Claims:I/We claim:
1. A continuous stave thickness measurement system (200) comprising:
a mechanism (202) for establishing contact on an inspecting point (206) on an inspecting surface (208) of a cooling channel (120) of a cooling stave (111), the mechanism (202) comprising: 5
a sensor body (302) housing an ultrasonic sensor (304), the ultrasonic sensor (304) being configured to transmit ultrasonic waves towards the inspecting point (206) and receive ultrasonic waves reflected from the inspecting point (206);
one or more rollers (306) coupled to the sensor body (302), 10 the one or more rollers (306) being configured to move the sensor body (302) along the inspecting surface (206) of the cooling channel (120); and
a stabilizing arrangement coupled to the sensor body (302), the stabilizing arrangement being configured to establish contact 15 with one or more opposite surfaces (308) of the cooling channel (120) to push the ultrasonic sensor (304) housed in the sensor body (302) against the inspecting point (206) on the inspecting surface (208); and
a processing device (700) communicably coupled to the ultrasonic 20 sensor (304) to receive the reflected ultrasonic waves from the ultrasonic sensor (304), transform the reflected ultrasonic waves into an electrical signal, and process the electrical signal into stave thickness of the cooling stave (111).
2. The continuous stave thickness measurement system (200) as claimed in claim 25 1, wherein the stabilizing arrangement includes a plurality of compression spring (310) mounted on respective plurality of shocker pistons (312) coupled
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to the sensor body (302), and wherein the plurality of shocker pistons (312) being configured to connect with the one or more opposite surfaces (308) of the cooling channel (120) to push the ultrasonic sensor (304) housed in the sensor body (302) against the inspecting point (206) on the inspecting surface (208).
3. The continuous stave thickness measurement system (200) as claimed in claim 5 2, wherein each shocker piston of the plurality of shocker pistons (312) being deployed with a wheel (314) at the one or more opposite surfaces (308) end.
4. The continuous stave thickness measurement system (200) as claimed in claim 2, wherein a plurality of shocker pistons (312) includes two shocker pistons.
5. The continuous stave thickness measurement system (200) as claimed in claim 10 1, wherein the stabilizing arrangement includes a single compression spring (310) mounted within a cylindrical frame (402) coupled to the sensor body (302), wherein the cylindrical frame (402) is being deployed with a wheel (314) at the one or more opposite surfaces (308) end.
6. The continuous stave thickness measurement system (200) as claimed in claim 15 1, wherein the stabilizing arrangement includes a plurality of legs (502) coupled to the sensor body (302), and wherein the plurality of legs (502) being configured to connect with the one or more opposite surfaces (308) of the cooling channel (120) to push the ultrasonic sensor (304) housed in the sensor body (302) against the inspecting point (206) on the inspecting surface (208). 20
7. The continuous stave thickness measurement system (200) as claimed in claim 6, wherein each leg of the plurality of legs (502) being deployed with a wheel (314) at the one or more opposite surfaces (308) end.
8. The continuous stave thickness measurement system (200) as claimed in claim 6, wherein a plurality of legs (502) is three. 25
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9. The continuous stave thickness measurement system (200) as claimed in claim 6, wherein a cushion (504) is placed in between each leg (502) and the wheel (314).
10. The continuous stave thickness measurement system (200) as claimed in claim 1, wherein a cross section of the cooling channel (120) is flat or curved. 5
11. The continuous stave thickness measurement system (200) as claimed in claim 1, wherein a cooling fluid (121) is being filled inside the cooling channel (120) to communicably couple the ultrasonic sensor (304) with the inspecting point (106).
12. The continuous stave thickness measurement system (200) as claimed in 10 claim 11, wherein the cooling fluid (121) is one of water or oil.
13. The continuous stave thickness measurement system (200) as claimed in claim 1, wherein the one or more opposite surfaces (308) are curved.
14. The continuous stave thickness measurement system (200) as claimed in claim 13, wherein a guide is positioned at a curved section of the cooling 15 channel (120) through which the sensor body (302) is guided through the curved section.
15. The continuous stave thickness measurement system (200) as claimed in claim 1, wherein the sensor body (304) is coupled with a chain type feeder (204) to move the sensor body (302) swirl in one axis and restricts the twist 20 along other two axes.
