USOO8426813B2
`
`(12) United States Patent
`US 8,426,813 B2
`(10) Patent N0.:
`
`(45) Date of Patent: *Apr. 23, 2013
`Furry
`
`CHEMICAL LEAK INSPECTION SYSTEM
`
`(54)
`
`(56)
`
`References Cited
`
`(75)
`
`Inventor: David W Furry, Blanket, TX (US)
`
`(73)
`
`Assignee: Leak Surveys, Inc., Early, TX (US)
`
`(*)
`
`Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`This patent is subject to a terminal dis-
`claimer.
`
`(21)
`
`Appl. N0.: 13/462,609
`
`(22)
`
`Filed:
`
`May 2, 2012
`
`U.S. PATENT DOCUMENTS
`
`3,032,655 A
`3,662,171 A
`4,158,133 A *
`
`5/1962 Romans et a1.
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`............. 250/214 R
`(Continued)
`
`EP
`EP
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`(Continued)
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`Hinnrichs, M., “Hand Held Imaging Spectrometer,” Proceedings of
`the 3lst Applied Imagery Pattern Recognition Workshop (Apr.
`2002), IEEE Computer Society, USA.
`
`(65)
`
`(63)
`
`(60)
`
`(51)
`
`(52)
`
`(58)
`
`Prior Publication Data
`
`US 2012/0273680 A1
`
`NOV. 1, 2012
`
`(Continued)
`
`Primary Examiner 7 David Porta
`Assistant Examiner 7 Shun Lee
`
`Related US. Application Data
`
`Continuation of application No. 11/298,862, filed on
`Dec. 10, 2005, now Pat. No. 8,193,496, which is a
`continuation of application No. PCT/US2004/012946,
`filed on Apr. 26, 2004.
`
`Provisional application No. 60/477,994, filed on Jun.
`11, 2003, provisional application No. 60/482,070,
`filed on Jun. 23, 2003, provisional application No.
`60/540,679, filed on Jan. 30, 2004.
`
`Int. Cl.
`
`(2006.01)
`
`G0115/02
`US. Cl.
`USPC ...................................... 250/330; 250/339.03
`Field of Classification Search .................. 250/330,
`250/339.03
`See application file for complete search history.
`
`(74) Attorney, Agent, or Firm 7 Chamberlain Hrdlicka
`
`ABSTRACT
`(57)
`A method of visually detecting a leak of a chemical emanat-
`ing from a component includes aiming a passive infrared
`camera system towards the component; filtering an infrared
`image with an optical bandpass filter, the infrared image
`being that ofthe 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 sys—
`tem includes: a lens; a refrigerated portion including 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.
`
`58 Claims, 31 Drawing Sheets
`
`
`
`FLIR Systems, Inc.
`1001-00001
`
`

`

`US 8,426,813 B2
`
`Page 2
`
`U.S. PATENT DOCUMENTS
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`
`FLIR Systems, Inc.
`1001-00002
`
`

`

`US 8,426,813 B2
`Page 3
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`
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`* cited by examiner
`
`FLIR Systems, Inc.
`1001-00003
`
`

`

`US. Patent
`
`Apr. 23, 2013
`
`Sheet 1 of 31
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`Us 8,426,813 B2
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`
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`FLIR Systems, Inc.
`1001-00004
`
`

`

`U.S. Patent
`
`Apr. 23, 2013
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`Sheet 2 of 31
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`US 8,426,813 B2
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`
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`FLIR Systems, Inc.
`1001-00005
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`

`

`US. Patent
`
`Apr. 23, 2013
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`Sheet 3 of 31
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`US 8,426,813 B2
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`
`FLIR Systems, Inc.
`1001-00006
`
`

`

`US. Patent
`
`Apr. 23, 2013
`
`Sheet 4 of 31
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`Us 8,426,813 B2
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`US. Patent
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`Apr. 23, 2013
`
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`US 8,426,813 B2
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`FLIR Systems, Inc.
`1001-00008
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`

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`Apr. 23, 2013
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`U.S. Patent
`
`Apr. 23, 2013
`
`Sheet 12 0f 31
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`US 8,426,813 B2
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`U.S. Patent
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`Apr. 23, 2013
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`US 8,426,813 B2
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`US. Patent
`
`Apr. 23, 2013
`
`Sheet 15 of 31
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`US 8,426,813 B2
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`ARBITRARY
`ABSORPTION UNITS
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`1001-00018
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`U.S. Patent
`
`Apr. 23, 2013
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`Sheet 16 of 31
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`US 8,426,813 B2
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`U.S. Patent
`
`Apr. 23, 2013
`
`Sheet 18 of 31
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`US 8,426,813 B2
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`1001-00021
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`

