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Prospect of Non DestructiveTesting and ConditionMonitoring Practice in
Bangladesh
Prospect of Non DestructiveTesting and ConditionMonitoring 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 aredesigned to help determine the condition of in-serviceequipment in order to predict when maintenanceshould be performed.
Non Destructive Testing and Condition Monitoring isthe part of Predictive Maintenance (PdM).
Predictive maintenance (PdM) techniques aredesigned to help determine the condition of in-serviceequipment in order to predict when maintenanceshould be performed.
Types of machines
MotorsPumpsFansGearboxesEnginesCompressorsSteam TurbinesGeneratorsGas TurbinesHydro Turbines
RotatingOr
Reciprocating Machines
MotorsPumpsFansGearboxesEnginesCompressorsSteam TurbinesGeneratorsGas TurbinesHydro Turbines
RotatingOr
Reciprocating Machines
Equipment Perform
ance
PP Lubrication Excellence
Proactive
Precision MaintenanceAlignment, Balance, etc.
Select SuppliersSupplier Specifications
MetricsEquipment Ranking
RCM
Predictive Reactive
We are inhere
Equipment Perform
ance
TimeFF
RCMTPM
RCA/FMEARCD
Training Programs
Written ProceduresJob Planning/Scheduling
CMMS System
We are inhere
Machine Condition Chart
Condition Monitoring For your Plant
VibrationAnalysis
Oil Analysis
UltrasoundAnalysis
ThermalAnalysis
If you think this is your plant, then your plant is stand on this 4 technologies
Machinery Health Monitoring StrategyMachinery Health Monitoring StrategyMachinery Health Monitoring StrategyMachinery Health Monitoring Strategy
~125Machines
Total # Machines 2,500Typical Industrial Process Plant
5%5%CriticalCritical
25%25%EssentialEssential
30%30%ImportantImportant
20%20%SecondarySecondary
20%20%NonNon--EssentialEssential
TurbinesGenerators
Compressors
MotorsPumps
FansGears
Application at Typical PlantApplication at Typical Plant
Online Solutions forOnline Solutions forcritical machinerycritical machinery
WirelessWirelessTransmittersTransmitters~1375 Machines
~500 Machines
~500 Machines
5%5%CriticalCritical
25%25%EssentialEssential
30%30%ImportantImportant
20%20%SecondarySecondary
20%20%NonNon--EssentialEssential
MotorsPumps
FansGears
WirelessWirelessTransmittersTransmitters
Multi TechnologiesMulti TechnologiesPortable SolutionsPortable Solutions
NDT and CM Customer in Bangladesh
Power Generation: 200+ Fertilizer Factory: 8Chemical Plant: 10+Refinery: 10+Oil Reserve TankGas Production Field: 23 +Gas Distribution: 6 Gas Transmission : 1774 KM
Power Generation: 200+ Fertilizer Factory: 8Chemical Plant: 10+Refinery: 10+Oil Reserve TankGas Production Field: 23 +Gas Distribution: 6 Gas Transmission : 1774 KM
Mining : 2CNG Cylinder Testing Point: 5+Aviation : 5+ Shipbuilding: 20+Cement : 50+Welding and welder performance test Paper : 35+ Sugar : 20+
Mining : 2CNG 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+
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
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 : 12,071MW
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
Present Installation of Power Production Capacity : 12,071MW
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
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 detectthe surface cracks or defects. Dyepenetrant Testing (DPT) is one of the mostwidely used nondestructive Testing (NDT)methods. DPT can be used to inspectalmost any material provided that itssurface is not extremely rough.
This method is commonly used for detectthe surface cracks or defects. Dyepenetrant Testing (DPT) is one of the mostwidely used nondestructive Testing (NDT)methods. DPT can be used to inspectalmost any material provided that itssurface is not extremely rough.
Dye Penetrant Testing Process
Three liquids areused in this method.
1. Cleaner2. Penetrant3. Developer
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
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
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 detailsendoscopy inspection a sand and foreign particle blocked waterline
Boiler Case StudyThis is an Oil Tanker AuxiliaryBoiler. The boiler cant be ran dueto its leaky tube. There were 400tubes. Two defective tubes foundby Endoscopy Inspection. And thenit is sealed from both side.
