Design and development of a laser gas analyzer utilizing a standard modular methodology

Abstract

This invention involves a standard modular analyzer that uses laser sensor technology for precise calibration and measurement on industrial sites. Unlike conventional modular analyzers, this device does not have a central board and is not dependent on specific brands for maintenance and repair. The design of this gas analyzer is such that its different parts can be operated and replaced as separate modules. The invention of the modular standard analyzer is designed to eliminate the time-consuming and costly problems associated with repairing or replacing parts. For this reason, the device has components with high compatibility and adaptability with standard spare parts. This system is designed in such a way that it has overcome the challenges related to the supply of spare parts and the analyzer is stable in the circuit.

Description

Design and Development of a Laser Gas Analyzer Utilizing a Standard Modular Methodology

[0001] This standard modular analyzer has different parts, each part can be considered as a separate module. For example, the power supply module can be easily replaced with different power supplies, so there is no need to worry about the failure of the analyzer's power supply. In this proposed method, the device is built based on standard modules and without a main board. As a result, in case of a problem with the analyzer, spare parts of any brand can be easily connected to it and the device will continue to work.

[0002] This patent involves the development of a totally modular gas analyzer which uses laser sensors and precise calibration to provide accurate measurements. The proposed modular system can be optimal for field analysis in industrial sites as it prevails the limitations of similar modular designs.

[0003] In fact, the proposed design in this patent offers distinct advantages over existing models such as enhanced compatibility and adaptability. Due to its totally modular method of development, this device is not limited to certain manufacturing brands for part replacements. Therefore, it represents a significant leap forward in the field of modular gas analyzers.

[0004] G01N 21 / 00 – G01N 21 / 27

[0005] EP2910927A1

[0006] Laser gas analyzer

[0007] This patent describes a laser gas analyzer equipped with a wavelength-variable laser and a light-split module designed to divide the emitted light, facilitating precise gas analysis.

[0008] Existing patents, such as EP2910927A1, describe laser gas analyzers with specific configurations. For instance, EP2910927A1 details a laser gas analyzer comprising a wavelength-variable laser configured to emit light and a light-split module designed to split the output light for precise gas analysis. While ours features a totally modular design with the following features:

[0009] – Modular Design Without Main Board:

[0010] Each component, such as the power supply, laser bench sensor, display, and monitoring system, functions as an independent module.

[0011] Modules can be easily replaced or upgraded with parts from different brands, ensuring flexibility and reducing reliance on specific manufacturers.

[0012] – Enhanced Maintenance and Reliability:

[0013] In the event of a component failure, standard modules allow for quick replacements without the need for exact brand matches.

[0014] This approach minimizes downtime and maintenance costs, ensuring continuous operation.

[0015] – Advanced Laser Sensor Technology:

[0016] Utilizes laser sensors operating within defined wavelength ranges for precise gas concentration measurements.

[0017] Eliminates the need for mechanical components like chopper motors, reducing mechanical failures and extending calibration lifespans.

[0018] – True Modularity: Unlike existing designs that may rely on proprietary components, our analyzer’s architecture allows for the integration of modules from various brands, enhancing adaptability and user convenience.

[0019] In conclusion, our invention is a breakthrough in modular laser gas analyzers because it provides true modularity, cross-brand compatibility, fast maintenance, and customizable designs. Unlike existing models that lock users into specific brands, our system offers a cost-effective, flexible, and sustainable solution for industrial gas analysis.

[0020] US20100028819

[0021] Combustion Gas Analysis

[0022] This patent outlines a method for determining concentrations of carbon monoxide, water vapor, and hydrocarbons in combustion gases. It employs a single tunable diode laser operating in the 2 to 2.5 micrometer wavelength range, enhancing sensitivity and accuracy in gas detection.

[0023] Our proposed design introduces a fully modular gas analyzer that employs laser sensors for precise measurements. This design allows for easy replacement of components from various manufacturers, enhancing compatibility and adaptability.

[0024] There are key differences between the two patents such as overall purpose, modularity and compatibility and the type of laser technology employed. While both inventions pertain to gas analysis using laser technology, our invention distinguishes itself by offering a fully modular system compatible with components from various manufacturers, suitable for a wide range of industrial applications. In contrast, US20100028819 is tailored for combustion gas analysis using a specific laser source.