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`U.S. Patent
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`Apr. 23, 2013
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`Sheet 19 of 31
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`US 8,426,813 B2
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`1001-00022
`
`

`

`US. Patent
`
`Apr. 23, 2013
`
`Sheet 20 of 31
`
`US 8,426,813 B2
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`FIG.20
`
`FLIR Systems, Inc.
`1001-00023
`
`

`

`US. Patent
`
`Apr. 23, 2013
`
`Sheet 21 of 31
`
`Us 8,426,813 B2
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`
`
`FLIR Systems, Inc.
`1001-00024
`
`

`

`U.S. Patent
`
`Apr. 23, 2013
`
`Sheet 22 0f 31
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`US 8,426,813 B2
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`FLIR Systems, Inc.
`1001-00026
`
`
`

`

`U.S. Patent
`
`Apr. 23, 2013
`
`Sheet 24 0f 31
`
`US 8,426,813 B2
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`1001-00027
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`

`U.S. Patent
`
`Apr. 23, 2013
`
`Sheet 25 of 31
`
`US 8,426,813 B2
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`883m
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`1001-00028
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`

`

`U.S. Patent
`
`Apr. 23, 2013
`
`Sheet 26 of 31
`
`US 8,426,813 B2
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`1001-00029
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`

`

`US. Patent
`
`Apr. 23, 2013
`
`Sheet 27 of 31
`
`US 8,426,813 B2
`
` 154
`
`SECOND
`CAMERA SYSTEM
`
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`FIRST CAMERA
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`OBTAIN IMAGE WITH
`FIRST CAMERA SYSTEM
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`COMPARE IMAGES FROM THE
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`IDENTIFY AND MAP IMAGE DIFFERENCES FOUND IN THE
`IMAGES FROM THE FIRST CAMERA SYSTEM AS COMPARED
`TO THE IMAGES FROM THE SECOND VIDEO CAMERA
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`
`
`CREATE COMPOSITE IMAGE BY ADDING MAPPED
`DIFFERENCES FROM INFRARED IMAGE TO THE SECOND IMAGE
`
`RECORD
`
` FIG. 37
`
`COMPOSITE
`IMAGE
`
`FLIR Systems, Inc.
`1001-00030
`
`

`

`U.S. Patent
`
`Apr. 23, 2013
`
`Sheet 28 of 31
`
`US 8,426,813 B2
`
`168
`
`OBTAIN IMAGE OF OBJECT IN LENS
`
`SPLIT IMAGE
`
`OBTAIN IMAGE
`WITH FIRST
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`UNFRARED)
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`(INFRARED) CAMERA SYSTEM AS
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`CREATE COMPOSITE IMAGE BY ADDING
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`IMAGE
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`COMPARE IMAGES FROM THE
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`
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`FOUND IN THE IMAGES FROM THE FIRST
`
`FIG. 33
`
`FLIR Systems, Inc.
`1001-00031
`
`

`

`U.S. Patent
`
`Apr. 23, 2013
`
`Sheet 29 0f 31
`
`US 8,426,813 B2
`
`OBTAIN IMAGE OF OBJECT IN LENS
`
`'
`
`SPLIT IMAGE
`
`
`
`
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`BY FIRST CAMERA
`
`SYSTEM
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`
`COMPARE IMAGES FROM THE
`CAMERAS TO IDENTIFY DIFFERENCES
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`IDENTIFY AND MAP IMAGE DIFFERENCES
`FOUND IN THE IMAGES FROM THE FIRST
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`
`
`IMAGES FROM THE SECOND VIDEO CAMERA
`
`
`
`CREATE COMPOSITE IMAGE BY ADDING
`MAPPED DIFFERENCES FROM FIRST
`
`INFRARED IMAGE TO THE SECOND IMAGE
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` RECORD
`COMPOSITE
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`IMAGE
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`FIG. 34
`
`FLIR Systems, Inc.
`1001-00032
`
`

`

`US. Patent
`
`Apr. 23, 2013
`
`Sheet 30 of 31
`
`US 8,426,813 B2
`
`OBTAIN IMAGE OF OBJECT IN LENS
`
`SPLIT IMAGE
`
`
`
`
`
`
`
`
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`
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`OBTAIN IMAGE WITH
`
`OBTAIN IMAGE WITH
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`SECOND VIDEO CAMERA
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`COMPARE IMAGES FROM THE
`CAMERAS TO IDENTIFY DIFFERENCES
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`
`IDENTIFY AND MAP IMAGE DIFFERENCES FOUND IN THE
`IMAGES FROM THE FIRST CAMERA SYSTEM AS COMPARED
`
`
`TO THE IMAGES FROM THE SECOND VIDEO CAMERA
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`
`
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`
`
`FLIR Systems, Inc.
`1001-00033
`
`