16. The continuous stave thickness measurement system (200) as claimed in claim 1, wherein the processing device (700) includes:
one or more processors (702);
a pulse generator (708), coupled to the one or more processors (702), to 25 produce a high voltage electrical pulses, wherein based on the generated high
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voltage electrical pulses, sound energy is propagated in the form of ultrasonic waves by the ultrasonic sensor (304);
a transceiver (710), coupled to the pulse generator (708) and the one or more processors (702), to receive reflected ultrasonic waves from the ultrasonic sensor (303) and to transform the reflected ultrasonic waves into an 5 electrical signal;
a digitizer (712), coupled to the transceiver (710) and the one or more processors (702), to process the electrical signal into stave thickness of the cooling stave (111) based on velocity and travel time of the reflected ultrasonic waves; and 10
a display (714), coupled to the digitizer (712) and the one or more processors (702), to display stave thickness of the cooling stave (111). , Description:CONTINUOUS STAVE THICKNESS MEASUREMENT SYSTEM
TECHNICAL FIELD
[0001] The present disclosure relates to a system for nondestructive thickness measurement of a cooling stave. In particular, the present disclosure relates to a 5 continuous stave thickness measurement system.
BACKGROUND
[0002] Background description includes information that may be useful in understanding the present subject matter. It is not an admission that any of the 10 information provided herein is prior art or relevant to the presently claimed subject matter, or that any publication specifically or implicitly referenced is prior art.
[0003] In the iron and steel industry, a large structure of blast furnace is used for smelting of iron from iron ore. An exemplary blast furnace (100) is shown in FIG. 1A. The blast furnace (100) is lined with refractory materials that can withstand 15 temperatures approaching 1900 °C. Irrespective of the use of the refractory materials, the best means of maintaining a furnace shell (101) of the blast furnace (100) is with cooling water. [0004] Coolers with water circulating water, installed between the furnace shell (101) and refractory lining are called cooling staves (111), as shown in FIG. 1B. The 20 cooling staves (111) in conjunction with the refractory linings are the key elements to achieve heat extraction and further to protect the shell (101) in most modern furnaces. The cooling staves (111) are designed with internal cooling channels (120) for circulating water for protecting steel shell (101) from heat.
[0005] Cooling stave (111) is the equipment for maintaining the furnace inside 25 profile and protecting the furnace shell (101) from the high-temperature gas or molten material by enhancing heat transfer. The cooling staves (111) are basically made of
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cast steel, cast iron, or copper. The cooling staves (111) are located inside the steel furnace shell (101) and hence they are exposed to hot metal and gases. The main reason for the damage of the cooling staves (111) is mechanical wear owing to the slag layer peel off on the hot face. The wear is caused by the descending burden material and the rising gas flow until a new slag layer formed over the hot face of the 5 cooling staves (111) and results in stave failures. Hence, thickness measurement of cooling staves (111) is of high importance and is one of the critical parameters which need to be monitored for the safe operation of blast furnaces (100). But, these cooling staves (111) are located inside the furnace shell (101) and are not accessible from outside. Hence, it is difficult to measure the remnant thickness of the cooling staves 10 (111).
[0006] Also, since these cooling staves (111) are made of copper, cast steel or cast iron, the cooling staves (111) extract more heat compared to a straight channel staves used in Middle Stack and Upper Stack. Accordingly, bent channel staves are more critical compared to the straight channel staves. 15
[0007] Further, the wear of the cooling staves (111) is due to many unavoidable factors such as burden speed, the hardness of burden material, the hardness of stave hot surface, and material pressure on staves, leading to a possible industrial hazard.
[0008] Yet further, as shown in FIG. 1C, each cooling stave (111) has an outlet pipe (130) for the cooling water and the outlet pipe (130) provide for the access 20 required for sensors to be inserted for measurement. Arrow referenced with numeral 140 shows the movement direction of the sensors within the outlet pipe (130).
[0009] In addition, the cooling staves (111) employ ribs (110) that provide slots for mounting refractory bricks which form an innermost lining of the furnace (100), in addition to serving as fins which enhance heat extraction rate. The innermost lining 25 of the furnace (100) is subjected to the flow of hot metal and gases, which will result into the wear of the cooling stave (110), especially the ribs (110). If the situation becomes worst, it can cause massive water ingression, which can lead to catastrophic
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failure of the furnace (100). Hence, it is crucial to monitor the thickness of the cooling staves (111) for preventing their catastrophic failure.
[0010] The cooling staves (111) have very limited accessibility for thickness measurement, i.e., only through the inlet pipes (131) and the outlet pipes (130) as the cooling staves (111) are located inside a steel shell (101). This difficulty has been 5 addressed in previous works where appropriate fixture and ultrasonic probes were designed for taking point measurements near outlet pipes (130) after draining the cooling fluid (water) (121) of the cooling stave (111).
