Confined space failsafe access system
10957180 ยท 2021-03-23
Inventors
Cpc classification
G08B17/10
PHYSICS
International classification
G08B17/12
PHYSICS
G08B27/00
PHYSICS
Abstract
A method and safety device for use in accessing confined spaces that incorporates atmospheric safety monitoring and alarm annunciation into a physical access device/mechanism for the purpose of preventing the human confined space entrant from entering a confined space containing a hazardous atmosphere.
Claims
1. A portable access system configured for temporary positioning in an entrance and exit port of a confined space to prevent access of a worker into life-threatening atmospheric confined space breathing conditions in the confined space, and to facilitate the worker's safe entrance into and exit from the confined space in reliance thereon, the portable access system comprising: an entrance assembly having an insertion end that is temporarily inserted through said entrance port into said confined space, and a positioning end, opposite the insertion end, that remains outside the confined space when the insertion end is temporarily inserted into said confined space, said positioning end having means to support said entrance extending into said confined space in advance of worker entry therein; a first sensor arranged on the insertion end for monitoring said confined space for a potential or actual dangerous, life-threatening breathing condition and generating a preemptive gas detection status signal to alert the worker's surrounding personnel and facilities managers overseeing the confined space of the potential or actual dangerous, life-threatening breathing conditions therein; an alarm status annunciator module arranged mounted on the positioning end of said entrance assembly outside the entrance port in communication with the first sensor for receiving the preemptive gas detection status signal, said entrance assembly supports both said first sensor and said alarm status annunciator; wherein upon receiving a preemptive gas detection status signal indicating that a potential or actual dangerous, life-threatening breathing condition exists in said confined space, whereby the alarm status annunciator module communicates a warning alarm signal and emits a first alarm to the worker's surrounding personnel and facilities managers that the potential or actual dangerous, life-threatening breathing condition exists within said confined space; and, a second sensor in said alarm status annunciator on said entrance assembly for monitoring the worker's movement within said confined space, and generating a movement monitoring signal for detecting a premature unsafe entry of a worker attempting to enter said confined space, without following predetermined critical safety procedures denying access during the potential or actual dangerous, life-threating breathing conditions within the confined space, and emitting a second alarm, whereby said first sensor and alarm status annunciator module, including said second sensor, are inserted together with said entrance assembly extending partially into said confined space; wherein said second sensor emits the second alarm when a worker entry is attempted before said first sensor detects that the potential or actual dangerous life-threatening condition exists within said confined space.
2. The portable access system of claim 1, in which said alarm status annunciator module directs power to said first sensor and controls an on/off state of said first sensor.
3. The portable access system of claim 1, in which said first sensor is powered from and with a wired data connection to said alarm status annunciator module, said alarm status annunciator module functioning as a repeater of said gas detection status signal from within said confined space, allowing said gas detection status signal to be transmitted from the first sensor to the worker's surrounding personnel and facilities managers located outside of said confined space.
4. The portable access system of claim 1, in which said entrance assembly is a ladder.
5. The portable access system of claim 4, in which said insertion end comprises a lower leg portion of said ladder and in which said first sensor samples gas from the lower leg portion of said ladder.
6. The portable access system of claim 4, in which said status annunciator module is mounted proximate an upper leg portion of said ladder extending outside of said entrance port.
7. The portable access system of claim 1, in which said entrance assembly is a carrier for lowering said worker into and raising said worker out of said confined space.
8. The portable access system of claim 1, further comprising an active module positioned on the insertion end of said access assembly in which said sensor is located.
9. The portable access system of claim 8, wherein said active module communicates wirelessly with said alarm status annunciator module.
10. The portable access system of claim 1, in which a video camera and integrated light are mounted on said entrance assembly such that when said entrance assembly is positioned within said confined space, said video camera and integrated light also are positioned within said confined space.
11. The portable access system of claim 1, wherein said second sensor is selected from the group consisting of at least one of an optical sensor, a position switch, an ultrasonic sensor, a pressure sensor, a load sensor, a conduction sensor, a Hall Effect sensor and a piezo electric sensor, or combinations thereof.
12. The access system of claim 1, further comprising a monitoring station computer for receiving the warning signal of the potential or actual dangerous, life-threatening breathing condition within the confined space, from said annunciator module through a wireless interface and/or wired connection to provide alerts to a monitoring person of the worker's surrounding personnel and facilities managers located adjacent to, and outside of said confined space, said monitoring station computer running software that receives and interprets the warning signal of the potential or actual dangerous, life-threatening breathing condition within the confined space.