`

`U.S. Patent
`
`Apr. 23, 2013
`
`Sheet 31 0f 31
`
`US 8,426,813 B2
`
`174
`
`OBTAIN IMAGE OF OBJECT IN LENS
`
`
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`
`SPLIT IMAGE
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`
`BY FIRST CAMERA
`
`SYSTEM
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`
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`
`COMPARE IMAGES FROM THE
`
`
`
`TRIGGER ALARM IF SUFFICIENT
`DIFFERENCES FOUND IN TWO IMAGES
`
`CAMERAS TO IDENTIFY DIFFERENCES
`
`
`
`
`
`RECORD POSITION
`COORDINATES
`
`AND/OR TIME WHEN
`ALARM TRIGGERED
`
`FIG. 38
`
`FLIR Systems, Inc.
`1001-00034
`
`

`

`US 8,426,813 B2
`
`1
`CHEMICAL LEAK INSPECTION SYSTEM
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`This application is a continuation of US. patent applica-
`tion Scr. No. 11/298,862, filed Dec. 10, 2005, entitled “Mcth-
`ods for Performing Inspections and Detecting Chemical
`Leaks Using an Infrared Camera System,” which is a continu-
`ation of PCT International Application No. PCT/2004/
`012946, filed Apr. 26, 2004, entitled “Systems and Methods
`for Performing Inspections and Detecting Chemical Leaks
`Using an Infrared Camera System,” which claims the benefit
`of US. Provisional Patent Application No. 60/477,994, filed
`Jun. 11, 2003, entitled “Method of Detecting Gas Leaks
`Using and Infrared Camera System,” US. Provisional Patent
`Application No. 60/482,070, filed Jun. 23, 2003, entitled
`“Method of Detecting Gas Leaks Using and Infrared Camera
`System,” and US. Provisional Patent Application No.
`60/540,679, filed Jan. 30, 2004, entitled “Method of Detect-
`ing Gas Leaks Using an Infrared Camera System,” all of
`which are incorporated herein by reference in their entirety
`for all purposes.
`
`
`
`TECHNICAL FIELD
`
`The present invention relates generally to visually detect-
`ing and identifying chemical, gas, and petroleum product
`leaks using an infrared (IR) camera system.
`
`BACKGROUND
`
`In the oil and gas business, in the petro-chemical industry,
`in processing plants, and for utility companies and utility
`providers, for example, often more time and money is spent
`trying to find leaks than fixing leaks. One of the biggest
`challenges is trying to find the leaks using conventional meth-
`ods. Many conventional methods can simply miss a leak and
`not detect it if the detector is not properly positioned over or
`downwind of the leak. Also, many conventional methods are
`very time consuming and labor intensive, which leads to more
`expense. Hence, there is a great need for a faster, more accu-
`rate, and less expensive method of detecting such leaks.
`Petroleum products, such as liquid, gas, and liquid/gas
`forms of hydrocarbon compounds (e. g., fossil fuels), are
`often transmitted or channeled in pipes. The conventional
`method of surveying lines for petroleum product leaks or for
`detecting petroleum product
`leaks in general
`is with a
`FLAME-PACK ionizer detector (also sometimes referred to
`as a “sniffer” device). Another recently developed system
`uses an active infrared system (having a transmitting infrared
`source and a receiving sensor) for detecting petroleum prod-
`uct fumes. However, such systems require that the detector be
`within the stream or plume of the petroleum product leak.
`These tests merely detect the presence of petroleum product
`fumes at or upwind of the detector. They do not provide a
`visual image of the leak. Also, these prior testing methods
`require the detector to be in the immediate proximity of the
`leak, which may be dangerous and/or difficult for the inspec-
`tor.
`
`Prior infrared systems designed for evaluating rocket
`fumes, for example, would provide an unfocused and fuzzy
`image, in which it was difficult to make out background
`objects. For example, using an infrared camera that images a
`broad range of infrared wavelengths (e. g., 3-5 microns) typi-
`cally will not be useful in detecting small leaks. One system
`uses a variable filter that scans through different bandwidths
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`2
`in an attempt to identify the bandwidth ofthe strongest inten—
`sity (as quantified by the system). The purpose of this system
`was an attempt to identify the chemical make-up of a rocket
`exhaust based on the wavelength at which the intensity was
`greatest for the rocket plume. However, this system is not
`designed to provide a focused visual image to view the rocket
`exhaust.
`
`Others have attempted to visualize petroleum product
`leaks using infrared cameras using a “warm” filter setup
`and/or an active infrared camera system. A warm filter setup
`is one in which a filter is used to limit the wavelengths of light
`that reach the infrared sensor, but the filter is not in a cooled
`or refrigerated portion ofthe camera, ifthe camera even has a
`refrigerated portion. Such systems have not been able to
`provide a focused image capable of quickly and easily detect-
`ing small leaks, nor being capable of detecting leaks from a
`distance (e.g., from a helicopter passing over a line). Other
`systems are active and require a laser beam to be projected
`through the area under inspection in order to detect the pres-
`ence of a chemical emanating from a component. However,
`with such systems, typically the narrow laser beam must cross
`the flow stream for the leak to be detected. Hence, a leak may
`be missed if the laser beam does not cross the path of the leak
`and such systems often are unable to reliably find small leaks.
`Hence, a need exists for a way to perform a visual inspection
`to find leaks with reliability and accuracy, while being faster
`and more cost effective than existing leak survey methods.
`The US. Environmental ProtectionAgency (EPA) has pro-
`posed rules to allow visual inspections using infrared cameras
`in performing leak inspection surveys. However, due to the
`lack of detection abilities and poor performance demon-
`strated by other prior and current systems, the EPA had not yet
`implemented such rules. Thus, even the EPA has been waiting
`for someone to provide a system or way of reliably and
`accurately detecting leaks of various sizes.
`
`SUMMARY OF THE INVENTION
`
`The problems and needs outlined above may be addressed
`by embodiments ofthe present invention. In accordance with
`one aspect ofthe present invention, a passive infrared camera
`system adapted to provide a visual image of a chemical ema-
`nating from a component having the chemical therein,
`is
`provided. The passive infrared camera system includes a lens,
`a refrigerated portion, and a refrigeration system. The refrig-
`erated portion has therein an infrared sensor device and an
`optical bandpass filter. The infrared sensor device is adapted
`to capture an infrared image from the lens. The optical band-
`pass filter is 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. The refrigeration system is adapted to cool the
`refrigerated portion of the infrared camera system.
`In accordance with another aspect of the present invention,
`a method ofvisually detecting a leak of a chemical emanating
`from a component, is provided. This method includes the
`following steps described in this paragraph. The order of the
`steps may vary, may be sequential, may overlap, may be in
`parallel, and combinations thereof. A passive infrared camera
`system is aimed towards the component. The passive infrared
`camera system includes a lens, a refrigerated portion, and a
`refrigeration system. The refrigerated portion includes
`therein an infrared sensor device and an optical bandpass
`filter. The optical bandpass filter is 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. The refrigeration system is
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`FLIR Systems, Inc.
`1001-00035
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`