[0025] US8724112B2

[0026] Laser Gas Analysis Apparatus

[0027] This patent presents a laser gas analysis apparatus that eliminates signal transmission delays caused by varying installation environments, thereby improving measurement accuracy.

[0028] Our proposed invention introduces a fully modular laser gas analyzer designed without a main board, allowing for seamless integration and interchangeability of components from various manufacturers. This design aims to enhance compatibility, reduce maintenance downtime, and eliminate dependence on specific brands, addressing limitations found in existing modular analyzers.

[0029] While these patents share common ground, the above-mentioned patent focuses on increasing measurement accuracy. On the other hand, our invention offers a significant advancement in the field of laser gas analyzers by providing a truly modular system that emphasizes compatibility, ease of maintenance, and operational efficiency, setting it apart from existing technologies.

[0030] US20190271641

[0031] Optical Absorption Spectroscopy Based Gas Analyzer Systems and Methods

[0032] This patent outlines a system for measuring concentrations of trace gases in gas mixtures using an absorption spectroscopy method. The system comprises a resonant optical cavity containing the gas mixture and a continuous-wave external cavity laser, enhancing sensitivity and accuracy in gas detection.

[0033] While both inventions provide gas analysis, their designs, components and main purposes are different. While the above-mentioned patent focuses on enhancing sensitivity and accuracy in gas detection, ours emphasizes key features such as a truly modular system that emphasizes compatibility, ease of maintenance, and operational efficiency, setting it apart from existing technologies.

[0034] Laser sensors represent an emerging technology in the field of gas analyzers. These sensors offer highly precise measurements due to their operation within a defined wavelength range and their ability to maintain consistent energy output during operation without energy loss. Compared to infrared sensors, laser sensors exhibit significantly extended calibration lifespans and eliminate the need for mechanical components such as chopper motors.

[0035] A gas analyzer comprises multiple distinct sections, each of which can be designed as an independent block or module. For instance, the power supply module allows for the seamless replacement of various power sources, eliminating concerns over analyzer power supply failures. This device is a laser-based gas measurement sensor, primarily utilized for gas monitoring in industrial processes.

[0036] The sensor features a chamber (referred to as a "bench") containing a concave mirror internally, while a laser source and a laser receiver are positioned externally. When gas enters the sensor chamber, the laser light interacts with the gas, altering the waveform. The gas concentration is then determined by quantifying the degree of waveform distortion. This methodology enables accurate and reliable gas concentration measurement.

[0037] In industry terms, if a device has the ability to put different parts together to achieve a goal or a function, that device is referred to as modular. The comprising parts are assembled, and remain interchangeable, in the sense that different brands and models can be used in order to optimize the device's performance.

[0038] Many companies manufacture modular analyzers, which usually include various components such as rack - power supply - bench sensor - display and monitoring system - main board - system and conduit, output system, alarm and box. However, these companies have the ability to modularize only with their own brand parts. This is due to their designs which have a specific rack of their own manufacture where only parts made by the same brand are can be installed.

[0039] Therefore, manufacturing companies usually cannot use parts from other brands and models because the available and accessible parts are not compatible with their brands, which is a limitation for modular analyzers.

[0040] As mentioned, conventional analyzers have a rack and a main board, and this is a limitation for complete modularity.

[0041] Normally, when a part breaks down in a typical modular analyzer, it needs to be purchased according to the manufacturer's serial number and installed in the analyzer, which means a long time for supply and delivery, and of course, in most cases, this part is removed from the manufacturer's production line and is no longer produced by the manufacturer, and the analyzer must be taken off the line, which means:

[0042] 1- The cost of purchasing a new analyzer

[0043] 2- Loss of time

[0044] 3- Loss of control and efficiency of a factory's production

[0045] 4- Increased environmental pollution.Solution of Problem

[0046] The invention of the standard modular analyzer has eliminated the aforementioned problems and limitations and has provided a new definition of modularity.

[0047] In the standard modular laser analyzer, by eliminating the rack, this limitation has been removed and it is possible to build an analyzer tailored to the customer's needs. In this way, it is possible to easily use all the parts manufactured by different brands, implement them in a single design, and finally measure the gas concentration.

[0048] In addition, the proposed analyzer is technically compatible with all components from all brands, and as a result, this capability creates a stable and always ready-to-use analyzer, and this feature distinguishes it from other gas analyzers on the market.