13. A method of assuring a worker's safe entry to, operation within and exit from a confined space, to prevent access to the worker into the confined space, in which a potential or actual dangerous, life-threatening breathing condition could exist, the method comprising the steps of: temporarily inserting, through an entrance and exit port, an insertion end of entrance assembly into said confined space, such that a positioning end of the entrance assembly, opposite the insertion end, remains temporarily positioned outside said confined space in advance of worker entry therein, to enable the worker to enter and exit said confined space through said entry and exit port and to prevent the worker entry into the confined space during the potential or actual dangerous, life-threatening breathing conditions therein; first monitoring atmospheric gas in said confined space, using a first sensor positioned on the insertion end of said entrance assembly, and transmitting a potential or actual dangerous, life-threatening breathing condition alarm signal emitting a first alarm to alert the worker's surrounding personnel and facilities managers overseeing the confined space of the potential or actual dangerous, life-threatening breathing conditions therein, the potential or actual dangerous, life-threatening breathing condition is detected by the first sensor; in response to receiving said potential or actual dangerous, life-threatening breathing condition alarm signal from the first sensor, communicating a preemptive warning signal to the surrounding personnel and facilities managers of the confined space that the potential or actual dangerous, life-threatening breathing condition exists within said confined space, using an alarm status annunciator module mounted on said positioning end; and, a second sensor monitoring a worker's movement during attempted entry into, operation within and exit from said confined space, using said second sensor also mounted on said positioning end, and generating a corresponding worker movement monitoring signal and emitting a second alarm indicating worker attempted entry based on the second monitoring, whereby said first and second sensors and alarm status annunciator module are inserted all together with said entrance assembly partially extending into said confined space having the potential or actual dangerous life, threatening breathing condition therein, to prevent the worker entry therein and transmitting the worker attempted entry movement signal to the worker's surrounding personnel and facilities managers immediately upon the worker attempted entry, to preemptively prevent the worker's attempted entry into the confined space; wherein further said second sensor emits said second alarm when the worker entry is attempted before said first sensor detects that the potential or actual dangerous, life-threatening breathing condition exists within the said confined space.
14. The method of claim 13, in which said alarm status annunciator module directs power to said first sensor and controls an on/off state of said first sensor.
15. The method of claim 13, in which said first sensor is powered from and with a wired data connection to said alarm status annunciator module, and functions as a repeater of said dangerous, life-threatening breathing condition alarm signal from within said confined space, allowing said dangerous life threatening breathing condition alarm signal to be transmitted from said confined space to the worker's surrounding personnel and facilities managers located adjacent to and outside of said confined space.
16. The method of claim 13, in which said entrance assembly is a ladder.
17. The method of claim 16, in which said insertion end of said ladder comprises a lower leg portion and in which said first sensor samples gas from the lower leg portion of said ladder.
18. The method of claim 16, in which said alarm status annunciator module is mounted proximate an upper leg portion of said ladder extending outside of said entry and exit port.
19. The method of claim 13, in which said entrance assembly is a carrier for lowering said worker into said confined space.
20. The method of claim 13, further comprising an active module positioned on the insertion end of said entrance assembly.
21. The method of claim 20, wherein said active module communicates wirelessly with said alarm status annunciator module.
22. The method of claim 13, in which a video camera and integrated light are mounted on said entrance assembly such that when said entrance assembly is positioned within said confined space, said video camera and integrated light also are positioned within said confined space to display the interior of said confined space before worker entry therein.
23. The method of claim 13, wherein said second sensor is selected from the group consisting of at least one of an optical sensor, a position switch, an ultrasonic sensor, a pressure sensor, a load sensor, a conduction sensor, a Hall Effect sensor and a piezo electric sensor, or combinations thereof.
24. The method of claim 13, in which a monitoring station computer receives said warning signal of the potential or actual dangerous, life-threatening breathing condition within the confined space, from said annunciator module through a wireless interface and/or wired connection to provide alerts to a monitoring person of the worker's surrounding personnel and facilities managers located adjacent to and outside of said confined space.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The present invention can best be understood in connection with the accompanying drawings. It is noted that the invention is not limited to the precise embodiments shown in the drawings in which the drawing Figures are described as follows:
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DETAILED DESCRIPTION OF THE INVENTION
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(18) Options include a work light 600, video camera sensor 700 to remotely monitor the working in the confined space 900, and various wireless telemetry for communicating to sensors and communicating to remote monitoring locations by WiFi, Bluetooth, ZigBee or other similar wireless communication protocols.
