Description:TECHNICAL FIELD
[0001] The present disclosure relates to the field of equipment testing. More particularly, the present disclosure relates to a device and method for assessing refractory erosion and disbonding in an industrial equipment.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present disclosure. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed disclosure, or that any publication specifically or implicitly referenced is prior art.
[0003] Industrial equipment, such as cyclone, riser and kiln, are critical components in the manufacturing process, subjected to extreme operating conditions. These types of equipment are lined with refractory materials to withstand high temperatures and extreme process and provide insulation. However, these harsh conditions within these vessels leads to the degradation of the refractory lining over time. This degradation manifests in various forms, including refractory erosion, disbonding and material damage. These issues significantly impact vessel performance, safety, and overall production efficiency.
[0004] The existing practice for inspecting refractory materials in industrial equipment often relies on time-consuming and potentially hazardous manual inspections through man-entry or visual assessments through camera systems. Manual inspections rely on the expertise of trained personnel, increasing the potential for human error. Camera-based inspections, while offering real-time monitoring, are limited in their ability to accurately assess the extent of erosion and disbanding.
[0005] Existing methods struggle to access complex or obstructed areas within industrial vessels, leading to incomplete assessments. These challenges result in inefficient maintenance planning, increased downtime, and higher operational risks due to undetected refractory failures.
[0006] To address these limitations, the present invention provides a novel device and method that overcome the shortcomings of the prior art.
OBJECTS OF THE PRESENT DISCLOSURE
[0007] Some of the objects of the present disclosure, which at least one embodiment herein satisfies are as listed herein below.
[0008] It is a primary object of the present disclosure to provide a device that enhances refractory inspection accuracy by utilizing LiDAR-based ARSCAN technology, enabling precise measurement of refractory erosion and disbonding in industrial equipment.
[0009] It is another object of the present disclosure to provide a device that eliminates manual inspection risks by deploying a fully automated, non-contact scanning system, reducing the need for human entry into hazardous environments.
[0010] It is yet another object of the present disclosure to provide a device that improves accessibility to hard-to-reach areas within industrial vessels, such as cyclones, risers, and kilns, through a specialized deployment mechanism with adjustable scanning capabilities.
[0011] It is yet another object of the present disclosure to provide a device that enables real-time data analysis and predictive maintenance by integrating advanced processing algorithms that generate 3D erosion maps and compare them with historical datasets for early failure detection.
[0012] It is yet another object of the present disclosure to provide a device that minimizes downtime and maintenance costs by providing a proactive and efficient inspection method, allowing timely refractory maintenance and reducing unexpected equipment failures.

SUMMARY
[0013] This section is provided to introduce certain objects and aspects of the present disclosure in a simplified form that are further described below in the detailed description. This summary is not intended to identify the key features or the scope of the claimed subject matter.
[0014] The present disclosure relates to the field of equipment testing. More particularly, the present disclosure relates to a device and method for assessing refractory erosion and disbonding in an industrial equipment.
[0015] In an aspect of the present disclosure, a device for assessing refractory erosion and disbonding in an industrial equipment is disclosed. The device includes a LiDAR scanner configured to capture high-resolution three-dimensional (3D) surface data of refractory linings. The device further includes a deployment unit comprising a pulley and a rope configured to allow controlled vertical movement of the LiDAR scanner inside the equipment. The device further includes a stabilizer unit comprising at least three centering legs, each of the at least three legs controlled by pneumatic cylinders, ensuring stable and centered positioning of the LiDAR scanner during operation. The device further includes a lower arm scanning unit, attached to the LiDAR scanner, controlled by a pair of pneumatic cylinders, enabling tilt adjustments of a lower arm within a 0° to 90° range to scan obstructed or non-visible areas. The device further includes a motorized assembly comprising a DC motor and a gear assembly and configured to allow the lower arm to rotate fully around an axis for comprehensive coverage. The device further includes a ring arrangement unit that is configured to enable activation and deactivation of the LiDAR scanner. The device further includes a processor, operatively coupled with the LiDAR scanner, the deployment unit, the stabilizer unit, the lower arm scanning unit, the motorized assembly, the ring arrangement unit. The processor is configured to deploy the LiDAR scanner into the equipment. The processor is configured to capture high-resolution three-dimensional profiles of a refractory lining of the equipment by performing scans at varying elevations. The processor is configured to analyse the captured profiles to identify areas of erosion and disbonding with reference to design drawings or historical datasets. The processor is configured to generate a color-coded map and a tabulated report comprising an extent and location of refractory degradation.