[0049] For example: All the different parts of a laser analyzer, including the power supply, laser bench sensor, display and monitoring system, main board, temperature control system, output channel, and alarm system, are interchangeable, and these modules are also interchangeable with any brand.

[0050] On the other hand, the standard modular analyzer, in addition to having all the features of an accurate, stable and reliable laser analyzer, also facilitates the repair and maintenance process. Moreover, the operator can be sure that even in the event of a problem, the design of the standard modular analyzer allows replacement parts to be found easily and in the shortest possible time and there is no need to depend on a specific company.

[0051] Finally, this versatility makes the analyzer stable and thus eliminates the cost of purchasing a new analyzer and speeds up the analyzer setup time and quickly puts the process control of plants such as petrochemicals and refineries and steel industries and power plants in the hands of the operator. After controlling the process, there is a huge saving in energy and raw materials consumption and another positive point is the control of exhaust gases and prevention of gas leakage into the environment.

[0052] The stability of the standard modular analyzer enables industries to effectively and continuously monitor emitted gases and respond quickly to any abnormalities, which leads to improved compliance with environmental regulations and increased operational efficiency. The use of this new standard modular analyzer eliminates maintenance-related problems, ensures workplace safety, and facilitates optimization of production and profits.

[0053] 2. Description of the device’s function

[0054] The laser analyzer includes a power supply, a laser bench sensor, a display and monitoring system, a main board, a temperature control system, an exhaust channel, and an alarm system, and a box that varies in type and size depending on customer needs.

[0055] This device has a gas measurement sensor with laser technology that is used to measure gases in industrial processes. The sensor consists of a chamber (or so-called bench) inside which a concave mirror is located, and the laser source and laser light receiver are installed outside the sensor. The gas enters the sensor chamber and after the laser light hits the gas, its waveform changes. The amount of change in the measured waveform will be proportional to the gas concentration and the amount of gas is measured in this way.

[0056] Steps to prepare a standard modular analyzer

[0057] 1- Specifying the type of gas to be measured

[0058] The required information is received from the installation site and a request to manufacture the analyzer is received in the percentage (%) or ppm range. For example, an industrial complex may need to measure CO2 gas in the range of 0 to 50%. At this stage, the type of sensor is generally specified.

[0059] 2- Specify the physical parameters of the sample to be measured

[0060] These parameters include sample pressure, sample temperature, and the amount of dust particles in the sample.

[0061] 3- Selecting a box suitable for the process

[0062] 4- Selecting a power supply module

[0063] 5- Selecting an analog module

[0064] 6- Selecting a laser module sensor suitable for the process

[0065] 7- Selecting an output module

[0066] 8- Selecting an alarm module

[0067] Steps of performing the gas measurement and analysis:

[0068] 1- Determining the type of gas to be measured

[0069] This information is received from the site and a request for the manufacture of an analyzer in the percentage (%) or ppm range is registered

[0070] At this stage, the type of sensor is generally determined.

[0071] 2- Determining the physical parameters of the sample to be measured, including pressure, temperature and the amount of dust particles in the sample

[0072] At this stage, the pressure required by the analyzer is provided by a pump or regulator via a flow meter.

[0073] 3- Determining the gases present in the background of the sample, i.e. checking what other gases are present in the sample and do these gases affect our measurement? If there is an interference effect, it must be removed.

[0074] This is one of the most complex steps in designing a laser gas sensor, because interfering gases are removed from the measurement in three ways:

[0075] - Removing the interference effect using software

[0076] - Removing the interference effect by designing appropriate electronic circuits and filters

[0077] - Removing the interference effect by selecting an appropriate laser source

[0078] Finally, the above is simulated in a computer.

[0079] 4- Selecting and purchasing raw materials for the design and construction of the analyzer

[0080] 5- Designing and constructing a bench sensor appropriate to the sample conditions, temperature, pressure, gas type, and percentage of background gases in the sample. For example, for corrosive samples, the sensor body is selected from stainless steel or even Hastelloy.

[0081] 6- Designing the bench sensor body and manufacturing it via a CNC lathe according to the desired material.

[0082] 7- The laser source, laser light receiver and concave mirror are installed inside the bench sensor and optical and mechanical adjustments are made to receive the maximum power of the laser light reflected from the concave mirror.