(19) Depending on the physical geometry of the confined space 900 and the appropriate entrance device 110 it may be more practical to use a self-powered gas sensor or meter 400 with a wireless connection to the alarm status annunciator module, (ASAM) 200 for more flexibility as shown in
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(27) The details of features in the overall system are otherwise the same as described in
(28) Options shown include a work light 600, video camera sensor 700 to remotely monitor the working in the confined space 900, and various wireless telemetry for communicating to sensors and communicating to remote monitoring locations by WiFi, Bluetooth, ZigBee or other similar wireless communication protocols.
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(31) Note that the gas sensor/meter 400 can connect wirelessly (if so capable) directly to the alarm status annunciator module, (ASAM) 200, or to the active/dormant Module (ADM) 300 depending on what makes most sense giving the wireless capability of the gas sensor/meter 400 and the physical geometry of the confined space and surrounding area. The gas sensor/meter 400 can also be wired to the active/dormant Module (ADM) 300.
(32) This method and invention is designed to prevent access into a confined space 900 that has an atmosphere that is not suitable to sustain life by generating a conspicuous alarm response when entry is initiated. It is accomplished by affixing a suitable regulatory agency compliant gas sensor or meter 400 to one end of a mechanical assembly 100 that facilitates access into and egress out of the confined space 900 by the entrant. The preferred gas sensor/meter 400 can be one of two basic types depending on the specific application and expected potential hazards. One type is self-contained and samples the atmosphere in its immediate vicinity. The other can incorporate a sampling tube to enable it to sample the atmosphere at some distance from the meter. This type of device can also effectively sample from multiple locations either by incorporating a manifold with multiple sampling tubes with multiple sampling locations, or a single sampling tube with multiple ports. This would allow sampling at more than one depth in the confined space with a single meter to take into account atmospheric stratification that could exist at different levels of the confined space due to variations in gas density. Either gas meter type requires the ability to communicate wirelessly or by wire a meter status condition including an alarm state to the system. Preferably the gas sensor or meter can also communicate its own health status including functionality of its sensors and battery charge status. The location of where the atmospheric sample is taken need not necessarily be where the meter is physically located by using a meter incorporating a sampling tube. In this case the sample is taken from the sampling point at the end of the sampling tube or from multiple sampling tubes or multiple sampling points along the length of the sampling tube. These gas meters as described are readily available in the marketplace from multiple vendors and, can be selected as required for specific features, ease of mounting and compatibility with communication with the other modules of the system.
(33) Examples of the entrance assembly 100 include but are not limited to a cable 120, ladder 110, ramp, stairway or any other assembly or device that will facilitate physical entry in to the confined space 900. For the purpose of simplifying the system description, we refer to this mechanical assembly that facilitates access and egress as the entrance assembly 100.
(34) The sampling point of the atmospheric sensor/meter 400 is immersed into the confined space 900 environment in advance of the entrant as a natural consequence of utilizing the entrance assembly 100. When the entrance assembly 100 is put into position, the atmospheric sensor/meter 400 sampling point will monitor the atmosphere and communicate its status using wired or wireless means to an alarm status annunciator module, (ASAM) 200, or the active/dormant Module (ADM) 300 depending on the system configuration chosen. The remote annunciators of the alarm status annunciator module, (ASAM) 200 can consist of audible alarms 220, visual alarms 210 and network, data telemetry 230, 240 for remote alerts and archival storage that an alarm event occurred though a networked computer 280.
(35) The alarm status annunciator module, (ASAM) 200, can be mounted on the opposite end of the entrance assembly 100 or mounted/positioned in close proximity to the confined space entrance 205. In either instance, the ASAM 200 resides outside of the confined space. The ASAM 200 can indicate an alarm condition with, but not limited to, red strobe lights 210R and a high decibel audio alarm 220. Conversely, the alarm status annunciator module, (ASAM) 200 can indicate that an acceptable atmosphere exists in the space with a green light 210G, or some other type of annunciator signal. The alarm condition will be generated after the ladder is inserted into the access port 910 into the confined space 900. (i.e. hatch or manway), but before the entrant has an opportunity to enter into the space. The alarm status annunciator module, (ASAM) 200 can also record the atmospheric readings from the gas sensor/meter 400 along with a time and date stamp in a digital memory log. The alarm status annunciator module, (ASAM) 200 can also interface with a local area network to communicate overall status and alarm conditions to other individuals and locations though a networked computer 280.
