TECHNICAL FIELD
[001] Present disclosure generally relates to the field of Metallurgy. Particularly, but not exclusively, the present disclosure relates to a cooling conduit associated with a metallurgical furnace. Further, embodiments of the disclosure disclose a device and a system for monitoring thickness of the conduit in the metallurgical furnace.
BACKGROUND OF THE DISCLOSURE
[002] Blast furnace is a vertical column that produces liquid metals i.e., molten iron from raw ores in the presence of other elements, such as air, coke, sinter, fluxes and so on. The molten iron produced in the blast furnace is further employed in steel making process, among several other purposes. Production of iron in molten phase in bulk quantities in a blast furnace involves generation of enormous amount of heat. The inner body of the blast furnace is essentially fabricated and lined with a refractory material so that the lining can withstand high degrees of furnace temperatures. Apart from providing the refractory lining, a typical blast furnace also employs one or more cooling arrangements to continuously remove heat from the furnace, so that the furnace can remain operational for extended periods of time without getting interrupted by complications or hazards associated with high degrees of temperatures. Over the past few decades, two types of cooling systems have been deployed extensively in blast furnaces. First one is the cooling plate type and the second one is cooling stave type, each having its own merits and demerits.
[003] Cooling plates [commonly known as flat plate coolers] are tongue shaped members which protrude through a single hole in the furnace shell and stick into the vessel. Such plates are securely fastened to the shell and the plates are connected to an external cooling source. These cooling plates are often positioned in staggered rows around the furnace. The spaces between these plates on the inside of the furnace are typically filled with a brick material to form a solid refractory system against the cooling plates and inside furnace wall. Cooling staves, on the other hand, are elements placed between the inner side of the shell of the furnace and the refractory lining. The staves are typically formed with a series of tubes to carry a heat transfer fluid, such as water. The staves can cool a furnace uniformly as they are installed strategically to almost completely cover or surround the steel shell of the furnace. The staves are typically bolted to the furnace wall and may have small gaps between them to allow for installation. The cooling staves are also defined

with a ribbed profile that provide slots for mounting refractory bricks to form the innermost lining of the furnace, thereby serving as fins which enhance convective heat transfer.
[004] Cooling staves, despite being widely employed in comparison to cooling plate counterparts in the blast furnaces, face a number of shortcomings. The cooling staves, typically manufactured of metals like copper, cast iron or cast steel, have to endure a greater bandwidth of temperatures of the furnace which are transient in nature. This results in wear of cooling staves which can be aggravated by few other factors, such as burden speed, hardness of burden material, material pressure and so on. The internal surfaces of cooling staves, especially those adjacent to the ribbed profile experience premature wear under the influence of flow of hot metal and gases. This can be accompanied with development and propagation of cracks due to stresses arising from pressure exerted by gaseous constituents as well as immense temperatures of the furnace. If left unmonitored, the cracks, as well as the progressive wear of the cooling staves may result in ingress of the coolant, like water, into the furnace, leading to a devastating condition.
[005] Present disclosure is directed to overcome one or more limitations stated above or any other limitations associated with the prior arts.
SUMMARY OF THE DISCLOSURE
[006] One or more shortcomings of the prior arts are overcome by the device and the system as disclosed in the present disclosure and additional advantages are provided through the device and the system. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.
[007] In one non-limiting embodiment of the present disclosure, a device for monitoring thickness of a conduit is disclosed. The device includes a strip comprising a plurality of sensors securable to at least a portion of an inner surface of the conduit, where leads of the strip extend from at least one of an inlet and an outlet of the conduit. The device includes at least two support members, each extending from either the inlet and the outlet of the conduit, and being configured to support the strip longitudinally relative to the at least a portion of the inner surface of the conduit.

The plurality of sensors is configured to transmit and receive signals through the conduit to monitor the thickness of the conduit.
[008] In an embodiment, the conduit is a cooling stave of a metallurgical furnace. Further, the inlet and the outlet extend substantially perpendicular to a longitudinal portion of the conduit.
[009] In an embodiment, the at least two support members and the leads of the strip extending from the inlet and the outlet are supported by couplers.
[0010] In an embodiment, each of the couplers is a T-coupler defined with a first section, with one end of the first section connectable with either of the inlet and the outlet, and an other end opposite to the one end connectable to a hose. Further, the T-coupler is defined with a second section transversely extending from a portion of the first section, the second section comprising at least one flange to secure one of the at least two support members and the leads of the strip.
[0011] In an embodiment, each of the at least two support members is defined with a gripping portion configured to secure the strip with at least a portion of the conduit.
[0012] In an embodiment, the conduit is circulated with a cooling fluid routed from the inlet towards the outlet, and wherein the cooling fluid is water. Further, the cooling fluid forms an acoustic coupling medium between the plurality of sensors and the at least a portion of the inner surface of the conduit.
[0013] In an embodiment, the plurality of sensors is arranged in an array, and each of the plurality of sensors is an ultrasonic sensor.
[0014] In another non-limiting embodiment, a system for monitoring thickness of a conduit in a metallurgical furnace is disclosed. The system includes a device having a strip comprising a plurality of sensors securable to at least a portion of an inner surface of the conduit, where leads of the strip extend from at least one of an inlet and an outlet of the conduit. The device includes at least two support members, each extending from either the inlet and the outlet of the conduit, and being configured to support the strip longitudinally relative to the at least a portion of the inner surface of the conduit. The plurality of sensors is configured to transmit and receive signals through

