Prospect of Non Destructive Testing

and Condition Monitoring Practice

in Bangladesh Ferdous KabirMarketing Manager

ASNT NDT Level II in Ect,UT,RT,MT,PTSaj Engineering & Trading

Company

The Fales & Gray Car Works Explosion of 1854

SULTANA steamboat Exploration and died 1800 for failure of Boiler

117 people hade died a fire in Tazreen Garments

What is PdM?

Non Destructive Testing and Condition Monitoring is the part of Predictive Maintenance (PdM).

Predictive maintenance (PdM) techniques are designed to help determine the condition of in-service equipment in order to predict when maintenance should be performed.

Types of machines

MotorsPumpsFansGearboxesEnginesCompressorsSteam TurbinesGeneratorsGas TurbinesHydro Turbines

Rotating Or

Reciprocating Machines

Heat

Noise

Smell

Smoke

Feel

Equipment Perform

ance

TimeFF

PP

Mechanical

UltrasoundVibration

Analysis

Oil Analysis

Thermograp

hyNDT

Lubrication Excellence

Proactive

Precision Maintenance Alignment, Balance, etc.

Select SuppliersSupplier Specifications

MetricsEquipment Ranking

RCMTPM

RCA/FMEARCDTraining ProgramsWritten Procedures

Job Planning/SchedulingCMMS System

Predictive Reactive

We are in here

Machine Condition Chart

Condition Monitoring For your Plant

Vibration Analysis

Oil Analysis

UltrasoundAnalysis

ThermalAnalysis

If you think this is your plant, then your plant is stand on this 4 technologies

Machinery Health Monitoring Machinery Health Monitoring Strategy Strategy

~125 Machines

~1375 Machines

~500 Machines

~500 Machines

Total # Machines 2,500Typical Industrial Process Plant

5%5%CriticalCritical

25%25%EssentialEssential

30%30%ImportantImportant

20%20%SecondarySecondary

20%20%Non-EssentialNon-Essential

TurbinesGenerators

Compressors

MotorsPumps

FansGears

Application at Typical Plant Application at Typical Plant

Online Solutions for Online Solutions for critical machinery critical machinery

WirelessWirelessTransmittersTransmitters

Multi TechnologiesMulti TechnologiesPortable SolutionsPortable Solutions

NDT and CM Customer in Bangladesh

Power Generation: 200+ Fertilizer Factory: 8 Chemical Plant: 10+ Refinery: 10+ Oil Reserve Tank Gas Production Field: 23 + Gas Distribution: 6 Gas Transmission : 1774 KM

Mining : 2 CNG Cylinder Testing Point: 5+ Aviation : 5+ Shipbuilding: 20+ Cement : 50+ Welding and welder performance test Paper : 35+ Sugar : 20+

Pharmaceuticals: 200+ Research and educational institutions

: 20+ Steel Structure : 20+ Survey Company : 6+ Bangladesh Railway : Boiler Manufacture : 10+ Steel structure: 20+

Steel Bridge LPG and LNG : Germans and Textile : 6000+ Gun Barrel and Shell : 1 Foundry (casting) Steel Mills

Power System Master Plan in Bangladesh

Present Installation of Power Production Capacity : 12,071 MW

Number of Power Plant : 200 +

Generation of 3/3/2016 : 8,173 MW

Generation Capacity Requirement 2021: 2,400 MW Generation Capacity Requirement 2030: 39,000 MW

Date of Inspection : 11 and 14 October, 2012Generation Capacity: 5 MWTotal Running Time: 40,564.50 Hours

Scope of Inspection in Engine

Piston Crown 20 pic (per pic two part) Piston Skirt 20 pic Gudgeon Pin 20 pic Big end bearing shell lower  (connecting

rod cap) 20 pic (20x2 =40 points) Big end bearing shell upper (connecting rod

cap) 20 pic (20x2 =40 points) Bearing housing  for 20 circle Connecting Rod Cylinder Liner

Defect Occurred

Hardness Testing

Dye Penetrant Testing

This method is commonly used for detect the surface cracks or defects. Dye penetrant Testing (DPT) is one of the most widely used nondestructive Testing (NDT) methods. DPT can be used to inspect almost any material provided that its surface is not extremely rough.

Dye Penetrant Testing Process

Three liquids areused in this method.

