Gas Monitoring Device, System and Methods

Abstract

A gas monitoring system for continuously detecting leakage of at least one gas and being operable in an extreme climate condition, the system involving a processor; at least one emergency shutdown valve responsive to a set of instructions from the processor; and a user interface in communication with the processor. The system further involves a weather-proof enclosure for housing system components. The weather-proof enclosure is adapted to operate at a temperature range of ambient temperature to a below-freezing temperature, wherein the at least one emergency shutdown valve comprises at least one latch valve.

1 . A gas monitoring system for continuously detecting leakage of at least one gas and being operable in an extreme climate condition, the system comprising:
 a processor;   at least one emergency shutdown valve responsive to a set of instructions from the processor; and   a user interface in communication with the processor.   
     
     
         2 . The system of  claim 1 , further comprising a weather-proof enclosure for housing system components, the weather-proof enclosure adapted to operate at a temperature range of ambient temperature to a below-freezing temperature, wherein the at least one emergency shutdown valve comprises at least one latch valve. 
     
     
         3 . The system of  claim 2 , wherein the at least one latch valve is configured to operate on a 24 VDC or 115 VAC/230 VAC electrical system. 
     
     
         4 . The system of  claim 1 , further comprising at least one multi-channel relay for simultaneously monitoring at least one gas, the at least one multi-channel relay in communication with the processor. 
     
     
         5 . The system of  claim 4 , wherein the at least one multi-channel relay comprises at least one Modbus transmitter. 
     
     
         6 . The system of  claim 5 , wherein the at least one Modbus transmitter is rated for a range of approximately 4 mA to approximately 20 mA. 
     
     
         7 . The system of  claim 4 , further comprising at least one ESD control circuit operatively coupled with the at least one at least one emergency shutdown valve and in communication with the at least one multi-channel relay. 
     
     
         8 . The system of  claim 7 , further comprising an emergency shutdown reset switch operably coupled with the at least one ESD control circuit. 
     
     
         9 . The system of  claim 4 , further comprising at least one warning feature responsive to the at least one multi-channel alarm relay. 
     
     
         10 . The system of  claim 9 , wherein the at least one warning feature comprises at least one of:
 an audible alarm having an optional silencing feature;   a visual alarm;   an alarm reset switch; and   a backup battery feature.   
     
     
         11 . The system of  claim 9 ,
 wherein the at least one warning feature is programmable and comprises a plurality of warning levels corresponding to predetermined warning thresholds; and   wherein the predetermined warning thresholds comprise approximately three programmable alarm levels per channel.   
     
     
         12 . The system of  claim 1 , wherein the user interface comprises:
 a control PCB panel; and   a display operably coupled with the control PCB panel.   
     
     
         13 . The system of  claim 12 , wherein the display comprises a digital display. 
     
     
         14 . The system of  claim 13 ,
 wherein the digital display comprises at least one of an LED display and an LCD display, and   wherein the digital display is in bi-directional communication with the processor.   
     
     
         15 . The system of  claim 1 , further comprising:
 at least one detector relay in communication with the processor;   at least one direct-connect sensor in communication with the at least one detector relay; and   at least one remote slave sensor device in communication with the at least one detector relay.   
     
     
         16 . The system of  claim 1 , further comprising an alarm reset switch operably coupled with the processor. 
     
     
         17 . The system of  claim 1 , further comprising a power source for powering the processor. 
     
     
         18 . The system of  claim 12 , wherein the at least one direct-connect sensor comprises at least one of an infrared sensor, a catalytic sensor, an electro-chemical sensor, a Riken sensor, a flame detector, and a photo-ionization detector. 
     
     
         19 . A method of fabricating a gas monitoring system for continuously detecting leakage of at least one gas and being operable in an extreme climate condition, the method comprising:
 providing a processor;   providing at least one emergency shutdown valve responsive to a set of instructions from the processor; and   providing a user interface in communication with the processor.   
     
     
         20 . A method of monitoring at least one gas by way of a gas monitoring system for continuously detecting leakage of at least one gas and being operable in an extreme climate condition, the method comprising:
 providing a gas monitoring system, the system providing comprising:
 providing a processor; 
 providing at least one emergency shutdown valve responsive to a set of instructions from the processor; and 
 providing a user interface in communication with the processor; 
   commencing operation by powering the gas monitoring system;   sensing a gas level by way of at least one direct-connect sensor;   determining the gas level using data obtained by the at least one direct-connect sensor;   determining whether the gas level is less than a threshold value;   if the gas level is less than the threshold value, sensing a gas level by way of at least one direct-connect sensor;   if the gas level is at least the threshold value, proceeding to performing a limit test, and performing the limit test;   if the gas level is less than the limit, determining the gas level using data obtained by the at least one direct-connect sensor;   if the gas level is equal to the limit, sending a warning by way of a first alarm feature;   if the gas level exceeds the limit, sending a warning and activating an alarm by way of a second alarm feature; and   if the gas level greatly exceeds the limit by a predetermined value, sending a warning, activating an alarm, and activating an ESD latch valve by way of a third alarm feature, and terminating operation of the gas monitoring system.