the conduit to monitor the thickness of the conduit. Further, the system includes a control unit communicatively coupled to the plurality of sensors. The control unit is configured to receive signals corresponding to detection of the thickness of the conduit from the plurality of sensors, and determine thickness of the conduit at one or more locations based on the signals received from the plurality of sensors.
[0015] In an embodiment, the system comprises a display unit communicatively coupled to the control unit, the control unit is configured to display the detected thickness of the conduit through the display unit.
[0016] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined together to form a further embodiment of the disclosure.
[0017] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES
[0018] The novel features and characteristics of the disclosure are set forth in the appended description. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:
[0019] FIG. 1A illustrates a schematic view of a metallurgical furnace showing a magnified view of a cooling stave, according to an embodiment of the present disclosure;
[0020] FIG. 1B illustrates a schematic sectional view of the cooling stave shown in FIG. 1A depicting the inlet and the outlet;

[0021] FIG. 2 illustrates a schematic sectional view of a conduit for cooling the metallurgical furnace having a system for monitoring thickness of the conduit, according to an embodiment of the present disclosure;
[0022] FIG. 3 illustrates a schematic view of a support member employed in the system of FIG. 2;
[0023] FIG. 4 illustrates a schematic top view of a flange of a coupler viewed along X-X in FIG. 2, according to an embodiment of the present disclosure;
[0024] FIG. 5 illustrates a schematic view of a T-coupler employed in the system of FIG. 2, according to an embodiment of the present disclosure;
[0025] FIGS. 6A and 6B illustrate schematic side view and front view, respectively, of the strip having a plurality of sensors configured to detect thickness of the conduit, according to an embodiment of the present disclosure;
[0026] FIG. 6C illustrates perspective view of an exemplary strip having the plurality of sensors, according to an embodiment of the present disclosure;
[0027] FIG. 7 illustrates a schematic sectional view of the conduit having the device for monitoring thickness of the conduit with another configuration of a T-coupler, according to an embodiment of the present disclosure; and
[0028] FIG. 8 is a flowchart depicting steps involved in monitoring the thickness of the conduit using the system of FIG. 2.
[0029] The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the device and the system illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION
[0030] The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the description of the disclosure. It should also be realized by those skilled in the art that such equivalent methods do not depart from the scope of the disclosure. The novel features which are believed to be characteristic of the disclosure, as to method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.
[0031] In the present disclosure, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.
[0032] While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.
[0033] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover non-exclusive inclusions, such that a device or a system that comprises a list of acts does not include only those acts but may include other acts not expressly listed or inherent to such a device or a system. In other words, one or more acts in a device or a system proceeded by “comprises… a” does not, without more constraints, preclude the existence of other acts or additional acts in the device or the system.
[0034] Embodiments of the present disclosure disclose a device for monitoring thickness of a conduit, for example, a cooling stave of a metallurgical furnace. The device includes a strip

comprising a plurality of sensors securable to at least a portion of an inner surface of the conduit, where leads of the strip extend from at least one of an inlet and an outlet of the conduit. The sensors may include ultrasonic sensors arranged as an array on the strip which may be configured to send and receive signals through one or more sections of the inner surface of the conduit. The device also includes at least two support members, each extending from either the inlet and the outlet of the conduit, and being configured to support the strip longitudinally relative to the at least a portion of the inner surface of the conduit. The inlet and the outlet extend substantially perpendicular to a longitudinal portion of the conduit. In an embodiment, the conduit is circulated with a cooling fluid, for example, water, to remove heat from the furnace. The cooling fluid is routed from the inlet towards the outlet. Further, the cooling fluid forms an acoustic coupling medium between the plurality of sensors and the at least a portion of the inner surface of the conduit.
[0035] In an embodiment, the at least two support members and the leads of the strip extending from the inlet and the outlet are supported by couplers, one coupler at each of the inlet and the outlet. In an embodiment, each coupler is a T-coupler defined with a first section, with one end of the first section connectable with either of the inlet and the outlet, and an other end opposite to the one end connectable to a hose. Further, the T-coupler is defined with a second section transversely extending from a portion of the first section. The second section has at least one flange which secures one of the at least two support members along with the leads of the strip. Further, each of the at least two support members is defined with a gripping portion configured to secure the strip with at least a portion of the conduit.
[0036] Embodiments of the present disclosure also disclose a system for monitoring the thickness of the conduit in a metallurgical furnace. The system, in addition to the device disclosed in the above paragraphs, includes a control unit interfaced with the device. The control unit is communicatively coupled to the plurality of sensors present in the strip and is configured to receive signals corresponding to detection of the thickness of the conduit from the plurality of sensors. Based on signals received from the plurality of sensors, the control unit is configured to determine thickness of the conduit at one or more locations in the conduit. The system also includes the T-coupler described above where the T-coupler includes a mechanism configured to adjust position of each of the at least two support members relative to the conduit, the inlet, and the outlet. The system further includes a display unit which is communicatively coupled to the control unit, where