[0011] WO201848083 relates to a device for measuring a stave thickness, comprising of the main body through which an operation rod passes, a link part for 10 connecting the main body and one end of the operation rod and a sensor part provided at one side of the link part so as to move according to the rotation of the link part, thereby enabling thickness measurement at a protruding part of a stave by moving the position of a sensor, and enabling the measurement of the remaining thickness from an early stage of wear without limitation. 15
[0012] JP2012207270A describes a method of measuring the residual thickness of blast furnace stave. The objective of this work was to provide a method of measuring the residual thickness of a blast furnace stave, which accurately measures the wear damage of a stave fixed on a blast furnace shell. The thickness of the stave wall towards the inner side of the furnace is measured with high precision by 20 inserting a resin-made soft probe through the water channel. It claims that a residual thickness measuring method of the shaft furnace stave along with the ultrasound soft probe made of resin.
[0013] JP202275515A describes a method for measuring the thickness of stave. It claims that the embedded rolled stock made from copper or its alloy and inserted into 25 a stave which was having provided a through a hole to a thickness direction and a thickness measuring method using an ultrasonic board thickness meter.
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[0014] KR101594719 relates to an apparatus and a method to measure stave thickness comprising of an ultrasonic wave sensor part which sends and receives an ultrasonic wave and an operating part connected to the ultrasonic wave sensor part. The operating part allows the ultrasonic wave sensor part to move along a cooling water passage provided in the stave of a blast furnace. 5
[0015] KR20120065119 relates to a device and method for measuring the thickness of a stave of a furnace. This method involves embedded ultrasonic sensor in the cooling channel of the stave. Hence the thickness of the stave can be periodically measured with the real-time and the attrition rate of the stave can be measured.
[0016] KR2012067786A relates to a device and a method for measuring the 10 thickness of a stave of a furnace. This method involves an ultrasonic-based technique comprising a special probe made straight to get access with cooling water channel surface in the stave. This technique also finds efficient to measure remnant thickness of the staves.
[0017] Also, Indian patent application 1356/KOL/2013 describes a mechanism 15 for measuring the stave rib thickness was claimed. The mechanism includes an ultrasonic probe, appropriate fixture and guiding mechanism. In the above patent addresses the issue of placing the ultrasonic at the intended location. Also, the Indian patent application ensures the measurement is from the rib section, and not from the thin section. 20
[0018] Above mentioned various approaches of the state of the art mainly intend to access only one rib (110) for single point measurement through a cooling outlet pipe (130) that seems to be unsuitable because with the thickness data of only one rib it is not appropriate to estimate the condition of the entire cooling stave (111). This is especially critical if localized defects have formed at locations away from the outlet 25 pipes (130). Also, the wear in the cooling staves (111) is not uniform along with the height of the blast furnace (100) due to different temperature and different reaction conditions.
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[0019] The above-mentioned approaches of the state of the art seem to be intended for thickness measurement of stave system where the ultrasonic sensor can be placed at the rib section using a fixture. Also, the above-mentioned approaches seem for point to point measurements, thereby covering the only top and bottom ribs for thickness measurement. As can be appreciated by those skilled in the art that since 5 the wear pattern is not uniform, neither of the approaches mentioned above discloses the mechanism to go inside the cooling channel (120) and give thickness profile along entire the cooling stave length in presence of cooling fluid (121).
[0020] Also, there does not seem to be an existing technology which can give the continuous full thickness measurements of bent channel cooling staves, generally 10 used in iron and steel manufacturing plants.
OBJECTS OF THE DISCLOSURE
[0021] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed hereinbelow. 15
[0022] An object of the present disclosure is to provide a continuous nondestructive stave thickness measurement system.
[0023] Another object of the present disclosure is to provide a system for nondestructive thickness measurement of a cooling stave from its cooling channel.
[0024] These and other objects and advantages of the present disclosure will be 20 apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings in which a preferred form of the present disclosure is illustrated.
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SUMMARY
[0025] This summary is provided to introduce concepts related to a continuous stave thickness measurement system. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit 5 the scope of the claimed subject matter.