(36) The active/dormant sensor 260 function can be either incorporated into the alarm status annunciator module, (ASAM) 200 or into a remote active/dormant Module (ADM) 300 that communicates with the alarm status annunciator module ASAM 200. The entrance assembly 100 is monitored by the active/dormant sensor 260 that can indicate an operational mode or a dormant mode. This sensor need not be inserted into the confined space. An operational mode would be when the entrance assembly 100 is put into a position where it would be used to gain access into a confined space 900. This same sensor can also monitor when an individual mounts the ladder. This would indicate that the gas sensor/meter 400 should be operational and atmospheric data is representative of conditions in the confined space 900. A dormant mode would be when it is stored or otherwise not currently in use. An example of an active dormant sensor 260 could be a device that would indicate that the entrance assembly 100 is in close proximity to the tank, manway or other physical structure of the confined space 900. There are many sensor technologies that could be adapted for this purpose including, but not limited to, optical, ultrasonic, pressure, load, conduction, Hall Effect, piezo electric, and others. A simple switch could be used to change state when the entrance assembly 100 is put into an operational position and it comes into contact with the entrance way or other mechanical feature of the confined space 900. Another example could be a simple mercury switch or inclinometer that could indicate horizontal or vertical position of the ladder or other entrance assembly 100. The concept in this case being that the entrance assembly 100 would be inserted into the confined space entrance port 910 in a vertical position when operational and in a horizontal position when it is not being utilized and in its dormant mode. The alarm status annunciator module, (ASAM) 200 uses this sensor information 260 to know when to expect relevant data from an atmospheric meter/sensor and thus know when to generate an alarm. The physical location of this sensor can be located within the alarm status annunciator module ASAM 200, or the remote active/dormant Module (ADM) 300.
(37) The operational/dormant sensor (ADS) 260 signal could be sourced from an independent system than the atmospheric sensor/meter 400 and thus could provide other status or alarm information. For example, if the operational/dormant sensor (ADS) 260 indicated an operational orientation and there was no atmospheric sensor/meter 400 data available within a timeout period, the alarm status annunciator module ASAM 200 would indicate an alarm condition to indicate that the system is not functionally operational. The alarm status annunciator module ASAM 200, could also monitor the battery condition of both the gas sensor/meter 400 and the operational/dormant sensor (ADS) 260 to generate low battery alarms. In some embodiments of the design the active/dormant sensor 260 could signal control of power to other modules in the system when it detects a dormant state, with the intention of reducing power to modules to conserve battery life when not in use. The alarm status annunciator module ASAM 200 could also monitor its own battery level as well as the battery condition of both the atmospheric sensor/meter 400 and the active/dormant sensor 260 to generate low battery alarms.
(38) This active/dormant sensor 260 assembly can be integrated into the alarm status annunciator module, (ASAM) 200, or it can be configured as a separate active/dormant module (ADM) 300 that has its own power source and transmits its status to the remotely located alarm status annunciator module (ASAM) 200 using a wireless data transmission such as Bluetooth 230, ZigBee 230, Wi-Fi 240 or other standard or proprietary wireless data transmission protocol.
(39) In general, the system is designed to be exceedingly difficult to defeat by the operator without causing permanent and obvious damage to the system so as to deter operators from temporarily cheating the system against their and their employer's best interests. In all situations, the alarm status annunciator module, (ASAM) 200, will indicate whether the system is functioning with an indication for Alarm 210R, Safe 210G and Indeterminate 210Y visual indicators. Tamper resistant designs will be utilized for any sensitive or programmable portions of the electro-mechanical assembly including such mechanisms as metal enclosed wire runs, anti-tamper assembly hardware, as well as safeguards against other obvious methods that might be utilized with the intention of circumventing the intention of the invention device.
(40) Many confined spaces 900 require an individual to enter through a hatch or manway 910 and descend down into the space using a portable ladder 110. Examples of this process can be seen when examining bulk transportation operations that utilize rail tankers, hopper cars, ISO tanks or tank truck carriers. Many other confined spaces 900 can utilize this invention and method and use of these examples should in no way be considered a limitation to the use of the invention.
(41) When it is necessary for an individual to enter into the tank for an inspection or a maintenance operation, they must open a hatch, test the atmosphere, insert a ladder, or other type of assembly that helps facilitate access into and egress out of the space and climb down into the tank area which is a confined space. This could include, but not be limited to, a ladder placed into a large vessel, tank or vault and mounted on the lip or flange of a manway, or hatch that opens into the vessel, tank or vault. In many instances, this is the only way that an individual can physically enter or exit the space. It is assumed that the atmosphere of the tank is monitored prior to entry by the entrant to ensure that it is safe.