`

`US 8,426,813 B2
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`3
`adapted to cool the refrigerated portion. An infrared image is
`filtered with the optical bandpass filter. The infrared image is
`that of the leak of the chemical emanating from the compo-
`nent. After the infrared image passes through the lens and
`optical bandpass filter, the filtered infrared image of the leak
`is received with the infrared sensor device. The filtered infra-
`red image received by the infrared sensor device is electroni-
`cally processed to provide a visible image representing the
`filtered infrared image. The leak is visually identified based
`on the visible image representing the filtered infrared image
`provided by the infrared camera system.
`The foregoing has outlined rather broadly features of the
`present invention in order that the detailed description of the
`invention that follows may be better understood. Additional
`features and advantages of the invention will be described
`hereinafter which form the subject of the claims of the inven-
`tion. It should be appreciated by those skilled in the art that the
`conception and specific embodiment disclosed may be
`readily utilized as a basis for modifying or designing other
`structures or processes for carrying out the same purposes of
`the present invention. It should also be realized by those
`skilled in the art that such equivalent constructions do not
`depart from the spirit and scope ofthe invention as set forth in
`the appended claims.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
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`The following is a brief description of the drawings, which
`illustrate exemplary embodiments of the present invention
`and in which:
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`FIG. 1 is perspective view of a chemical leak detection
`system of a first embodiment;
`FIG. 2 is a schematic of the infrared camera system of the
`chemical leak detection system of FIG. 1;
`FIGS. 3A-3D are absorption graphs for methane;
`FIG. 4 is a transmission curve illustrating a pass band of an
`optical bandpass filter;
`FIG. 5 is an absorption graph for a small sct of alkanc
`che nicals with the pass band of the first embodiment trans-
`posed thereon;
`FIG. 6 is an absorption graph for a small set of alkene
`che nicals with the pass band of the first embodiment trans-
`posed thereon;
`FIG. 7 is an absorption graph for a small set of aromatic
`che nicals with the pass band of the first embodiment trans-
`posed thereon;
`FIG. 8 is an absorption graph fo