[0026] The present disclosure relates to a continuous stave thickness measurement system (200). The system (200) includes a mechanism (202) for establishing contact on an inspecting point (206) on an inspecting surface (208) of a cooling channel (120) of a cooling stave (111). The mechanism (202) includes a 10 sensor body (302) housing an ultrasonic sensor (304), the ultrasonic sensor (304) being configured to transmit ultrasonic waves towards the inspecting point (206) and receive ultrasonic waves reflected from the inspecting point (206); one or more rollers (306) coupled to the sensor body (302), the one or more rollers (306) being configured to move the sensor body (302) along the inspecting surface (206) of the 15 cooling channel (120); and a stabilizing arrangement coupled to the sensor body (302), the stabilizing arrangement being configured to establish contact with one or more opposite surfaces (308) of the cooling channel (120) to push the ultrasonic sensor (304) housed in the sensor body (302) against the inspecting point (206) on the inspecting surface (208). The system (200) further includes a processing device (700) 20 communicably coupled to the ultrasonic sensor (304) to receive the reflected ultrasonic waves from the ultrasonic sensor (304), transform the reflected ultrasonic waves into an electrical signal, and process the electrical signal into stave thickness of the cooling stave (111).
[0027] In an aspect, the stabilizing arrangement includes a plurality of 25 compression spring (310) mounted on a respective plurality of shocker pistons (312) coupled to the sensor body (302). The plurality of shocker pistons (312) is configured to connect with the one or more opposite surfaces (308) of the cooling channel (120)
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to push the ultrasonic sensor (304) housed in the sensor body (302) against the inspecting point (206) on the inspecting surface (208). In the said aspect, each shocker piston of the plurality of shocker pistons (312) being deployed with a wheel (314) at the one or more opposite surfaces (308) end. Also, a plurality of shocker pistons (312) includes two shocker pistons. 5
[0028] In an aspect, the stabilizing arrangement includes a single compression spring (310) mounted within a cylindrical frame (402) coupled to the sensor body (302). The cylindrical frame (402) is deployed with a wheel (314) at the one or more opposite surfaces (308) end.
[0029] In an aspect, the stabilizing arrangement includes a plurality of legs (502) 10 coupled to the sensor body (302). The plurality of legs (502) is configured to connect with the one or more opposite surfaces (308) of the cooling channel (120) to push the ultrasonic sensor (304) housed in the sensor body (302) against the inspecting point (206) on the inspecting surface (208). In the present aspect, each leg of the plurality of legs (502) is deployed with a wheel (314) at the one or more opposite surfaces 15 (308) end. Also, a plurality of legs (502) is three.
[0030] Also, in an aspect, a cushion (504) is placed in between each leg (502) and the wheel (314).
[0031] In an aspect, a cross section of the cooling channel (120) is flat or curved.
[0032] In an aspect, a cooling fluid (121) is being filled inside the cooling 20 channel (120) to communicably couple the ultrasonic sensor (304) with the inspecting point (106).
[0033] In an aspect, the cooling fluid (121) is one of water or oil.
[0034] In an aspect, the one or more opposite surfaces (308) are curved.
[0035] In an aspect, a guide is positioned at a curved section of the cooling 25 channel (120) through which the sensor body (302) is guided through the curved section.
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[0036] In an aspect, the sensor body (304) is coupled with a chain type feeder (204) to move the sensor body (302) swirl in one axis and restricts the twist along other two axes.
[0037] In an aspect, the processing device (700) includes one or more processors (702); a pulse generator (708) to produce a high voltage electrical pulses, wherein 5 based on the generated high voltage electrical pulses, sound energy is propagated in the form of ultrasonic waves by the ultrasonic sensor (304); a transceiver (710) to receive reflected ultrasonic waves from the ultrasonic sensor (303) and to transform the reflected ultrasonic waves into an electrical signal; a digitizer (712) to process the electrical signal into stave thickness of the cooling stave (111) based on velocity and 10 travel time of the reflected ultrasonic waves; and a display (714) to display stave thickness of the cooling stave (111).
[0038] These and other objects and advantages of the present invention will be apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings in which a 15 preferred form of the present invention is illustrated.