the control unit is configured to display the detected thickness of the conduit through the display unit.
[0037] The present disclosure is explained with the help of figures. However, such exemplary embodiments should not be construed as limitations of the present disclosure since the device and the system disclosed may be used or employed in any metallurgical process or any metallurgical facility. A person skilled in the art may envisage various such embodiments without deviating from scope of the present disclosure.
[0038] FIGS. 1A and 1B are exemplary embodiments of the present disclosure showing schematic views of a metallurgical furnace (50) and a cooling stave (52), respectively. Metallurgical furnace, such as a blast furnace, requires arrangements to extract heat on a continuous basis and in an efficient manner to ensure functioning for extended durations without any complications or potential hazards. A blast furnace has an inner refractory lining (not shown) which is designed and fabricated to endure elevated temperatures, for example, close to 1900O C, which may fluctuate from time to time depending on the operational characteristics of the furnace. Refractory bricks may be arranged in a predefined manner to form the refractory lining. The refractory lining and the shell (50A) of the blast furnace (50) may be equipped with cooling arrangements, such as the cooling stave (52), for extraction and removal of heat from the furnace. A cooling stave (52) may use a cooling medium, such as a cooling fluid (CF), which may convectively extract/absorb heat from the refractory lining, and the shell (50A) altogether, to maintain the temperature of the shell (50A) within permissible/safe levels.
[0039] As shown in FIG. 1A, the cooling stave (52) may be in the form of a conduit [the term “conduit” is interchangeably used in place of cooling stave throughout the specification] which may extend vertically, substantially vertical or at other inclinations to define a column like structure. In an embodiment, orientation of longitudinal portion of the cooling stave (52) may conform to the profile of the shell (50A) of the furnace (50). The longitudinal profile of the conduit (1) may be such that it extends for predefined dimensions relative to the furnace inner shell (not shown) and the refractory lining (not shown) so as to optimize heat transfer. In an embodiment, the furnace (50) may have a number of such cooling staves (52) or conduits to effectively remove heat from the furnace (50) during operation. The cooling stave (52) or the conduit may be

interposed between the shell (50A) of the furnace (50) and the refractory lining. In an embodiment, the cooling stave (52) is made of material selected from metallic groups like copper, cast iron, cast steel, etc., or an alloy. As shown in FIG. 1B, the cooling stave (52) may define a channel or a passage (54) extending longitudinally within. The passage or the channel (54) may be bounded by a wall of the cooling stave (52) having a predetermined thickness to form a shell [hollow] like structure. The passage or the channel (54) may be intended to route a cooling fluid, like water, so that the cooling fluid may flow in heat exchange communication with the inner layers of the furnace (50) including the refractory lining. As the cooling fluid flows, it may extract heat from the refractory lining, and therefore, the shell (50A) by one of the heat transfer modes, for instance, by convection. In an embodiment, the channel, or the passage (54) may have a height ranging from 2.5 m to 3 m. Further, the cooling stave may include an inlet (53) and an outlet (52), both having flow passages (53A) and (52A) respectively, which will be explained in detail in forthcoming paragraphs. The cooling stave (52) may also have ribbed profile to assist enhancement of heat removal rate by the cooling fluid (CF). The ribbed profile (51R) may provide slots (51S) for mounting refractory bricks to form the innermost lining of the furnace (50), thereby serving as fins which enhance convective heat transfer.
[0040] Reference is now made to FIG. 2 which is an exemplary embodiment illustrating a system (100) associated with a cooling stave (52) shown in FIGS. 1A and 1B, which will be hereafter referred to as conduit (1). The conduit (1) defines the channel or the passage (4) to allow flow of the cooling fluid (CF), for example, water. The direction of flow of the cooling fluid (CF) is indicated by arrows referenced by reference sign (FD). To route the cooling fluid (CF), the conduit (1) may be defined with an inlet (3) and an outlet (2), both of which may extend perpendicularly or substantially perpendicular from the conduit (1) as shown. The phrase substantially perpendicular herein above and below refers to a nearly perpendicular orientation of the inlet (3) and the outlet (2) relative to the longitudinal portion of the conduit (1). In other embodiments, the inlet (3) and the outlet (2) may angularly oriented relative to the longitudinal portion of the conduit (1), depending on the profile of the furnace (50) as well as design requirements. The innermost portion of the conduit (1) may be defined with ribbed profile having a plurality of ribs (1R) which may be spaced apart from one another longitudinally. In an embodiment, the ribs (1R) may have profiles including, but not limited to dovetail profile, trapezoidal, square, rectangular, or any other