[0016] In an embodiment, the LiDAR scanner is configured to emit laser beams to capture a precise topography of the equipment, enabling generation of a detailed digital elevation model of the equipment.
[0017] In an embodiment, the pulley is mounted on a top hook with the rope enabling controlled vertical movement of the LiDAR scanner to scan an entire profile of the equipment.
[0018] In an embodiment, the at least three legs are configured to adjust automatically to a diameter of the equipment at each scan location to enable execution of multiple scans at varying elevations.
[0019] In an embodiment, the ring arrangement unit is actuated by a plurality of pneumatic pistons configured to allow control over an operation of the LiDAR scanner.
[0020] In an embodiment, the processor is configured to enable historic comparison and monitoring of refractory material degradation, facilitating efficient maintenance planning and extension of the operational life of the equipment.
[0021] In an embodiment, the deployment unit is configured to implement an automated tension control mechanism to regulate speed and stability of vertical movement of the LiDAR scanner.
[0022] In an aspect of the present disclosure, a method for assessing refractory erosion and disbonding in an industrial equipment is disclosed. The method begins with deploying, by the processor, the LiDAR scanner into the equipment. The method proceeds with capturing, by the processor, high-resolution three-dimensional profiles of a refractory lining of the equipment by performing scans at varying elevations. The method proceeds with analysing, by the processor, the captured profiles to identify areas of erosion and disbonding with reference to design drawings or historical datasets. The method ends with generating, by the processor, a color-coded map and a tabulated report comprising an extent and location of refractory degradation.

BRIEF DESCRIPTION OF DRAWINGS
[0023] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in, and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure, and together with the description, serve to explain the principles of the present disclosure.
[0024] In the figures, similar components, and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description applies to any one of the similar components having the same first reference label irrespective of the second reference label.
[0025] FIG. 1 illustrates an exemplary block diagram representation of the proposed device for assessing refractory erosion and disbonding in an industrial equipment, in accordance with an embodiment of the present disclosure.
[0026] FIG. 2 illustrates an exemplary representation of the proposed device for assessing refractory erosion and disbonding in an industrial equipment, in accordance with an embodiment of the present disclosure.
[0027] FIG. 3 illustrates an exemplary representation of the proposed device with a magnified representation of a ring assembly of the device, in accordance with an embodiment of the present disclosure.
[0028] FIG. 4 illustrates an exemplary representation of the proposed device for assessing refractory erosion and disbonding in an industrial equipment, in accordance with an embodiment of the present disclosure.
[0029] FIG. 5 illustrates an exemplary flowchart representation of the proposed method for assessing refractory erosion and disbonding in an industrial equipment, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0030] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit, and scope of the present disclosure as defined by the appended claims.
[0031] FIG. 1 illustrates an exemplary block diagram representation of the proposed device for assessing refractory erosion and disbonding in an industrial equipment, in accordance with an embodiment of the present disclosure.
[0032] Illustrated in Fig. 1 is a block diagram representation of the device 100 for assessing refractory erosion and disbonding in an industrial equipment. The device includes a processor 102.
[0033] In an embodiment, the processor 102 is operatively coupled with a Light Detection and Ranging (LiDAR) scanner 104. The LiDAR scanner 104 is configured to capture high-resolution 3D surface data of refractory linings and transmits the data to the processor 102 for analysis. The LiDAR scanner 104 is configured to emit laser beams to capture a precise topography of the equipment, enabling generation of a detailed digital elevation model of the equipment. The LiDAR scanner 104 emits laser beams that bounce off the surface of the equipment and return to the LiDAR scanner 104. By measuring the time taken for the laser beams to return, the LiDAR scanner 104 calculates the exact distance to different points on the surface of the equipment. These distance measurements are used to create a high-resolution three-dimensional (3D) model, capturing the precise topography of the refractory lining. The collected data is processed to generate a detailed digital elevation model (DEM), which visually represents areas of erosion, disbonding, and wear. The DEM helps maintenance teams analyze refractory degradation, compare with historical data, and plan preventive maintenance actions efficiently.
