Conduit Thickness Measurement Using Segmented Carrier Link
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Solution Overview
Problem
Conventional methods for measuring the thickness of cooling staves in blast furnaces are inadequate as they cannot accurately assess uniform wear along the length, require coolant drainage, and are cumbersome due to the need for a couplant for air gap elimination, leading to operational disruptions and safety hazards.
Innovation Solution
A device and system comprising a guide tube with pivotally connected links and a sensor-equipped carrier link that can traverse the conduit, using protrusions and guide projections to contact the conduit surface for precise thickness measurement without draining coolant or applying a couplant, facilitated by an image capturing unit and control unit for continuous monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional thickness measuring devices are positioned at accessible locations (inlet or outlet) of the cooling stave, then the measurement process can be performed, but the wear pattern along the length of the cooling stave cannot be measured accurately
Solution Approach 1:
The measurement device is divided into multiple segments or links that can be positioned at different locations along the cooling stave. Each segment can independently measure thickness at its specific position, enabling comprehensive assessment of wear patterns along the entire length of the stave rather than at a single accessible location.
Solution Approach 2:
The measurement approach transitions from a single-point measurement (inlet or outlet only) to multi-point measurement along the length of the cooling stave. This dimensional expansion from one location to multiple locations along the stave allows capture of the complete wear pattern profile.
2Measurement precision
If conventional measuring techniques are used, then thickness can be measured at specific locations, but coolant must be drained for testing which disrupts blast furnace operations
Solution Approach 1:
The measurement device is designed to operate autonomously within the cooling stave without requiring external intervention or coolant drainage. The device can be introduced through existing access points and performs measurements independently, eliminating the need to stop coolant flow or drain coolant for testing.
Solution Approach 2:
The measurement process can continue uninterrupted during normal blast furnace operation. By eliminating the need to drain coolant or stop operations for measurement, the useful action of thickness measurement is performed continuously without breaking the productive cycle of the blast furnace.
3Measurement precision
If conventional measuring devices are used to achieve zero air gap, then a thin layer of couplant (oil, grease, water) must be applied between the measuring device and the cooling stave
Solution Approach 1:
The requirement for couplant application is extracted and eliminated from the measurement process. The device design inherently achieves the necessary contact or measurement without requiring external couplant substances, thereby simplifying the device configuration and operation.
Solution Approach 2:
The device uses its own structural features (such as protrusions or contact elements) as the intermediary to achieve proper contact with the cooling stave surface, eliminating the need for external couplant mediators. The device's built-in contact mechanisms serve the intermediary function that would otherwise require separate couplant materials.
4Reliability
If cooling staves are inspected periodically for leakage, then safety can be maintained, but the cooling staves are located inside the shell and are not accessible from outside
Solution Approach 1:
The measurement device is designed to be nested within or introduced through the existing structure of the cooling stave and blast furnace shell. The device can be accessed through existing access points, openings, or by being pushed through the cooling stave itself, allowing inspection of the inner surfaces without requiring external access to the enclosed space.
Solution Approach 2:
The inspection process replaces complex mechanical access systems with simpler introduction methods. Instead of requiring physical access to the interior of the shell and cooling stave, the device can be introduced through existing pathways, openings, or by being propelled through the cooling stave, substituting complex mechanical access with simpler introduction mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate, continuous measurement of conduit thickness along its length without disrupting blast furnace operations, reducing the risk of coolant leakage and enhancing safety by eliminating the need for external intervention or couplant application.
Implementation Method 1
The at least one sensor is an ultrasonic sensor
Data Source
AI summary
The present disclosure discloses a system (500) for measuring thickness along a length of a conduit (111). The system includes a guide tube and a device (300) positioned in the guide tube (370). The device is configured to displace along the guide tube into the conduit. The device includes a plurality of links (100) pivotally connected to each other. Further, at least one carrier link (304) is positioned between at least a pair of the plurality of links and is configured to accommodate at least one sensor (340). Additionally, at least one protrusion (330) extends from the at least one carrier link and is configured to support a portion of the at least one sensor, to contact the conduit for measuring thickness of the conduit. Furthermore, a control unit (400) is communicatively coupled to the device (300) to operate the device and measure thickness along the length of the conduit.