BRIEF DESCRIPTION OF DRAWINGS
[0039] The illustrated embodiments of the subject matter will be best understood by reference to the drawings, wherein like parts are designated by like numerals 20 throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
[0040] FIG. 1A illustrates a front view of a conventional blast furnace;
[0041] FIGS. 1B and 1C illustrate an enlarged view of a copper cooling staves 25 used in the blast furnace;
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[0042] FIG. 2A illustrates a mechanism of a continuous stave thickness measurement system inserted through an outlet pipe in accordance with an embodiment of the present disclosure;
[0043] FIG. 2B illustrates the mechanism of the continuous stave thickness measurement system gradually entering in a cooling channel in accordance with an 5 embodiment of the present disclosure;
[0044] FIG. 2C illustrates the mechanism of the continuous stave thickness measurement system establishing contact with an inspection point in the cooling channel after expanding its plurality of legs in accordance with an embodiment of the present subject matter; 10
[0045] FIGS. 3A and 3B illustrate the top view of a first embodiment of the mechanism of the continuous stave thickness measurement system inside different cooling channel cross sections in accordance with an embodiment of the present disclosure;
[0046] FIG. 3C illustrates an implementation of the first embodiment of the 15 mechanism of the continuous stave thickness measurement system, in accordance with the present disclosure;
[0047] FIGS. 4A and 4B illustrate the top view of a second embodiment of the mechanism of the continuous stave thickness measurement system inside different cooling channel cross sections in accordance with an embodiment of the present 20 disclosure;
[0048] FIGS. 5A and 5B illustrate the top view of a third embodiment of the mechanism of the continuous stave thickness measurement system inside different cooling channel cross sections in accordance with an embodiment of the present disclosure; 25
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[0049] FIG. 6A illustrates legs of a plurality of legs at a retracted position inside the cooling channel while maneuvering inside in accordance with an embodiment of the present disclosure;
[0050] FIG. 6B illustrates legs in expanding position for establishing contact with an inspection point in accordance with an embodiment of the present disclosure; 5
[0051] FIG. 7 illustrates the functional components of a processing device coupled to the mechanism of the continuous stave thickness measurement system in accordance with an embodiment of the present disclosure;
[0052] FIG. 8A illustrates ultrasonic A-Scan of a thin section of the stave in a blast furnace using a designed probe holding assembly; and 10
[0053] FIG. 8B illustrates ultrasonic A-Scan of a thin section of the stave in a blast furnace using a designed probe holding an assembly.
[0054] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods 15 illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION
[0055] The detailed description of various exemplary embodiments of the 20 disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein 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 25 spirit and scope of the present disclosure as defined by the appended claims.
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[0056] It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof. 5
[0057] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising”, “includes” and/or “including,” 10 when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
[0058] It should also be noted that in some alternative implementations, the 15 functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
[0059] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of 20 ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. 25
[0060] Embodiments and/or implementations described herein relate to a continuous stave thickness measurement system (200). The system (200) maneuvering through a cooling channel (120) of a cooling stave (111) having ribs
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(110) is shown in FIGS 2A-2C. As shown in figures, the cooling channel (120) is curved in cross-section. However, as can be appreciated by those skilled in the art, the cooling channel (120) can have any other cross section.
[0061] As shown in FIG. 2A, the system (200) includes a mechanism (202) which is being inserted into the cooling channel (120) through the inlet pipe (131) 5 and the outlet pipe (130). The mechanism (202) is movable inside the cooling channel in the to-and-fro direction (140) using a chain-type feeder (204). The chain type feeder (204) is configured to move the mechanism (202) [or a sensor body (304) shown in FIG. 3A-3B, 4A-4B, and 5A-5B] along the cooling channel (120). The chain type feeder (204) provides the swirl in one axis and restricts the twist along the 10 other two axes.
[0062] With the chain type feeder (204), the continuous stave thickness measurement system (200) is self-aligned with the sensor body (304) entering the cooling channel (120) through the outlet pipe (130) and takes a sharp bend to slide into the cooling channel (120). In an implementation, a guide may be deployed at the 15 curved section between outlet pipe (130) and the cooling channel (120) to help in easy maneuvering through the cooling channel (120) and enabling the continuous stave thickness measurement.
[0063] FIG. 2B shows the mechanism (132) gradually entering and moving beyond the curved cross-section of the cooling channel (120), while FIG. 2C shows 20 the mechanism (132) sliding in the cooling channel (120) and establishing contact on an inspection point (206) of an inspecting surface (208) after expanding its plurality of legs (210).
[0064] In an implementation of the present disclosure, the mechanism (202) includes a sensor body housing an ultrasonic sensor. In an aspect, the ultrasonic 25 sensor is configured to transmit ultrasonic waves towards the inspecting point (208) and receive ultrasonic waves reflected from the inspecting point (208).
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[0065] The mechanism (202) further includes one or more rollers coupled to the sensor body. The one or more rollers are configured to move the sensor body along inspecting surface (208) of the cooling channel (120).