1. Cleaner2. Penetrant3. Developer

Applications of RVI

It can be applied to a number of areas including:– Aerospace – Power generation – Oil and Gas – Chemicals– Automotive – Construction – Security – Manufacturing – Pharmaceutical etc. – Research and education

It is also used for:•Gas turbine blades •Blade cooling holes •Boiler tubes •Turbine rotor bores •Steam pipework •Boiler headers •Valves •Steam chests

www.sajetc.com

Industrial Endoscopic Inspection

Turbine Case Study#

GE 9E Gas Turbine is not running due to lack of sufficient fuel pressure. After a details endoscopy inspection a plastic cap was found.

www.sajetc.com

GE 9E Gas Turbine increase temperature faster. After a details endoscopy inspection a sand and foreign particle blocked water line

Boiler Case StudyThis is an Oil Tanker Auxiliary Boiler. The boiler cant be ran due to its leaky tube. There were 400 tubes. Two defective tubes found by Endoscopy Inspection. And then it is sealed from both side.

Turbine Case Study#1Severe Crack found Turbine

Nozzle of Alstom 34.5MW Turbine after the Endoscopy Inspection.

Dye Penetrant Testing Service

Magnetic Particle Inspection

Vibration Analysis and Dynamic Balancing

Hardness Testing Service

See the Image See the Temperature, See the Temperature See the Problem.

Infrared & Thermal Testing

IR Thermography Service

IR Thermography at Sangu Gas Field

Mechanical Application

A- Over heating bearing & shaft B- Blockage in process line C- Conveyor belt failure

IR Thermography at Garments Industry

LUBE OIL TESTING SERVICE

1. Oxidation, 2. Nitration, 3. Sulfation, 4. Incorrect lubricant, 5. Anti-Wear additives, 6. Soot, 7. Glycol,

8. Water Content, 9.TAN, 10. TBN, 11. Viscosity

ULTRASONIC TESTING

Ultrasonic Thickness Gagging Service

CONVENTIONAL ULTRASONIC TESTING SERVICE

Advanced Phased Array Ultrasonic Application at

Present in Bangladesh

What we see in Medical Ultrasonic Test

What is the Difference in Medical Ultrasonogram and Phased Array Ultrasonic Test?

Nothing Special, Both are Phased Array Ultrasonic Test

Medical Industrial

WELDING AREA OF STRUCTUREWELDING AREA OF STRUCTURE

Web Butt Joint Flange Butt Joint

PAU in Shipbuilding Industry

Ghorashal Power Plant Unit -2

Clint: Technoprome Export ,Russia

Restoration of 190 MW Meghnaghat Power Plant

GAS Pipe Line Inspection

Shahbagpur Gas Process Plant, BAPEX

Pipe Line is our Next Target…

Project Completed by AUT East West Pipeline Project , Chine

(4,167 km) (www.chinaoilweb.com)

Nord Stream Project (Russia to Germany (1,212 km) sea base of Baltic sea

Blue Stream Project (1,213), sea base of Black sea

CEMENT PLANT

BOILER MANUFACTURER

XRF Analyzer

Vibration Analysis and Dynamic Mass Balancing

Ultrasonic Detection System

Our Completed 70 NDT Service Projects

01. 110MW Power Plant (PDB)02. Ashugong Power Plant (Unit-2)03. Rawjan Power Plant04. Sylhet 150MW Power Plant05. Katakhale Power Plant06. Siddirgonj Power Plant…….07. Ghorasal ST (Gas) : Unit - 2……….08. Renata Pharmaceuticals Ltd

(Mirpur)

09.Renata Pharmaceuticals Ltd (Rajandropur)

10. Army Aviation11. Karnaphuli Steel Mill 12. Modern Erection13. ACME Pharmaceuticals 14. SK+F Pharmaceuticals 15. HP Chemicals 16.Samuda Chemical 17. Sarker Steel

…………………………………

SAJ Upcoming Services

i. Ultrasonic Predictive Maintenance

ii. Laser Alignment iii.XRF Service

NDT and CM Concept Sharing with Future User

(PMRE , Department BUET)

Department of IP, SUST

NDT and CM concept share with Industrial Service

Engineers

DEMONSTRATION

TRANINING

Basic Vibration Analysis Training at Meghnaghat Power Limited,

NDT Product Training at Ghorashal Training Center,

BPDB, Palash, Narsingdi

Videoscope Operational Training at Biman Bangladesh Airlines

Vibration Analysis ISO Category Level-I Training at Chevron

Bangladesh

Vibration Analysis Training at KAFCO

PAUT Operational Training at DUET

SEMINAR

Rana Plaza , Savar

We are experience d in our field,

Let us help you

Thank You