[0034] In an embodiment, the processor 102 is operatively coupled with a deployment unit 106. The deployment unit 106 includes a pulley and rope system controlled by the processor 102 for vertical movement of the LiDAR scanner 104 inside the equipment. The deployment unit 106 is configured to implement an automated tension control mechanism to regulate speed and stability of vertical movement of the LiDAR scanner 104. The automated tension control mechanism precisely regulates the speed and stability of vertical movement of the LiDAR scanner 104 inside the equipment. This mechanism ensures that the LiDAR scanner 104 moves at a consistent and controlled pace, preventing sudden drops or oscillations that could affect scan accuracy. By dynamically adjusting the tension in the pulley and rope system, an optimal positioning, allowing for smooth and steady scanning at various elevations. The system automatically compensates for external forces such as gravity or mechanical vibrations, ensuring high-precision data acquisition without distortions. This controlled deployment enhances the efficiency and reliability of the inspection process, leading to accurate assessment of refractory conditions.
[0035] In an embodiment, the processor 102 is operatively coupled with a stabilization unit 108. The stabilization unit 108 controls the centering legs and a lower arm of the device 100 to stabilize and adjust the position of the LiDAR scanner 104, ensuring accurate data collection. The stabilization unit 108 manages the centering legs and the lower arm to maintain the LiDAR scanner 104 in a steady position during operation. The centering legs automatically expand or contract to adapt to the equipment's diameter, preventing unwanted movement or misalignment. The lower arm adjusts its orientation and tilt to ensure the LiDAR scanner 104 captures comprehensive 3D data, even in hard-to-reach areas. By actively stabilizing the LiDAR scanner 104, the stabilization unit 108 eliminates vibrations and positional shifts, ensuring precise and high-quality data acquisition. This mechanism enhances measurement accuracy, leading to reliable refractory erosion and disbonding assessments.
[0036] In an embodiment, the processor 102 is operatively coupled with a lower arm scanning unit 110. The lower arm scanning unit 108 extends and tilts within a 0° to 90° range to scan obstructed or hard-to-reach areas of the equipment, ensuring comprehensive refractory inspection.
[0037] In an embodiment, the processor 102 is operatively coupled with a motorized assembly 112. The motorized assembly 110 includes a DC motor and gear assembly, allowing full rotational coverage of the scanned area, controlled by the processor 102.
[0038] In an embodiment, the processor 102 is operatively coupled with a ring arrangement unit 114. The ring arrangement unit 112 uses pneumatic pistons to activate or deactivate the LiDAR scanner 104 as needed, based on processor 102.
[0039] In an embodiment, the processor 102 is operatively coupled with a plurality of sensors 116. The plurality of sensors 116 includes position sensors 116-2, inclination sensors 116-4, and force sensors 116-6 configured to provide real-time feedback on scanner alignment, movement, and contact stability.
[0040] In an embodiment, the processor 102 is operatively coupled with a communication unit 118. The communication unit 118 enables real-time transmission of inspection data to remote monitoring stations or cloud-based platforms for further analysis and reporting.
[0041] In an embodiment, the processor 102 is operatively coupled with a power management unit 120. The power management unit 120 regulates power supply to the various components, ensuring efficient energy use for prolonged operation.
[0042] In an embodiment, the processor 102 is operatively coupled with a user interface 122. The user interface 122 allows operators to monitor system status, control scanning operations, and view processed inspection results in real-time. The user interface 122 displays a color-coded 3D model of the refractory lining, highlighting areas of erosion and disbonding for easy interpretation. The user interface 122 also includes historical comparison tools, enabling users to track material degradation trends over time and make data-driven maintenance decisions. Operators can adjust scan parameters, control the deployment unit 106, and activate or deactivate the scanning process through an interactive control panel. Further, the user interface 122 displays detailed reports, including tabulated degradation data and maintenance recommendations, which can be exported for further analysis. The user interface 122 ensures efficient inspection management, reducing human error and enhancing operational efficiency.