[0066] The mechanism further includes a stabilizing arrangement coupled to the sensor body. The stabilizing arrangement is configured to establish contact with one 5 or more opposite surfaces of the cooling channel (120) to push the ultrasonic sensor housed in the sensor body against the inspecting point (206) on the inspecting surface (208).
[0067] FIGS. 3A-3B illustrate a top view of a first embodiment of the mechanism (202) of the continuous stave thickness measurement system (200) inside 10 different cooling channel (120) cross sections in accordance with an embodiment of the present disclosure. The cooling channel (120) has a circular cross-section in the embodiment represented in FIGS. 3A, while the cooling channel (120) has an oval cross-section in the embodiment represented in FIGS. 3B. In both embodiments, the cooling channel (120) is filled with a cooling fluid (water) (121). 15
[0068] Inside the different cooling channel (120) cross-sections, the mechanism (202), shown in FIGS. 3A and 3B, includes a sensor body (302) housing an ultrasonic sensor (304). The sensor body (302) is shown carrying the sensor (304) on its one side facing the inspecting surface (208) of the cooling channel (120). It should be appreciated by those skilled in the art that the height of the sensor body (302) 20 should be less than the diameter of the outlet pipe (130). If the height of the sensor body (302) is more than the diameter of the outlet pipe (130) the sensor body (302) will simply not be able to enter through. Also, the diameter of the cooling channel (120) needs to be more than that of the sensor body (302).
[0069] In an aspect, the sensor body (108) is carrying the sensor (112) through 25 the outlet pipe (130) and slide itself in the cooling channel (120) continuously where the cooling stave (111) thickness is needed to be measured at the inspection point (208). Accordingly, as shown in FIGS. 3A and 3B, the mechanism (202) is
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configured for engaging the sensor (304) to the inspecting point (206) of the cooling channel (120).
[0070] Further, as can be appreciated by those skilled in the art, the inspecting point (206) is one of the many points that can be measured by the system (100) as a measurement point which an operator of the system wants to assess in quick 5 succession. Hence the system (100) is designed as a continuous stave thickness measurement system (100) in accordance with the present disclosure.
[0071] Also, the sensor body (302) may include one or more rollers (306) coupled to it. Generally, the one or more rollers (306) are deployed at the bottom (side at which the sensor (304) is housed) of the sensor body (302) to maneuver the 10 sensor body (302) along the cooling channel (120) for assessing as many inspecting points (206).
[0072] Although two rollers (306) are deployed in the first embodiment shown in FIGS. 3A-3C, in a second embodiment shown in FIGS. 4A-4B, and in a third embodiment shown in FIGS. 5A-5B, it can be appreciated by those skilled in the art 15 that a single roller can be deployed at the bottom side of the sensor body (302). The number of rollers (306) can be selected as per the design requirement and easy maneuvering of the sensor body (302).
[0073] Further, the mechanism (202) further includes a stabilizing arrangement coupled to the sensor body (302), to establish contact with one or more opposite 20 surfaces (308) of the cooling channel (120) to push the sensor (304) housed in the sensor body (302) against the inspecting point (206) on the inspecting surface (208). FIG. 3B has three opposite surfaces (308) of the different radius with their center being at different locations, while FIG. 3A shows a single opposite surface.
[0074] In the first embodiment represented in FIGS. 3A-3C, the stabilizing 25 arrangement includes a plurality of compression springs (310) mounted on a plurality of shocker pistons (312) coupled to the sensor body (302). The plurality of shocker
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pistons (312) is being configured to connect with one or more opposite surfaces (308) of the cooling channel (120). Further, in an aspect, each shocker piston of the plurality of shocker pistons (312) is deployed with a wheel (314) at the opposite surfaces (308) end. In the said aspect, each wheel (314) may be coupled to other wheels by a base frame (316). 5
[0075] In the second embodiment represented in FIGS. 4A-4B, the stabilizing arrangement includes a single compression spring (310) mounted within a cylindrical frame (402) coupled to the sensor body (302). The cylindrical frame (402) is being configured to connect with one or more opposite surfaces (308) of the cooling channel (120). Further, in an aspect, the cylindrical frame (402) is deployed with the 10 wheel (314) at the opposite surface (308) end.
[0076] In the third embodiment represented in FIGS. 5A-5B, the stabilizing arrangement includes a plurality of legs (502) coupled to the sensor body (302). The plurality of legs (502) is configured to connect with one or more opposite surfaces (308) of the cooling channel (120) to push the sensor (304) housed in the sensor body 15 (302) against the inspecting point (206) on the inspecting surface (208). In an aspect, each leg of the plurality of legs (502) being deployed with a wheel (314) at the opposite surfaces (308) end.