[0083] 8- The temperature control system, including a heater and a temperature sensor, is installed on the sensor body so that the temperature of the bench sensor and consequently the sample temperature are always maintained at a constant value and the variable parameter is removed from the measurement and compensation list and the temperature measurement and control are performed independently of the gas concentration measurement.

[0084] This is done using common industrial controllers with high accuracy, and the device finds its optimal control points in Auto tune mode and maintains the bench sensor temperature quickly and accurately.

[0085] 9- Design and construction of an electronic board for analyzing and measuring the signal received from the bench sensor

[0086] In this board, a constant current and voltage are given to the laser source, the light produced from the source is radiated into the bench, and after passing through the gas inside the bench, the reflected light returns to the laser receiver, and the round-trip energy changes will be proportional to the concentration of the measured gas. These processes are performed by the electronic board.

[0087] This board is designed and constructed in such a way that it measures the gas and has two outputs: 4-20 mA and RS-485.

[0088] 10- Calibration using calibration gas

[0089] In this step, the measurable gas is applied to the sensor and the operating range of the device is calibrated.

[0090] This is done with software designed and built for the sensor, and after performing adjustments and calibration at zero and maximum points, the laser sensor enters the next stage to connect to various parts in the analyzer box.

[0091] 11- Connecting the signal output parameter display sections to the analyzer HMI and displaying parameters such as gas concentration, sensor bench temperature, analyzer output current and alarms

[0092] 12- Sending the generated analog signal to the isolation board so that the signal can be sent to the control room at a distance.

[0093] 13- All steps have a test sheet and are recorded in all parts of the process.

[0094] 14- Final test and installation of approval and test labels on the analyzerAdvantage Effects of the Invention

[0095] • Ensuring the stability of the device, eliminating stress and worry for the user or operator and the maintenance and repair team

[0096] • Reducing costs, because there is no need to buy a complete analyzer or a specific part from a specific brand

[0097] • Speeding up production efficiency control and factory protection

[0098] • Maintaining the stability of factory production line at the highest efficiency

[0099] • Increasing factory profits by optimizing energy consumption

[0100] • Protecting the environment

[0101] • Reliable and sustainable due to modular design

[0102] • Easy maintenance due to compatibility with standard parts

[0103] • Not dependent on the products of a particular brand

[0104] • Adaptable to different industrial environments

[0105] • Highly accurate calibration

[0106] • Customizable and targeted gas measurements

[0107] • Small and compact design

[0108] • No need for mechanical parts (mechanical choppers)

[0109] • Timesaving

[0110] • Ensures workplace safety

[0111] • Provides effective production control

[0112] • Boosts performance and profit

[0113] Shows a general view of the claimed device.

[0114] Displays a side view of the claimed device.

[0115] Displays a different side view of the claimed device.

[0116] Captures a view of the inner parts of the claimed device.

[0117] Contains a block diagram of the total modular laser analyzer.Description of Embodiment's

[0118] Shows a general view of the claimed device in its assembled form.

[0119] Illustrates a general view of the claimed device’s components and the connection between its parts wherein:

[0120] 1) Electronic board

[0121] 2) Sensor body

[0122] 3) Sensor cover

[0123] 4) Sensor holder base

[0124] 5) Sensor holder base

[0125] 6) Sample input connection

[0126] 7) Sample output connection

[0127] 8) Analog output port

[0128] Displays a view of the claimed device from a different angle wherein:

[0129] 4) Sensor holder base

[0130] 9) Sensor power input port

[0131] 10) RS233 output port

[0132] Shows a view of the inner parts of the claimed device wherein the placement and connection between these parts can be seen:

[0133] 11) Mirror and filter

[0134] 12) Concave mirror and laser light sending and receiving point

[0135] 13) Laser source

[0136] 14) Laser receiver

[0137] Contains a block diagram of the total modular laser analyzer which includes: power supply, laser bench sensor, display and monitoring system, temperature control system, output channel and alarm system, and a box tailored to customer needs.Examples

[0138] The presented laser gas analyzer in this patent is revolutionizing the way we monitor air quality, especially in industrial settings. With its totally modular methodology and high-accuracy sensors, this powerful tool ensures precise detection of harmful gases.

[0139] A factory's most crucial asset, its personnel, and the environment are very important, and laser gas analyzers with the standard method have the ability to protect these valuable assets with accurate and stable measurement and control.