(42) By integrating atmospheric sensors with remote annunciation and telemetry onto the ladder, or any other device that facilitates entry, it would be impossible for an individual to enter into a confined space without the benefit of prior knowledge on the condition of the atmosphere. Even if the individual neglects to meter the atmosphere prior to entry, to ensure that it is safe, the atmospheric sensors on the entrance assembly that is inserted into the confined space will report on an unsafe atmosphere in advance of entry.
(43) An application example would be as follows:
(44) An operator needs to conduct a maintenance/repair operation inside of a truck carrier tank 900. The operator opens the batch covering the manway 910. This is when the atmosphere of the tank should be tested. If the atmosphere is not safe, then no further steps should be taken by the operator to enter the space. If the atmosphere is safe, entrance assembly 100 is used to allow the entrant to climb down into the confined space 900, in this example a tank, to conduct business. The entrance assembly 100 is stored on the wall in a horizontal position as shown in
(45) The system integrity will be failsafe by incorporating several features to ensure that the system is operating within normal limits. The monitoring of the battery life for active/dormant sensor 260 to make sure that the battery is not close to its lower operational limit of charge. If the battery is low, then an alarm event will be triggered to notify the operator that the system needs attention and the battery should be replaced or recharged. The dormant mode can also indicate to the alarm status annunciator module, (ASAM) 200 that the gas sensor/meter 400 should be powered off. If gas sensor/meter 400 readings are still detected, then the operator has left the atmospheric meter/monitor powered on and will be draining the battery unnecessarily. The alarm status annunciator module, (ASAM) 200 can alert the operator to shut off the gas sensor/meter 400 to preserve battery life or the system could automatically shut off the necessary components not required in the dormant mode. The operator removes the entrance assembly 100 from its horizontal storage location and inserts it vertically into the open manway (entrance port 910) to allow access into the tank (confined space 900). The active/dormant sensor 260 now indicates that the ladder is in an operational configuration. The alarm status annunciator module, (ASAM) 200 will log the time and date that the entrance assembly 100 was placed in an operational configuration. When the entrance assembly 100 is placed in this position, the alarm status annunciator module, (ASAM) 200 will now try and communicate with the gas sensor/meter 400 on the end of the entrance assembly 100. If it cannot establish communications with the gas sensor/meter 400 it will go into an equipment failure alarm mode. This alarm will now alert the operator that no further action should be taken until the equipment is made operational. This may be a simple matter of turning on the gas sensor/meter 400 that was accidently left off, or changing a discharged battery. If communications are established the alarm status annunciator module, (ASAM) 200 will now monitor atmospheric conditions from the gas sensor/meter 400 and indicate safe conditions with a green annunciator light 210G. If data is returned that indicates an unsafe condition, the alarm status annunciator module, (ASAM) 200 will go into an alarm mode, sound a high decibel alarm 220 and activate the alarm light indicators 210R. If safety protocols dictate that an individual must test the atmosphere of the confined space before the entrance assembly 100 is inserted, then this alarm is an indication of a procedural error on the part of the employee and an accident was averted.
(46) The alarm status annunciator module, (ASAM) 200 data can also be transmitted to a networked monitor 280 in the form of a PC console 280a, tablet 280b or mobile device (such as a smartphone 280c or wearable mobile device 280d, i.e., a smart watch) via a network where the status of multiple locations can be displayed. In some instances, it may be necessary to place a wireless repeater on the opposite end of the ladder to allow the wireless signal to be transmitted outside of the tank. This repeater would be incorporated into the alarm status annunciator module, (ASAM) 200 or active/dormant Module (ADM) 300. Remote antennas can also be used to allow proper signal strength and is received for all of the wireless information. See
(47) Other features could be integrated onto the ladder to increase its capabilitysuch as a video camera 700 that can allow others to observe the entrant inside of the confined space, as well as illuminators or an integrated work light 600 that can serve to light up the space and allow an entrant to see.
(48) If a safety protocol is adopted that the entrant must meter the atmosphere of the confined space prior to inserting the ladder, then the system alarm serves a dual function. If the entrance assembly 100 alarm initiatesit not only will alert the employee of the problem before entry and potentially save his life, it will also inform management that this individual has not tested the atmosphere in advance of entry as per established procedures. They will now be aware that this worker is operating in an unsafe manner that is not compliant with regulatory agency mandates and the employee's training. As a result of this procedural omission, the entrant is putting themselves and their employers at risk of potential negative consequences. Action can be taken by management in advance of an accident to mitigate a hazardous action by the employee with either retraining or termination.
(49) While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention as claimed.