[0043] FIG. 2 illustrates an exemplary representation of the proposed device for assessing refractory erosion and disbonding in an industrial equipment, in accordance with an embodiment of the present disclosure.
[0044] Illustrated in Fig. 2 is a representation of the device 100.
[0045] In an embodiment, the device 100 includes the LiDAR scanner 104 that serves as the core scanning unit, emitting laser beams to capture high-resolution 3D topography data of the refractory lining inside the industrial equipment. The LiDAR scanner 104 measures the remaining thickness of the refractory material, detecting erosion and disbonding with millimeter precision.
[0046] In an embodiment, a top hook 202 of the deployment unit 106 of the device 100 is mounted at an uppermost section of the equipment and acts as an anchor for the pulley and rope system, enabling the controlled vertical movement of the LiDAR scanner 104 within the vessel. The pulley is mounted on the top hook 202 with the rope enabling controlled vertical movement of the LiDAR scanner 104 to scan an entire profile of the equipment. This mechanism allows the LiDAR scanner 104 to be lowered or raised systematically for comprehensive scanning coverage. To ensure stability and accurate positioning, the device 100 features three centering legs 204, which extend outward to brace against the interior walls of the equipment. The centering legs 204 prevent unwanted movement or vibrations that could distort the scan results. Each of the three centering legs 204 is controlled by a pneumatic cylinder 206 of the stabilization unit 108, which allows for precise adjustments based on the diameter of the vessel, ensuring that the LiDAR scanner 104 remains stable and centered at every scanning position.
[0047] In an embodiment, to address blind spots and ensure complete data acquisition, the device 100 includes a lower arm scanning unit 110, which is configured to reach areas that are otherwise inaccessible due to obstructions. The lower arm scanning unit 110 is particularly useful in scanning curved, recessed, or structurally complex sections of industrial vessels such as risers and cyclones. The lower arm scanning unit 110 is dynamically controlled by a pair of pneumatic cylinders 208, which allow tilting between 0° and 90°, adjusting the scanning angle as required. The pneumatic cylinders 208 ensure that the lower arm scanning unit 110 can be precisely positioned to scan targeted sections without manual intervention.
[0048] In an embodiment, to ensure full 360° coverage of the internal surfaces of the equipment, the lower arm scanning unit 110is equipped with a DC motor 210, which drives a gear assembly that enables continuous rotation around its axis. This DC motor-driven rotation allows the LiDAR scanner 104 to map the entire circumference of the vessel, ensuring that no critical data points are missed.
[0049] In an embodiment, the device 100 provides a fully automated, non-destructive refractory inspection method, eliminating the risks associated with human entry into hazardous environments. The LiDAR scanner 104, in conjunction with the lower arm scanning unit 110 and the centering legs 204, ensures stable and precise scanning at multiple elevations within the equipment. The three centering legs 204 are configured to adjust automatically to a diameter of the equipment at each scan location to enable execution of multiple scans at varying elevations. The top hook 202 and the pulley and rope system enable smooth deployment, while the pneumatic cylinders 208 ensure stability and adaptability to different vessel diameters. The adjustability of the lower arm scanning unit 110 extends scanning capabilities to hard-to-reach areas, while the DC motor-driven rotation guarantees full 360° coverage. This combination of advanced scanning, automated deployment, and real-time data processing enhances inspection accuracy, reduces downtime, and supports predictive maintenance in high-temperature industrial equipment such as kilns, risers, and cyclones.
[0050] FIG. 3 illustrates an exemplary representation of the proposed device with a magnified representation of a ring arrangement unit of the device, in accordance with an embodiment of the present disclosure.
[0051] Illustrated in Fig. 3 is a representation 300 of the ring arrangement unit 114 of the device 100.