shape. Each rib may define a slot (1L) with respect to an adjacent rib so that the ribs (1R) manifest as fins which may take part in enhancement of heat extraction rate. The slots (1L) may also allow mounting of refractory bricks so that the ribs (1R) together with the slots (1L) containing the refractory bricks may define innermost lining of the furnace (50). This configuration of the conduit (1) renders an inner surface (1S) of the conduit (1) get exposed to the effects of temperatures of the furnace (50). For example, the inner surface (1S) of the conduit (1) may be susceptible to high temperatures resulting from various chemical reactions and combustions inside the furnace (50), as well as to dynamic effects due to flow of hot metal and gases. Hence, physical characteristics such as thickness, density, etc., need to be monitored on a regular basis to ensure safe and uninterrupted operation of the conduit (1).
[0041] To monitor the physical properties of the conduit (1) which may include, but not limited to thickness, density, etc., especially at the inner surface (1S), the present disclosure discloses a device (10) which forms a part of the system (100) mentioned above. The device (10) may include a strip (5) comprising a plurality of sensors (6) securable to at least a portion (1A) of the inner surface (1S) of the conduit (1). The location of plurality of sensors (6) in the strip (5) may correspond to detection of thickness at various points of the conduit (1) along the inner surface (1S). The strip (5) having the sensors (6) may be positioned adjacent to the inner surface (1S) of the conduit (1) such that the sensors (6) may have access to the thickness of the inner surface (1S). In other words, the inner surface (1S) may be completely exposed to the sensors (6) in the strip (5). In an embodiment, the inner surface (1S) of the conduit (1) may abut or maintain contact with the plurality of sensors (6) when the strip (5) is supported inside the channel or the passage (4). In order to position the strip (5) inside the channel or the passage (4), one of the inlet (3) and the outlet (2) may be used. For instance, the strip (5) containing sensors (6) may be maneuvered or guided through the inlet (3) or the outlet (2) until the desired positioning of the strip (5) is attained, as depicted in FIG. 2. Maneuvering or guiding the strip (5) through the inlet (3) or the outlet (2) may be performed manually or using tools and devices. Once the strip (5) is in position relative to the inner surface (1S), the leads (5A, 5B) of the strip (5) may be drawn out either from one or both the inlet (3) and the outlet (2). In an embodiment, the leads (5A, 5B) of the strip (5) are inclusive of the wire harness as well as the electrodes of the strip (5). The leads (5A, 5B) of the strip (5) extending out of the conduit (1) through the inlet (3) and/or the outlet (2) may be connected to an

electrical source for powering the sensors (6). In an embodiment, the leads (5A, 5B) may be guided along the internal walls of the inlet (3) and/or outlet (2) of the conduit (1) so that the leads (5A, 5B) do not interfere with or impede the flow of the cooling fluid (CF). The inflow and outflow are depicted by numerals (4I) and (4O), respecitvely.
[0042] In an embodiment, the sensors (6) may be ultrasonic sensors which transmit signals in the form of ultrasonic waves (acoustic/ultrasonic sound waves) which penetrate and propagate through the inner surface (1S) of the conduit (1). The signals so propagating may get reflected back to the sensors (6) which may be indicate thickness the inner surface (1S). the thickness of the conduit (1) at the inner surface (1S) is susceptible to wear under the influence of temperatures, fluid pressures, dynamic effects of flowing hot metal and gases, and so on. In another embodiment, the sensors (6) emitting the ultrasonic signals may detect thickness of the inner surface (1S) of the conduit (1). The transmitted and reflected signals may be accompanied with variations in at least one of frequency, phase, amplitude, and so on which may be indicative of thickness of the inner surface (1S). To attain this, the sensors (6) may be oriented normally relative to the inner surface (1S) so that the transmission and reception of signals may be optimized. In an embodiment, each sensor of the plurality of sensors (6) may have an integrated transmission and reception modules [not shown]. In another embodiment, other forms of non-contact sensors which may be electronic, electro-mechanical or radiation-based may be employed in place of ultrasonic sensors. Examples include piezoelectric transducer, electronically operated pressure transducer, X-ray based sensor, infrared/UV sensors, radars which make use of radio waves, and so on. The signals transmitted from and received by the sensors (6) may be subjected to subsequent signal processing procedures to ascertain the thickness, at the inner surface (1S) of the conduit (1). In an embodiment, the strip (5) may have a plane which conforms with the contour of the conduit (1) so that the sensors (6) may always remain normal or substantially normal to the inner surface (1S) of the conduit (1). This may be essential when there are transitions in the contour of the shell (50A), and hence, the conduit (1) so that the strip (5) may also have transitions conforming to those in the conduit (1).
[0043] Reference is now made to FIGS. 3, 4 and 5 along with FIG. 2. FIG. 3 illustrates an exemplary support member (7) which supports the strip (5) inside the conduit (1), while FIG. 4 illustrates top view of a flange (8F) in a coupler (8) associated with the support member (7). FIG. 5 illustrates a schematic front view of the coupler (8) which assists in connecting the support

