, and simplifies this difficult measurement.
• This novel method provides higher absolute accuracy of tube temperature within the field of view of the instrument, pixel by pixel. The simplified fashion of assuming a hot uniform background temperature and cancelling its effect, as presently done, may not create the desired accuracy.
• the firmware inside the instrument combined with MikroSpec*" 1 , off-line software has the ability to predict and cancel the effects of unwanted incoming radiance toward the thermal imager, pixel by pixel, in order to infer the true temperature of tubes at every point based on apparent temperature measurements.
• the novel method of the present invention relies on a more comprehensive understanding of the background radiation influence and provides for its cancellation. Through innovative and novel design changes to a standard thermal imager such as
• Mikron's Model 7200V a new class of thermal imagers can be designed that has the ability to perform dual functions
• This new model has a temperature span of -40 to 2000 °C. It satisfies the existing dominant market requirements for PPM applications with a temperature span of -40 to 500 °C, including during the day with sunlight present.
• it allows industrial users with large furnaces such as petrochemical companies and utility power plants, to thermally profile their furnaces conveniently and safely at higher temperatures up to 2,000 °C.
• a second filter having a band width of 6.7um to 6.9um will allow the thermal imager to accurately read the surface temperature of the targeted plastic since certain plastics are only abso ⁇ tive in this range, once again assuring the consistency in temperature necessary to produce a quality product.
• a still further application calls for the use of a second filter having a band width of 4.8 to 5.2um.
• the utility of the modified imager is directed to the fabrication of tempered glass, such as used in car windshields. This filter allows for the monitoring of the temperature across the glass product at its abso ⁇ tive wavelength assuring the necessary uniformity required to achieve a satisfactory product.

Landscapes

• Physics & Mathematics (AREA)
• General Physics & Mathematics (AREA)
• Spectroscopy & Molecular Physics (AREA)
• Health & Medical Sciences (AREA)
• Toxicology (AREA)
• Engineering & Computer Science (AREA)
• Multimedia (AREA)
• Signal Processing (AREA)
• Radiation Pyrometers (AREA)
• Photometry And Measurement Of Optical Pulse Characteristics (AREA)

Applications Claiming Priority (3)

Publications (2)

Family

ID=32850842

Family Applications (1)

Country Status (3)

Families Citing this family (7)

Citations (1)

Family Cites Families (13)

• 2004
  • 2004-02-02 EP EP04707355A patent/EP1588136A4/de not_active Withdrawn
  • 2004-02-02 WO PCT/US2004/002762 patent/WO2004069547A2/en active Application Filing
  • 2004-02-02 JP JP2006503212A patent/JP2006518464A/ja active Pending

Patent Citations (1)

Also Published As

Similar Documents

Legal Events