[0077] In accordance with the embodiment shown in FIGS. 5A -5B, three legs (502) have been shown while in other embodiments more numbers of legs can be 20 used to improve the stability.
[0078] In an aspect, a cushion (504) is deployed between each leg (502) and the wheel (314) for allowing contraction and expansion of the sensor body (304) while moving into the passage of the cooling channel (120). Also, the cooling staves (111) are continuously in a run and because of thermal loads, they could be deformed. 25 Thus, the cushions (504) are provided to take auto contraction/expansion based on the passage inner boundary. They may be loaded with a sliding mechanism surrounded
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by a spring to provide more stiffness hence single axis sliding motion by restoring the potential energy.
[0079] Further, as shown in FIGS. 6A and 6B, the mechanism (202) may further include a plurality of legs (602) coupled to the sensor body (304). The plurality of legs (502) is being configured to connect with one or more opposite surfaces (308) to 5 push the sensor body (302) and thereby the sensor (304) against the inspecting point (206) to establish a proper contact. In an aspect, each leg of the plurality of legs (502) is being deployed with a wheel (604) at the opposite surfaces (308) end.
[0080] The wheels (604) and the rollers (306) add to stability to the sensor body (302) and the mechanism (202) while they are being placed in the curved section as 10 they both neutralize their potential at the middle of the curved section of the cooling channel (120).
[0081] Also, as shown in FIGS. 6A and 6B, the legs of the plurality of legs (602) are retractable inside the cooling channel (120). FIG. 6B shows the legs (602) are employed for point contact in an expanded position and the sensor body (302) being 15 in contact with the inspection point (206). It can be appreciated by those skilled in the art that legs (602) have the flexibility to expand as per the gap they need to expand till they make proper contact of the sensor body (302) with the opposite inspection point (206). Thus, the proposed system (100) is versatile making it possible to be retrofitted in the existing cooling channels without any engineering modifications. 20
[0082] Further, as shown in FIG. 7, the expansion and retraction command for the plurality of legs (602) is given through a processing device (700) in accordance with an embodiment of the present disclosure. Shown in FIG. 6A is the legs of a plurality of legs (602) a retracted position inside the cooling channel (120) while maneuvering inside and FIG. 6B illustrates legs (602) in expanding position for 25 establishing contact with an inspection point (206) in accordance with an embodiment of the present subject matter. Once the mechanism (202) maneuvering inside the cooling channel (120), the legs (602) are established in a retracted mode
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whereas when the inspection point (206) is identified, the legs (602) are expanded till it touches the opposite surfaces (308) and comfortably pressurizes the inspection point (206).
[0083] FIG. 7 illustrates the functional components of the processing device (700) proposed herein. The processing device (700) includes one or more 5 processor(s) (702), an interface(s) (704), and a memory (706). The processor(s) (702) may be implemented as one or more microprocessors, microcomputers, microcontrollers, digital signal processors, central processing units, logic circuitries, and/or any devices that manipulate data based on operational instructions. Among other capabilities, the one or more processor(s) (702) are configured to fetch and 10 execute computer-readable instructions and one or more routines stored in the memory (706). The memory (706) may store one or more computer-readable instructions or routines, which may be fetched and executed to manage warehouse over a network service. The memory (706) may include any non-transitory storage device including, for example, volatile memory such as RAM, or non-volatile 15 memory such as EPROM, flash memory, and the like.
[0084] In an aspect, the processor(s) (702) is communicably coupled to the ultrasonic sensor (304) to receive the sensed signal. The processor(s) (702) collects the data and processes it into stave thickness. The processor(s) (702) is also coupled to the plurality of legs (602). 20
[0085] The interface(s) (704) may include a variety of interfaces, for example, interfaces for data input and output devices referred to as I/O devices, storage devices, and the like. The interface(s) (704) may facilitate communication of the processing device (700) with various devices coupled to the processing device (700). The interface(s) (704) may also provide a communication pathway for one or more 25 processing components of the processing device (700). Examples of such processing components include, but are not limited to, a pulse generator (708), a transceiver (710), a digitizer (712), and a display (714).
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[0086] The processing device (700) includes data (716) that may include data that is either stored or generated as a result of functionalities implemented by any of the processing components of the processing device (700).