member (7) relative to the conduit (1). Once the strip (5) having sensors (6) are positioned inside the conduit (1), support members (7X, 7Y) may be inserted from each of the inlet (3) and the outlet
(2) to support or hold the strip (5) longitudinally relative to the inner surface (1S). This
configuration can be seen clearly in FIG. 2. The support members (7X, 7Y) may be guided through
each of the inlet (3) and the outlet (2) until they contact the strip (5), and may be restrained in
desired position so as to firmly hold or secure the strip (5) against the inner surface (1S). This
ensures that the sensors (6) are precisely positioned corresponding to a plurality of measuring
points on the inner surface (1S). In an embodiment, the sensors (6) may contact the inner surface
(1S) of the conduit (1) under the pressing forces of the support members (7X, 7Y) to serve as
contact type sensors. In another embodiment, the support members (7X, 7Y) may ensure non-
contact of the sensors (6) relative to the inner surface (1S) by sturdily supporting the ends or
substantial end portions of the strip (5). This configuration allows incorporation of non-contact
type sensors which may send signals from a distance towards the inner surface (1S). Once the strip
(5) is supported by the support members (7X, 7Y), cooling fluid (CF) may be routed from the inlet
(3) towards the outlet (2) to remove heat from the furnace under operating conditions. Water as
the cooling fluid (CF) may serve as an acoustic coupling medium which ensures propagation of
signals, for example, ultrasonic (acoustic) signals of the (ultrasonic) sensors (6). In an embodiment,
the inlet (3) and outlet (2) positions may be interchanged.
[0044] As shown in FIG. 3, each support member (7X, 7Y) [collectively referred by numeral ‘7’] may have a horizontal member (7H) and a vertical member (7V), each interconnected by a connecting member (7C). The angle between the horizontal and vertical members (7H, 7V) may be fixed or adjusted depending on requirement. In an embodiment, the connecting member (7C) may be a fastener, like a fixed nut, a coupling element, or any other connecting means. In another embodiment, each of the horizontal and vertical members (7H, 7V) may resemble a stick, a bar, or a rod which may be manufactured using materials like polymers, metals [less reactive/unreactive with cooling fluids] and so on. In an embodiment, the support members (7) ensure that the strip (5) is maintained under desired tension so that the sensors (6) may always be biased to stay close to the inner surface (1S) for measurements. In an embodiment, the strip (5) may be manufactured of a flexible material, including, but not limited to a polymeric material, so that there is flexibility with respect to maneuvering and positioning the strip (5) relative to the inner surface (1S). The

support members (7), as shown in FIG. 3, may have a gripping portion (7A) configured to secure the strip (5) with at least a portion (1A) of the conduit (1), for example, the inner surface (1S). In an embodiment, the gripping portion (7A) may be a washer, a flanged member, a clamp, and so on. The support members (7X, 7Y) along with the leads (5A, 5B) may be supported by a coupler (8) [see FIG. 2] which will be explained below.
[0045] FIG. 4 shows top view of a flange (8F) of the coupler (8) which secures the support members (7X, 7Y) and the leads (5A, 5B) inside the inlet (3) and the outlet (2). Reference is also made to FIG. 4 as FIG. 4 is considered along X-X in FIG. 2. A mechanical coupler (8X, 8Y), as shown in FIG. 2, may be provided at ends of each of the inlet (3) and the outlet (2) to support and secure the leads (5A, 5B) and the support members (7X, 7Y). The coupler (8X, 8Y) may be connected such that it may provide passageway for routing the cooling fluid (CF) into the inlet (3) as well as out of the outlet (2). In an embodiment, each coupler (8X, 8Y) is a T-coupler defined with a first section (8A) which may be horizontal, and a second section (8B) extending transversely from a portion of the first section (8A) to form an inverted T-shaped structure. This can be seen clearly in FIG. 5. As evident from FIG. 5, the first section (8A) may extend horizontally to define two distinct ends i.e., one end (8P) which may adjoin [secured with] the inlet (3) and the outlet (2), and another end (8Q) distal from the one end (8P) which may be fluidly connected to a hose (H) for routing the cooling fluid (CF). The first end (8P) may be fastened with the inlet (3) and the outlet (2). Further, the T-coupler (8X, 8Y) may be defined with a second section (8B) transversely extending from a portion of the first section (8A) as shown in FIG. 2 and FIG. 5. The second section (8B) may be fitted with at least one flange (8F) which secures the support members (7X, 7Y) and the leads (5A, 5B) of the strip (5) extending inside the inlet (3) and the outlet (2). The connection can be clearly seen in FIG. 2. The flange (8F), as shown in FIG. 5, may be sandwiched between extensions (8M, 8N) defined in the second section (8B). Further, the flange (8F) may be secured to extensions (8M, 8N) using fasteners (8S) like studs, bolts, etc. Referring back to FIG. 2 along with FIG. 4, the flange (8F) may have one or more mechanisms (9) to secure the support members (7X, 7Y), as well as the leads (5A, 5B). The leads (5A, 5B) and the respective support members (7X, 7Y) may be guided together or may be spaced apart as shown in FIG. 2 inside the inlet (3) and the outlet (2). The mechanism (9) may allow horizontal adjustment of the support members (7X, 7Y) and the leads (5A, 5B) relative to the inner surface (1S), while the connecting