[0052] In an embodiment, the LiDAR scanner 104 is the core sensing component of the device 100, responsible for capturing high-resolution 3D topography data of refractory linings inside the industrial equipment. The LiDAR scanner 104 emits laser beams that reflect off the surface of the refractory material, allowing the device 100 to generate detailed digital elevation models for assessing erosion and disbonding. The LiDAR scanner 104 operates in real-time, continuously mapping the interior of vessels such as kilns, risers, and cyclones with millimeter-level precision.
[0053] In an embodiment, to ensure efficient control over its operation, the device 100 incorporates the ring arrangement unit 114, which is placed around the LiDAR scanner 104 to manage its activation and deactivation. The ring arrangement unit 114 serves as a mechanical switch, allowing the operator to engage or disengage the scanner as needed. The ring arrangement unit 114 is actuated by pneumatic pistons 302, which provide precise movement for controlling the operational state of the LiDAR scanner 104. When the device 100 needs to begin scanning, the pneumatic pistons 302 engage the ring arrangement 114, allowing the LiDAR scanner 104 to activate and commence data collection. Conversely, when scanning is completed or if adjustments are required, the pneumatic pistons 302 disengage the ring arrangement unit 114, deactivating the LiDAR scanner 104.
[0054] In an embodiment, the automated activation mechanism ensures that the LiDAR scanner 104 only operates when necessary, optimizing energy efficiency and component longevity. The ring arrangement unit 114 prevents accidental operation, reducing wear and tear on the LiDAR scanner 104. By utilizing pneumatic actuation, the device 100 ensures smooth and precise engagement of the LiDAR scanner 104 without mechanical strain. The operator can remotely control the activation and deactivation of the LiDAR scanner 104 without needing direct manual intervention. This feature enhances the safety and convenience of the inspection process, particularly in hazardous environments where direct access to the LiDAR scanner 104 is impractical.
[0055] In an embodiment, the precise control provided by the pneumatic pistons 302 ensures that the LiDAR scanner 104 remains in a stable operational state, reducing potential errors in data collection. The ring arrangement unit 114 also acts as a protective barrier, shielding the LiDAR scanner 104 from external disturbances that could interfere with its performance. The modular configuration of the device 100 allows for easy maintenance and quick replacement of the ring arrangement unit 114 or the pneumatic pistons 302 if required. By integrating this mechanism, the device 100 enables seamless and reliable LiDAR scanning in high-temperature industrial settings. The combination of LiDAR technology and automated activation control ensures a fully autonomous, non-contact, and precise refractory inspection solution.
[0056] In an embodiment, to ensure full coverage of the scanned areas, the lower arm scanning unit 110 is capable of rotating 360° around its axis. This rotation is powered by the DC motor 210 and the gear assembly 304, enabling continuous and seamless movement. The 360° rotation of the lower arm scanning unit 110 ensures that even the most challenging areas of the equipment are fully scanned, resulting in comprehensive 3D data for accurate erosion assessment.
[0057] FIG. 4 illustrates an exemplary representation of a top view of the proposed device for assessing refractory erosion and disbonding in an industrial equipment, in accordance with an embodiment of the present disclosure.
[0058] Illustrated in Fig. 4 is a representation 400 of a top view of the device 100 in which the centering legs 204 and the pneumatic cylinder 206 are visible.
[0059] In an embodiment, the three centering legs 204 play a crucial role in maintaining the stability and alignment of the LiDAR scanner 104 within the industrial equipment during the scanning process. The three centering legs 204 extend outward to brace against the inner walls of the vessel, ensuring that the LiDAR scanner 104 remains centered and steady at different scanning elevations. By preventing unwanted movement, the centering legs 204 help eliminate vibration-induced errors, leading to more accurate 3D mapping of the refractory surface.
[0060] In an embodiment, each of the three centering legs 204 is adjustable, allowing the device 100 to adapt to various diameters of industrial vessels such as kilns, risers, and cyclones. The pair of pneumatic cylinders 208 controls the movement of the lower arm scanning unit 110, which is responsible for scanning obstructed or hard-to-reach areas. The pair of pneumatic cylinders 208 allows the lower arm scanning unit 110 to tilt dynamically between 0° and 90°, providing flexibility in adjusting the scanning angle. The precise pneumatic control ensures smooth and controlled movement, reducing the risk of mechanical stress or misalignment.