[0087] The processing components may be implemented as a combination of hardware and programming (for example, programmable instructions) to implement 5 one or more functionalities of the processing components. In examples described herein, such combinations of hardware and programming may be implemented in several different ways. For example, the programming for the processing components may be processor executable instructions stored on a non-transitory machine-readable storage medium and the hardware for the processing components may include a 10 processing resource (for example, one or more processors), to execute such instructions. In the present examples, the machine-readable storage medium may store instructions that, when executed by the processing resource, implementing the processing components. In such examples, the processing device (700) may include the machine-readable storage medium storing the instructions and the processing 15 resource to execute the instructions or the machine-readable storage medium may be separate but accessible to the processing device (700) and the processing components. In other examples, the processing components may be implemented by electronic circuitry.
[0088] In an alternative implementation and as can be appreciated by those 20 skilled in the art, the processing device (700) may exclude some of the processing components to implement the functionality of the processing device (700), without departing from the scope of the subject matter.
[0089] In operation, once the processor(s) (702) controls and sets the plurality of legs (502) to establish a connection with the one or more opposite surfaces (308) to 25 push the sensor body (302) and thereby the sensor (304) against the inspecting point (206) to establish a proper contact, the pulse generator (708) produces a high voltage electrical pulses. Based on the generated high voltage electrical pulses, the ultrasonic
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sensor (304) propagates sound energy in the form of ultrasonic waves towards the inspecting point (206). In response to the transmitted ultrasonic waves, the transceiver (710) receives reflected ultrasonic waves from the ultrasonic sensor (306) and transforms the reflected ultrasonic waves into an electrical signal. The digitizer (712) processes the electrical signal into stave thickness of the cooling stave (111) 5 based on velocity and travel time of the reflected ultrasonic waves.
[0090] Further, using water as couplant between the sensor (304) and the inspection point (206), the stave thickness can be defined as follows based on the back wall echo and water path:
Stave Thickness = Backwall Echo – Water Path * (??????/ ????????????) 10
where ?????? and ???????????? are the longitudinal wave velocity in copper and water respectively.
[0091] Since the ultrasonic waves may not get transmitted/propagated from the 15 ultrasonic sensor (304) to the inspecting point (206) unless the contact is proper, a cooling fluid (water) (121) is being filled inside the cooling channel (120). The cooling fluid (121) acts as a couplant and establishes to communicably couple the ultrasonic sensor (304) with the inspection point (206) as shown in FIG. 3A-3B, 4A-4B, and 5A-5B. Accordingly, the cooling fluid (water) (121) here acts as a couplant 20 between the ultrasonic sensor (304) and the inspection point (206).
[0092] Thus, for taking continuous readings, the cooling fluid (water) (121) filled in the cooling channel (120) can act as a couplant and also act same as in the immersion ultrasonic testing. Hence, there is no extra mechanism required for couplant spray as well as for applying pressure in contact ultrasonic testing. 25
[0093] Although the cooling fluid (121) generally includes water; however, the cooling fluid (121) can be oil acting as the couplant.
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[0094] Further, sound propagation and echo reading are explained in both Contact Ultrasonic Testing and Immersion Ultrasonic Testing shown in FIGS. 8A and 8B, respectively. A thin layer of couplant (i.e., oil, grease, water) (shown as 121) is applied between the ultrasonic sensor (304) and a specimen (206), and the pressure is applied to the ultrasonic sensor (304). The continuous movement of the ultrasonic 5 sensor (304) and pressure exertion to the ultrasonic sensor (304) cannot be possible simultaneously and required to carry lubricant. Hence, the cooling fluid (121) is used as a couplant between the ultrasonic sensor (304) and inspecting point (206), i.e., pressure exertion to the ultrasonic sensor (304) is not required in such case. The ultrasonic sensor (304) along with the sensor body (302) needs to be able to move 10 downward/upward for continuous measurements.
TECHNICAL ADVANTAGES
[0095] The present disclosure provides a continuous stave thickness measurement system. 15
[0096] There is no need for any extra couplant carrying mechanism or back pressure exertion to avoid air gap between inspection point and ultrasonic sensor in the continuous stave thickness measurement system.
[0097] The present disclosure provides a mechanism which is self-aligning and guiding in a cooling channel inner profile will add stability to the mechanism. 20
[0098] The present disclosure provides a system which is continuous in nature, where one can take the reading of as many inspection points, that can give the health of entire stave.
[0099] Furthermore, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present 25 disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or
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applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.
[00100] The claims, as originally presented and as they may be amended, 5 encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.
[00101] While the foregoing describes various embodiments of the invention, 10 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 included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge 15 available to the person having ordinary skill in the art.