member (7C) allows vertical adjustment of the support members (7X, 7Y) and the leads (5A, 5B). In another embodiment, each of the mechanism (9) and the connecting member (7C) may allow both horizontal and vertical adjustments of the support members (7X, 7Y) and the leads (5A, 5B). The flange (8F) may have slot cut (8R) or a rail like arrangement which may allow movement of the mechanism (9) horizontally for horizontal adjustment of the support members (7X, 7Y) and the leads (5A, 5B).
[0046] With reference to FIG. 2 and FIG. 3, it may be appreciated that once the strip (5) is secured over the inner surface (IS) with the help of horizontal member (7H), the vertical member (7V) is coupled with the horizontal member (7H) using the connector (7C). The first section (8A) will be placed and coupled with the inlet (3). The flange (8F) will be placed over the vertical member (7V) in such a manner that the vertical member (7V) passes through opening of the flange (8F). The strip (5) will be further adjusted over the slot cut (8R) of the flange (8F). The second section (8B) will be placed over the flange (8F) and fixedly coupled with the first section (8A) at the extensions (8M ,8N) using the fasteners (8S).
[0047] Now reference is made to FIGS. 6A-6C which illustrate exemplary side view, front view, and perspective view of the strip (5) according to some embodiments of the disclosure. The sensors (6) may be formed as an array on the strip (5) as shown. The internal wiring harness (5W) associated with leads (5A, 5B) of the sensors (6) are shown in FIG. 6B. The extremities of the strip (5) having connections (5A’, 5B’) for leads (5A, 5B) are shown in FIG. 6C. In an embodiment, the length (L) of the strip (5) may vary between 2.5 m and 5 m, with a preferred length of 4 m. The sensors (6) may be distributed uniformly over the length (L) with the number of sensors (6) depending on overall length (L) and requirement of measurements. FIG. 6C shows sensor less regions (SLR) and the region (SR) where sensors (6) are distributed on the strip (5). In an embodiment, considering overall length (L) as 4 m, the sensor less region (SLR) may extend up to 0.5 m on either extremities, while the region (SR) may extend up to 3 m. In another embodiment, each sensor (6) may have a height of 3 mm measured from strip (5) surface, and may have effective dimensions of 5 mm – 10 mm. For example, if the sensor (6) is square shaped, each side may measure 5 mm – 10 mm, if the sensor is circular, the diameter may vary between 5 mm – 10 mm, and so on. When embedded/installed inside the conduit (1), the sensors (6) may detect thickness and optionally other physical properties at a plurality of points in the conduit (1) in a real time

manner. That is, the sensors (6) may detect the thickness and other physical properties of the conduit (1) when the furnace operations are ongoing. In an embodiment, the strip (5) may serve as a housing for the wire harness and cables associated with the sensors (6).
[0048] FIG. 7 is an exemplary embodiment which illustrates another configuration of the device (10) of the present disclosure. The configuration of the coupler (18X, 18Y) shown in FIG. 7 differs from that shown in FIG. 2, in which the coupler (18X, 18Y) secures both support members (17X, 17Y) and the leads (15A, 15B) combinedly at the second section (18B) through fasteners (18S). The first section (18A), like in case of FIG. 2, allows connectivity of the support members (17X, 17Y) and the leads (15A, 15B) with the inlet (3) and the outlet (2) at one end (18P), and to the hose (H) at another end (18Q).
[0049] FIG. 8 is a flowchart which depicts steps involved in monitoring the thickness of the conduit (1) according to an exemplary embodiment. The steps 701-704 are described with reference to FIG. 2 which illustrates the system (100). The system (100), in addition to the device (10) components, may include a control unit (25) communicatively interfaced with the plurality of sensors (6), among other components. Insertion and positioning of the strip (5) having sensors (6) inside the conduit (1) to hold the sensors (6) relative to the inner surface (1S) is indicated by step 701. Once positioned, the strip (5) may be supported by support members (7X, 7Y) as indicated by step 702. Once the sensors (6) detect the thickness of the conduit (1) through signal transmission and reception, signals corresponding to the detected thickness may be passed on to the control unit (25), as indicated by step 703. The control unit (25) may ascertain or determine thickness of the conduit (1) based on the signals received from the plurality of sensors (6). This is indicated by step 704. In an embodiment, the control unit (25) may receive signals corresponding to plurality of thickness values from the plurality of sensors (6) which may be mapped on to or compared with pre-stored thickness values. The pre-stored thickness values may correspond to thicknesses of various locations/sites at the inner surface (1S) of the conduit (1) in the absence of any damages like wear, deformation, cracks, defects, weakened sections and so on. In an embodiment, a memory unit [not shown] associated with the control unit (25) may have the pre-stored values so that the control unit (25) may readily fetch the pre-stored values for comparison with the values detected by the sensors (6). If the comparison results in a difference which exceeds a threshold limit, then a defect such as wear, crack, etc., in the conduit (1) may be ascertained. The ascertainment may