[0061] In an embodiment, the pair of pneumatic cylinders 208 helps in fine-tuning the scanning approach, ensuring that even complex surface geometries are accurately captured. Together, the centering legs 204 and the pair of pneumatic cylinders 208 work in synchronization to optimize scanner positioning, maintain structural stability, and enhance data accuracy during refractory inspection. Their integration ensures that the device 100 operates autonomously and reliably, minimizing human intervention and improving inspection efficiency.
[0062] FIG. 5 illustrates an exemplary flowchart representation of the proposed method for assessing refractory erosion and disbonding in an industrial equipment, in accordance with an embodiment of the present disclosure.
[0063] Illustrated in Fig. 5 is a flowchart representation of the method 500 of assessing refractory erosion and disbonding in the industrial equipment. The method 500 begins with deploying 502, by the processor 102, the LiDAR scanner 104 into the equipment. The method 500 proceeds with capturing 504, by the processor 102, high-resolution three-dimensional profiles of a refractory lining of the equipment by performing scans at varying elevations. The method 500 proceeds with analysing 506, by the processor 102, the captured profiles to identify areas of erosion and disbonding with reference to design drawings or historical datasets. The method 500 ends with generating 508, by the processor 102, a color-coded map and a tabulated report comprising an extent and location of refractory degradation.
[0064] In an embodiment, the method 500 begins with the deployment of the LiDAR scanner 104 into the industrial equipment, ensuring precise positioning using the pulley and rope system. The top hook 202 secures the deployment unit 106, allowing controlled vertical movement of the scanner inside the vessel. As the LiDAR scanner 104 is lowered, the three centering legs 204 extend outward to brace against the inner walls of the equipment, ensuring stability and alignment during data collection.
[0065] In an embodiment, the LiDAR scanner 104 emits laser beams to capture high-resolution three-dimensional profiles of the refractory lining. Multiple scans are performed at varying elevations to generate a comprehensive digital model of the interior. The lower arm scanning unit 110, controlled by the pair of pneumatic cylinders 208, adjusts dynamically between 0° and 90° to scan hard-to-reach areas. The 360° rotation mechanism, powered by the DC motor 210 and the gear assembly 304, ensures full coverage of the refractory surface.
[0066] Once scanning is complete, the captured 3D point cloud data is processed to create a detailed topographical representation of the refractory lining. The device 100 analyses the scanned profiles, identifying regions where erosion and disbonding have occurred. To enhance accuracy, the scanned data is compared with design drawings or historical datasets, highlighting deviations from the original refractory thickness. Advanced algorithmic processing identifies critical wear zones, predicting potential refractory failures. A color-coded map is then generated, visually representing the extent and severity of degradation across the scanned area. Areas with minimal wear appear in green, while moderate and severe erosion are marked in yellow and red, respectively. In parallel, a tabulated report is produced, detailing the precise location, depth, and extent of refractory degradation. The report provides valuable insights for proactive maintenance planning, allowing plant operators to schedule repairs before significant damage occurs. The automated inspection process eliminates the need for manual entry, significantly enhancing operator safety. The non-contact LiDAR-based approach ensures greater accuracy and repeatability compared to conventional methods.
[0067] In an embodiment, the remote operation capability of the device 100 enables real-time data transmission to maintenance teams, facilitating quick decision-making. The ring arrangement unit 114, actuated by the set of pneumatic pistons 302, controls the activation and deactivation of the LiDAR scanner 104 as needed. By automating the scanning process, the method 500 minimizes human error and improves overall inspection efficiency. The collected data also contributes to long-term condition monitoring, helping industries optimize refractory material lifespan. With a fully digitalized inspection workflow, plant operators can reduce downtime, enhance equipment reliability, and improve cost-effectiveness. The integration of LiDAR scanning with Augmented Reality SCAN (ARSCAN) technology ensures precise, repeatable, and high-resolution refractory assessments.
