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