be based on differences in signal characteristics such as frequency, amplitude, phase, etc., corresponding to thicknesses of the conduit in undamaged and damaged conditions. The presence of plurality of sensors (6) may allow detection of the thickness values at various locations in the conduit (1) in a real-time and continuous basis, which may further be processed and indicated to the personnel by the control unit (25). In an embodiment, the control unit (25) may be communicatively interfaced with a display unit (40), such as a monitor or any other analog/digital display device, through which the thickness values or any other physical properties like density, etc., may be indicated to the personnel. In an embodiment, the control unit (25) may be interfaced with communication modules to distantly transmit the determined thickness values in a real-time manner, so that the thickness values may be monitored online.
[0050] In an embodiment of the disclosure, the control unit (25) (like an electronic control unit) may be a centralized control unit, or a dedicated control unit associated with the furnace (50) components. The control unit (25) may be implemented by any computing systems that is utilized to implement the features of the present disclosure. The control unit may be comprised of a processing unit. The processing unit may comprise at least one data processor for executing program components for executing user- or system-generated requests. The processing unit may be a specialized processing unit such as integrated system (bus) controllers, memory management control units, floating point units, graphics processing units, digital signal processing units, etc. The processing unit may include a microprocessor, such as AMD Athlon, Duron or Opteron, ARM’s application, embedded or secure processors, IBM PowerPC, Intel’s Core, Itanium, Xeon, Celeron, or other line of processors, etc. The processing unit may be implemented using a mainframe, distributed processor, multi-core, parallel, grid, or other architectures. Some embodiments may utilize embedded technologies like application-specific integrated circuits (ASICs), digital signal processors (DSPs), Field Programmable Gate Arrays (FPGAs), etc.
[0051] In some embodiments, the control unit may be disposed in communication with one or more memory devices (e.g., RAM, ROM etc.) via a storage interface. The storage interface may connect to memory devices including, without limitation, memory drives, removable disc drives, etc., employing connection protocols such as serial advanced technology attachment (SATA), integrated drive electronics (IDE), IEEE-1394, universal serial bus (USB), fiber channel, small computing system interface (SCSI), etc. The memory drives may further include a drum, magnetic

disc drive, magneto-optical drive, optical drive, redundant array of independent discs (RAID), solid-state memory devices, solid-state drives, etc.
[0052] The device and the system disclosed in the present disclosure have several inherent advantages. One advantage is that the possibility of detecting and continuous monitoring of the thickness of the conduit through a number of sensors while the furnace is operating. This in-situ monitoring allows prevention of potential hazards which is crucial for safe working environment. Another advantage is that the real-time, in-situ monitoring allows immediate stopping and fixing in case a defect such as a crack, wear, weakening, etc., is detected in the conduit. This not only ensures safety but also is beneficial in terms of reduced lead times, economy, and improvement in furnace efficiency. Yet another advantage is the implementation of easily available components like fasteners, couplers, etc., which may be readily installed, adjusted, and detached depending on requirement. The flexibility of these components allows installation/embedding of the strip of sensors conveniently and in less time. A still another advantage is possibility of remote/online diagnostics of the conduit due to communication capabilities of the sensors interfaced with the control unit.
Equivalents:
[0053] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
[0054] It will be understood by those within the art that, in general, terms used herein, and
especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such

phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."
[0055] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope being indicated by the following claims.

Table of reference numerals
Component/Step Numeral

System 100
Device 10
Furnace 50
Shell 50A
Ribbed profile 51R
Slots 51S, 1L
Cooling stave 52
Inlet 53, 3
Outlet 52, 2
Inlet and outlet flow passages 53A, 52A
Conduit 1
Inner surface 1S
Portion of inner surface 1A
Ribs 1R
Channel or passage 4, 54
Inflow, Outflow 4I, 4O
Strip 5
Leads of strip 5A, 5B
Connections for leads 5A’, 5B’
Wiring harness 5W
Plurality of sensors 6
Support members 7, 7X, 7Y,17X, 17Y
Horizontal and vertical members 7H, 7V
Connecting member 7C
Gripping portion 7A
Couplers 8X, 8Y or (18X, 18Y)