[0068] In an embodiment, the processor 102 is configured to enable historic comparison and monitoring of refractory material degradation, facilitating efficient maintenance planning and extension of the operational life of the equipment. The processor 102 plays a crucial role in analysing and comparing historical refractory data with newly acquired LiDAR scan results to monitor material degradation over time. By identifying patterns of erosion and disbonding, the device 100 enables maintenance teams to detect early signs of wear and schedule preventive repairs before critical failures occur. The device 100 automatically processes the scanned data, overlaying it on previous inspection records or design specifications to highlight areas with significant changes. This predictive maintenance approach helps in optimizing repair schedules, reducing unexpected downtime, and minimizing operational costs. As a result, the device 100 effectively contributes to extending the operational life of industrial equipment by ensuring timely and data-driven maintenance decisions.
[0069] In an embodiment, industrial equipment such as cyclones, risers, and kilns operate under extreme conditions, requiring refractory linings to withstand high temperatures and intense processes while providing insulation. Over time, these harsh conditions cause refractory degradation, leading to erosion, disbonding, and material damage, which affect vessel performance, safety, and efficiency. Various factors, including operational age, temperature fluctuations, airflow, catalyst type, and material properties, influence the rate of refractory wear. The device 100 enables operators to monitor and quantify refractory degradation with each turnaround, ensuring accurate assessment of maintenance needs. The device 100 is configured to inspect equipment ranging from 500 mm to 30,000 mm in diameter, covering a broad range of industrial applications. The LiDAR scanner 104 operates at temperatures up to 50°C, ensuring functionality in challenging environments. The LiDAR scanner 104 features a tilt angle adjustable from 0° to 90°, enabling comprehensive surface coverage. Further, the device 100 provides a continuous 360° rotation, ensuring full scanning coverage of the refractory lining. By offering detailed 3D mapping and analysis, the device 100 helps operators make informed maintenance decisions, reducing downtime and operational risks. This automated and precise solution enhances safety, efficiency, and the overall lifespan of industrial equipment.
[0070] A use case of the device 100 is described herein. In a cement factory, the refractory lining inside a rotary kiln is subject to extreme temperatures and constant mechanical stress, leading to erosion and disbonding over time. Traditional inspection methods require manual entry, exposing workers to high-temperature environments and potential safety hazards. To overcome these challenges, the device 100 is deployed to inspect the refractory condition of the kiln without requiring human entry. The device 100 is positioned at the access point of the kiln, and the LiDAR scanner 104 is lowered inside using the pulley and rope mechanism for precise deployment. The three centering legs 204 extend outward, stabilizing the LiDAR scanner 104 within the cylindrical structure of the kiln to eliminate vibrations. As the LiDAR scanner 104 moves downward, the LiDAR scanner 104 performs 3D scans at varying elevations, generating a high-resolution topographical profile of the refractory lining. The lower arm scanning unit 110, controlled by the pneumatic cylinders 208, dynamically adjusts its angle between 0° and 90°, ensuring that hidden or obstructed areas are fully captured. The DC motor 210 and the gear assembly 304 allow for 360° rotation, covering the entire inner surface of the kiln. The scanned data is processed to detect refractory wear, and deviations are identified by comparing the data against historical thickness records or design drawings. A color-coded map is generated, where green areas indicate minimal wear, while yellow and red regions highlight significant erosion. A tabulated report provides detailed information on erosion depth, location, and affected zones, enabling maintenance teams to prioritize repairs. The device 100 transmits real-time data to the operators, ensuring timely and informed decision-making. By eliminating the need for manual inspections, the device 100 enhances safety, accuracy, and efficiency while reducing kiln downtime. With predictive maintenance capabilities, the cement factory can extend the lifespan of refractory materials and optimize operational costs. The automated and repeatable nature of the inspection ensures consistent quality control and improves plant reliability.