Turbine Case Study#1Severe Crack found Turbine Nozzleof Alstom 34.5MW Turbine after theEndoscopy Inspection.
Dye Penetrant Testing Service
Magnetic Particle Inspection
Vibration Analysis andDynamic Balancing
Hardness Testing Service
See the ImageSee the Temperature,
See the TemperatureSee the Problem.
Infrared & Thermal Testing
See the ImageSee the Temperature,
See the TemperatureSee the Problem.
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. Incorrectlubricant, 5. Anti-Wear additives, 6. Soot, 7. Glycol,8. Water Content, 9.TAN, 10. TBN, 11. Viscosity
ULTRASONIC TESTINGULTRASONIC TESTING
Ultrasonic Thickness Gagging Service
CONVENTIONAL ULTRASONIC TESTING SERVICE
Advanced Phased Array UltrasonicApplication at Present in BangladeshAdvanced Phased Array UltrasonicApplication at Present in Bangladesh
What we see in Medical Ultrasonic Test
What is the Difference in Medical Ultrasonogramand Phased Array Ultrasonic Test?
Nothing Special, Both are Phased Array Ultrasonic Test
Medical Industrial
WELDING AREA OF STRUCTUREWELDING AREA OF STRUCTURE
Web Butt JointFlange Butt Joint
PAU in Shipbuilding Industry
Ghorashal Power PlantUnit -2
Clint: Technoprome Export,Russia
Ghorashal Power PlantUnit -2
Clint: Technoprome Export,Russia
Restoration of 190 MW MeghnaghatPower 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 toGermany (1,212 km) sea base of Balticsea
Blue Stream Project (1,213), sea base ofBlack sea
East West Pipeline Project , Chine(4,167 km) (www.chinaoilweb.com)
Nord Stream Project (Russia toGermany (1,212 km) sea base of Balticsea
Blue Stream Project (1,213), sea base ofBlack sea
CEMENT PLANTCEMENT PLANT
BOILER MANUFACTURERBOILER 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 Plant
04. Sylhet 150MW Power Plant
05. Katakhale Power Plant
06. Siddirgonj Power Plant…….
07. Ghorasal ST (Gas) : Unit - 2……….
08. Renata Pharmaceuticals Ltd (Mirpur)
01. 110MW Power Plant (PDB)
02. Ashugong Power Plant (Unit-2)
03. Rawjan Power Plant
04. Sylhet 150MW Power Plant
05. Katakhale Power Plant
06. Siddirgonj Power Plant…….
07. Ghorasal ST (Gas) : Unit - 2……….
08. Renata Pharmaceuticals Ltd (Mirpur)
09.Renata Pharmaceuticals Ltd(Rajandropur)
10. Army Aviation
11. Karnaphuli Steel Mill
12. Modern Erection
13. ACME Pharmaceuticals
14. SK+F Pharmaceuticals
15. HP Chemicals
16.Samuda Chemical
17. Sarker Steel …………………………………
09.Renata Pharmaceuticals Ltd(Rajandropur)
10. Army Aviation
11. Karnaphuli Steel Mill
12. Modern Erection
13. ACME Pharmaceuticals
14. SK+F Pharmaceuticals
15. HP Chemicals
16.Samuda Chemical
17. Sarker Steel …………………………………
SAJ Upcoming Services
i. Ultrasonic PredictiveMaintenance
ii. Laser Alignment
iii. XRF Service
i. Ultrasonic PredictiveMaintenance
ii. Laser Alignment
iii. XRF Service
NDT and CM Concept Sharing with FutureUser
(PMRE , Department BUET)
Department of IP, SUST
NDT and CM concept share withIndustrial Service Engineers
DEMONSTRATIONDEMONSTRATION
TRANINING
Basic Vibration Analysis Trainingat Meghnaghat Power Limited,
NDT Product Training at GhorashalTraining Center, BPDB, Palash,
Narsingdi
Videoscope Operational Training at BimanBangladesh Airlines
Vibration Analysis ISO CategoryLevel-I Training at Chevron
Bangladesh
Vibration Analysis Training at KAFCO
PAUT Operational Training at DUET
SEMINARSEMINAR
Rana Plaza , Savar
We are experience din our field,
Let us help you
Thank You
We are experience din our field,
Let us help you
Thank You