First section 8A, 18A
Second section 8B, 18B
One end 8P, 18P
Another end 8Q, 18Q
Flange 8F
Fasteners 8S, 18S
Slot cut/Rail 8R
Extensions 8M, 8N
Mechanism 9
Cooling fluid CF
Flow direction FD
Viewing direction X-X
Hose H
Control unit 25
Display unit 40
Length of strip L
Sensor region SR
Sensor less region SLR
Monitoring steps 701-704

We Claim:
1. A device (10) for monitoring thickness of a conduit (1), the device (10) comprising:
a strip (5) comprising a plurality of sensors securable to at least a portion (1A) of an inner surface (1S) of the conduit (1), wherein leads (5A, 5B) of the strip (5) extend from at least one of an inlet (3) and an outlet (2) of the conduit (1); and
at least two support members (7X, 7Y), each extending from either the inlet (3) and the outlet (2) of the conduit (1), and being configured to support the strip (5) longitudinally relative to the at least a portion (1A) of the inner surface (1S) of the conduit (1); wherein, the plurality of sensors (6) is configured to transmit and receive signals through the conduit (1), to monitor the thickness of the conduit (1).
2. The device (10) as claimed in claim 1, wherein the conduit (1) is a cooling stave of a metallurgical furnace.
3. The device (10) as claimed in claim 1, wherein the inlet (3) and the outlet (2) extend substantially perpendicular to a longitudinal portion of the conduit (1).
4. The device (10) as claimed in claim 1, wherein the at least two support members (7X, 7Y) and the leads (5A, 5B) of the strip (5) extending from the inlet (3) and the outlet (2) are supported by couplers (8X, 8Y).
5. The device (10) as claimed in claims 1 and 4, wherein each of the couplers (8X, 8Y) is a T-coupler, defined with:
a first section (8A), wherein one end (8P) of the first section (8A) is connectable with either of the inlet (3) and the outlet (2), and an other end (8Q) opposite to the one end (8P) is connectable to a hose (H); and
a second section (8B) transversely extending from a portion of the first section (8A), the second section (8B) comprising at least one flange (8F) to secure one of the at least two support members (7X, 7Y), and the leads (5A, 5B) of the strip (5).

6. The device (10) as claimed in claim 1, wherein each of the at least two support members (7X, 7Y) is defined with a gripping portion (7A) configured to secure the strip (5) with at least a portion (1A) of the conduit (1).
7. The device (10) as claimed in claim 1, wherein the conduit (1) is circulated with a cooling fluid (CF) routed from the inlet (3) towards the outlet (2), and wherein the cooling fluid (CF) is water.
8. The device (10) as claimed in claim 7, wherein the cooling fluid (CF) forms an acoustic coupling medium between the plurality of sensors (6) and the at least a portion (1A) of the inner surface (1S) of the conduit (1).
9. The device (10) as claimed in claim 1, wherein the plurality of sensors (6) is arranged in an array, and wherein each of the plurality of sensors (6) is an ultrasonic sensor.
10. A system (100) for monitoring thickness of a conduit (1) in a metallurgical furnace, the system (100) comprising:
a device (10), comprising:
a strip (5) comprising a plurality of sensors (6) securable to at least a portion
(1A) of an inner surface (1S) of the conduit (1), wherein leads (5A, 5B) of the strip
(5) extend from at least one of an inlet (3) and an outlet (2) of the conduit (1); and at least two support members (7X, 7Y), each extending from either the inlet
(3) and the outlet (2) of the conduit (1), and being configured to support the strip
(5) longitudinally relative to the at least a portion (1A) of the inner surface (1S) of
the conduit (1);
wherein, the plurality of sensors (6) is configured to transmit and receive signals
through the conduit (1), to monitor the thickness of the conduit (1); and
a control unit (25) communicatively coupled to the plurality of sensors (6), the control unit (25) is configured to:
receive, signals corresponding to detection of the thickness of the conduit
(1) from the plurality of sensors (6); and

determine thickness of the conduit (1) at one or more locations based on the signals received from the plurality of sensors (6).
11. The system (100) as claimed in claim 10, wherein the at least two support members (7X,
7Y) and the leads (5A, 5B) of the strip (5) extending from at least one of the inlet (3) and
the outlet (2) are supported by a T-coupler (8), and wherein the T-coupler (8) is defined
with:
a first section (8A), wherein one end (8P) of the first section (8A) is connectable with either of the inlet (3) and the outlet (2), and an other (8Q) end opposite to the one end (8P) is connectable to a hose (H); and
a second section (8B) transversely extending from a portion of the first section (8A), the second section (8B) comprising at least one flange (8F) to secure one of the at least two support members (7X, 7Y), and the leads (5A, 5B) of the strip (5).
12. The system (100) as claimed in claim 11, wherein each of the T-couplers (8) comprise a mechanism (9) configured to adjust position of each of the at least two support members (7X, 7Y) relative to the conduit (1), the inlet (3) and the outlet (2).
13. The system (100) as claimed in claim 10 comprises a display unit (40) communicatively coupled to the control unit (25), wherein the control unit (25) is configured to display the detected thickness of the conduit (1) through the display unit (40).