Prospect of non destructive testing and condition monitoring scope in bangladesh
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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
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The Fales & Gray Car Works Explosion of 1854
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SULTANA steamboat Exploration and died 1800 for failure of Boiler
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117 people hade died a fire in Tazreen Garments
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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.
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Types of machines
MotorsPumpsFansGearboxesEnginesCompressorsSteam TurbinesGeneratorsGas TurbinesHydro Turbines
Rotating Or
Reciprocating Machines
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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
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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
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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
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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
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Mining : 2 CNG Cylinder Testing Point: 5+ Aviation : 5+ Shipbuilding: 20+ Cement : 50+ Welding and welder performance test Paper : 35+ Sugar : 20+
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Pharmaceuticals: 200+ Research and educational institutions
: 20+ Steel Structure : 20+ Survey Company : 6+ Bangladesh Railway : Boiler Manufacture : 10+ Steel structure: 20+
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Steel Bridge LPG and LNG : Germans and Textile : 6000+ Gun Barrel and Shell : 1 Foundry (casting) Steel Mills
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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
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Date of Inspection : 11 and 14 October, 2012Generation Capacity: 5 MWTotal Running Time: 40,564.50 Hours
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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
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Defect Occurred
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Hardness Testing
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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.
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Dye Penetrant Testing Process
Three liquids areused in this method.
1. Cleaner2. Penetrant3. Developer
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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
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Industrial Endoscopic Inspection
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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
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GE 9E Gas Turbine increase temperature faster. After a details endoscopy inspection a sand and foreign particle blocked water line
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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.
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Turbine Case Study#1Severe Crack found Turbine
Nozzle of Alstom 34.5MW Turbine after the Endoscopy Inspection.
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Dye Penetrant Testing Service
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Magnetic Particle Inspection
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Vibration Analysis and Dynamic Balancing
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Hardness Testing Service
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See the Image See the Temperature, See the Temperature See the Problem.
Infrared & Thermal Testing
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IR Thermography Service
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IR Thermography at Sangu Gas Field
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Mechanical Application
A- Over heating bearing & shaft B- Blockage in process line C- Conveyor belt failure
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IR Thermography at Garments Industry
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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
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ULTRASONIC TESTING
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Ultrasonic Thickness Gagging Service
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CONVENTIONAL ULTRASONIC TESTING SERVICE
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Advanced Phased Array Ultrasonic Application at
Present in Bangladesh
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What we see in Medical Ultrasonic Test
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What is the Difference in Medical Ultrasonogram and Phased Array Ultrasonic Test?
Nothing Special, Both are Phased Array Ultrasonic Test
Medical Industrial
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WELDING AREA OF STRUCTUREWELDING AREA OF STRUCTURE
Web Butt Joint Flange Butt Joint
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PAU in Shipbuilding Industry
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Ghorashal Power Plant Unit -2
Clint: Technoprome Export ,Russia
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Restoration of 190 MW Meghnaghat Power Plant
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GAS Pipe Line Inspection
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Shahbagpur Gas Process Plant, BAPEX
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Pipe Line is our Next Target…
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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
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CEMENT PLANT
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BOILER MANUFACTURER
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XRF Analyzer
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Vibration Analysis and Dynamic Mass Balancing
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Ultrasonic Detection System
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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)
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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
…………………………………
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SAJ Upcoming Services
i. Ultrasonic Predictive Maintenance
ii. Laser Alignment iii.XRF Service
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NDT and CM Concept Sharing with Future User
(PMRE , Department BUET)
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Department of IP, SUST
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NDT and CM concept share with Industrial Service
Engineers
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DEMONSTRATION
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TRANINING
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Basic Vibration Analysis Training at Meghnaghat Power Limited,
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NDT Product Training at Ghorashal Training Center,
BPDB, Palash, Narsingdi
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Videoscope Operational Training at Biman Bangladesh Airlines
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Vibration Analysis ISO Category Level-I Training at Chevron
Bangladesh
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Vibration Analysis Training at KAFCO
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PAUT Operational Training at DUET
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SEMINAR
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Rana Plaza , Savar
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