[0140] Imagine that due to the failure of an analyzer, a factory's efficiency is reduced or the protection of a part of the factory is taken out of service. In this case, the factory, personnel, and the environment are at risk, and to put a typical module analyzer into operation, they must wait for the supply of the required part from the analyzer manufacturer and be behind the production line of the specific manufacturer of that brand of analyzer.

[0141] It is conceivable that during this wait, the factory efficiency will decrease, and due to the removal of the gas parameter measured by the analyzer, the factory and personnel will be at risk, and it will also cause pollution in the environment.

[0142] By investing in this technology, businesses not only prioritize employee safety, but also increase factory efficiency and industries will adhere to environmental regulations and help create a healthier planet. Using this device is a smart decision for humans and the environment.

[0143] In addition, analyzers made with this method have been tested and are being used in various industries, including petrochemicals and steel.

[0144] [Pic. 1] Shows a working prototype of a total modular laser analyzer in an explosion-proof box for a petrochemical and steel plant

[0145] [Pic. 1]

[0146]

[0147] The newly developed Laser Gas Analyzer represents a significant leap forward in industrial applications, primarily due to its totally modular methodology. This innovative design not only enhances the accuracy of sensor data but also ensures ease of integration into existing systems. Industries such as manufacturing, oil and gas, and environmental monitoring can greatly benefit from this technology. With precise measurements of gas concentrations, companies can ensure compliance with regulations, improve safety, and optimize operations. This analyzer stands to reduce costs while producing more reliable results, proving itself as a valuable asset in modern industrial settings.

Claims

A laser gas analyzer is developed with a totally modular method for gas measurement using sensor with laser technology which includes but is not limited to:1)Power supply2)Laser bench sensor3)Display and monitoring system4)Temperature control system5)Output channel and alarm systemAccording to claim 1, the claimed device comprises multiple interchangeable modules, wherein each module operates independently and can be replaced without affecting the functionality of the device.According to claim 1, the claimed device is constructed without a main board, allowing direct integration and replacement of modules from different manufacturers without compatibility constraints.According to claim 1, the claimed device features a modular power supply system within the analyzer that enables the replacement of power units from any brand, ensuring continuous operation in case of failure.According to claim 1, the claimed device features a modular bench design, including a concave mirror, laser source, and receiver, wherein the bench can be replaced or upgraded independently.According to claim 1, the claimed device is designed to be compatible with standard industrial components, allowing seamless integration of spare parts from different manufacturers.According to claim 1, the claimed device includes a replaceable and independent temperature control system module ensuring optimal operational conditions, without requiring specific proprietary parts.According to claim 1, the claimed device features a removable and replaceable display and monitoring system, enabling easy integration of different interface solutions based on customer needs.According to claim 1, the claimed device includes an interchangeable output module capable of supporting both analog (4-20 mA) and digital (RS-485) communication protocols, adaptable to different industrial environments.According to claim 1, the claimed device facilitates maintenance by providing a modular design wherein each component can be replaced quickly without requiring system-wide recalibration, reducing downtime and maintenance costs.According to claim 1, the claimed modular design allows component customization based on environmental conditions such as corrosive atmospheres, high temperatures, and pressure variations.According to claim 1, the claimed device is capable of integrating sensor modules from different manufacturers, ensuring flexibility in sensor selection for measuring various gases.According to claim 1, the claimed device has a modular architecture allowing in-field upgrades of components such as laser sources, detectors, and signal processing units without replacing the entire system.According to claim 1, the claimed design includes a customizable and modular alarm system that can be replaced or expanded based on specific industrial safety requirements.According to claim 1, the claimed device is designed without a proprietary rack, ensuring full modularity and flexibility in arranging components based on space constraints and user preference.According to claim 1, the claimed design has a modular framework that allows future scalability, enabling easy addition of new features, sensors, or functionalities without redesigning the entire system.According to claim 1, the claimed device has a modular architecture designed to be installed and integrated into any industrial system without requiring specific infrastructure modifications.According to claim 1, the claimed device reduces e-waste by enabling replacement of only defective modules instead of discarding the entire device.According to claim 1, the claimed device is capable of operating with redundant modular components, ensuring continuous operation even if a single module fails.According to claim 1, the claimed design allows the selection of different housing materials, such as stainless steel or explosion-proof enclosures, to suit various industrial conditions.According to claim 1, the claimed device includes standardized connection interfaces across all modules, ensuring universal compatibility and ease of module replacement.

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