Damage detection system and method of use

A damage detection system for refractory linings for molten metal vessels, comprising:

• an electrically conductive grid disposed underneath a surface of a refractory lining closest to a molten metal when in use;
• one or more electrically conductive electrodes disposed in contact with the molten metal when in use;
• and
• an electrical power source;
• wherein the electrically conductive metallic grid and the one or more electrically conductive electrodes are electrically connected to each other, such as to form an open electrical circuit powered by the electrical power source,
• wherein a detected closure of the electrical circuit during normal use of the molten metal vessel indicates that the refractory lining is damaged,
• wherein the refractory lining is installed in a molten metal vessel or vessel spout, a ladle, a tundish, a reaction chamber or a trough, or in a cupola hearth or a siphon, a blast furnace, or a main, secondary or tilting runner,
• wherein the electrical power source comprises two batteries connected in parallel, and
• wherein the detected closure of the electrical circuit leads to a triggering of an alarm and wherein each of the batteries connected in parallel is associated with a separate alarm.