[0071] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions, or examples, which are comprised to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
ADVANTAGES OF THE INVENTION
[0072] The device 100 eliminates the need for manual entry into high-temperature industrial equipment, reducing risks associated with human exposure to extreme environments and hazardous conditions
[0073] Utilizing LiDAR-based ARSCAN technology, the device 100 captures high-resolution 3D profiles, enabling precise measurement of refractory erosion and disbonding with millimeter-level accuracy.
[0074] The deployment unit, including the lower arm scanning unit with 360° rotation, ensures full inspection of hard-to-reach areas by the device 100, overcoming limitations of traditional camera-based or visual assessments.
[0075] By enabling predictive maintenance, the device 100 helps in early detection of refractory degradation, allowing timely repairs and preventing costly unplanned shutdowns of industrial equipment.
[0076] The device 100 ensures consistent and reliable results with minimal human intervention, improving efficiency, repeatability, and long-term condition monitoring of refractory linings.
, Claims:1. A device (100) for assessing refractory erosion and disbonding in an industrial equipment, the device (100) comprising:
a LiDAR scanner (104) configured to capture high-resolution three-dimensional (3D) surface data of refractory linings;
a deployment unit (106) comprising a pulley and a rope configured to allow controlled vertical movement of the LiDAR scanner (104) inside the equipment;
a stabilizer unit (108) comprising at least three centering legs (204), each of the at least three centering legs (204) controlled by pneumatic cylinders (206), ensuring stable and centered positioning of the LiDAR scanner (104) during operation;
a lower arm scanning unit (110), attached to the LiDAR scanner (104), controlled by a pair of pneumatic cylinders (208), enabling tilt adjustments of a lower arm within a 0° to 90° range to scan obstructed or non-visible areas;
a motorized assembly (112) comprising a DC motor (210) and a gear assembly (304) and configured to allow the lower arm to rotate fully around an axis for comprehensive coverage;
a ring arrangement unit (114) configured to enable activation and deactivation of the LiDAR scanner (104); and
a processor (102), operatively coupled with the LiDAR scanner (104), the deployment unit (106), the stabilizer unit (108), the lower arm scanning unit (110), the motorized assembly (112), the ring arrangement unit (114), the processor (102) being configured to:
deploy the LiDAR scanner (104) into the equipment;
capture high-resolution three-dimensional profiles of a refractory lining of the equipment by performing scans at varying elevations.
analyse the captured profiles to identify areas of erosion and disbonding with reference to design drawings or historical datasets; and
generate a color-coded map and a tabulated report comprising an extent and location of refractory degradation.
2. The device (100) as claimed in claim 1, wherein the LiDAR scanner (104) is configured to emit laser beams to capture a precise topography of the equipment, enabling generation of a detailed digital elevation model of the equipment.
3. The device (100) as claimed in claim 1, wherein the pulley is mounted on a top hook (202) with the rope enabling controlled vertical movement of the LiDAR scanner (104) to scan an entire profile of the equipment.
4. The device (100) as claimed in claim 1, wherein the at least three centering legs (204) are configured to adjust automatically to a diameter of the equipment at each scan location to enable execution of multiple scans at varying elevations.
5. The device (100) as claimed in claim 1, wherein the ring arrangement unit (114) is actuated by a plurality of pneumatic pistons (302) configured to allow control over an operation of the LiDAR scanner (104).
6. The device (100) as claimed in claim 1, wherein the processor (102) is configured to enable historic comparison and monitoring of refractory material degradation, facilitating efficient maintenance planning and extension of the operational life of the equipment.
7. The device (100) as claimed in claim 1, wherein the deployment unit (106) is configured to implement an automated tension control mechanism to regulate speed and stability of vertical movement of the LiDAR scanner (104).
8. A method (500) for assessing refractory erosion and disbonding in an industrial equipment, the method (500) comprising steps of:
deploying (502), by a processor (102), a LiDAR scanner (104) into the equipment;
capturing (504), by the processor (102), high-resolution three-dimensional profiles of a refractory lining of the equipment by performing scans at varying elevations;
analysing (506), by the processor (102), the captured profiles to identify areas of erosion and disbonding with reference to design drawings or historical datasets; and
generating (508), by the processor (102), a color-coded map and a tabulated report comprising an extent and location of refractory degradation.