Prospect of Non Destructive Testing and Condition Monitoring Scope in Bangladesh
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The document discusses non-destructive testing (NDT) and condition monitoring practices in Bangladesh. It outlines various NDT techniques like vibration analysis, ultrasound analysis, infrared thermography, and lubricant analysis that are used to monitor the condition of critical equipment in industries. It provides examples of applications in power plants, oil and gas pipelines, boilers, turbines and various manufacturing sectors. The document also shares case studies of defects detected by NDT methods in engines, boilers and turbines to enable predictive maintenance and avoid failures.
Prospect of Non Destructive Testing and Condition Monitoring Scope in Bangladesh
- 1. Prospect of Non Destructive Testing and Condition Monitoring Practice in Bangladesh Prospect of Non Destructive Testing and Condition Monitoring Practice in Bangladesh Ferdous Kabir Marketing Manager ASNT NDT Level II in Ect,UT,RT,MT,PT Saj Engineering & Trading Company
- 2. The Fales & Gray Car Works Explosion of 1854
- 3. SULTANA steamboat Exploration and died 1800 for failure of Boiler
- 4. 117 people hade died a fire in Tazreen Garments
- 5. 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. 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.
- 8. Types of machines Motors Pumps Fans Gearboxes Engines Compressors Steam Turbines Generators Gas Turbines Hydro Turbines Rotating Or Reciprocating Machines Motors Pumps Fans Gearboxes Engines Compressors Steam Turbines Generators Gas Turbines Hydro Turbines Rotating Or Reciprocating Machines
- 9. EquipmentPerformance PP Lubrication Excellence Proactive Precision Maintenance Alignment, Balance, etc. Select Suppliers Supplier Specifications Metrics Equipment Ranking RCM Predictive Reactive We are in here EquipmentPerformance Time FF RCM TPM RCA/FMEA RCD Training Programs Written Procedures Job Planning/Scheduling CMMS System We are in here Machine Condition Chart
- 10. Condition Monitoring For your Plant Vibration Analysis Oil Analysis Ultrasound Analysis Thermal Analysis If you think this is your plant, then your plant is stand on this 4 technologies
- 11. Machinery Health Monitoring StrategyMachinery Health Monitoring StrategyMachinery Health Monitoring StrategyMachinery Health Monitoring Strategy ~125 Machines Total # Machines 2,500 Typical Industrial Process Plant 5%5% CriticalCritical 25%25% EssentialEssential 30%30% ImportantImportant 20%20% SecondarySecondary 20%20% NonNon--EssentialEssential Turbines Generators Compressors Motors Pumps Fans Gears Application at Typical PlantApplication at Typical Plant Online Solutions forOnline Solutions for critical machinerycritical machinery WirelessWireless TransmittersTransmitters~1375 Machines ~500 Machines ~500 Machines 5%5% CriticalCritical 25%25% EssentialEssential 30%30% ImportantImportant 20%20% SecondarySecondary 20%20% NonNon--EssentialEssential Motors Pumps Fans Gears WirelessWireless TransmittersTransmitters Multi TechnologiesMulti Technologies Portable SolutionsPortable Solutions
- 12. 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 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
- 13. Mining : 2 CNG Cylinder Testing Point: 5+ Aviation : 5+ Shipbuilding: 20+ Cement : 50+ Welding and welder performance test Paper : 35+ Sugar : 20+ Mining : 2 CNG Cylinder Testing Point: 5+ Aviation : 5+ Shipbuilding: 20+ Cement : 50+ Welding and welder performance test Paper : 35+ Sugar : 20+
- 14. 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+
- 15. 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
- 17. 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 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
- 18. Date of Inspection : 11 and 14 October, 2012 Generation Capacity: 5 MW Total Running Time: 40,564.50 Hours
- 19. 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
- 20. Defect Occurred
- 21. Hardness Testing
- 22. 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. 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.
- 23. Dye Penetrant Testing Process Three liquids are used in this method. 1. Cleaner 2. Penetrant 3. Developer Three liquids are used in this method. 1. Cleaner 2. Penetrant 3. Developer
- 37. 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
- 41. 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
- 42. GE 9E Gas Turbine increase temperature faster. After a details endoscopy inspection a sand and foreign particle blocked water line
- 43. Boiler Case Study This 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.
- 44. Turbine Case Study#1 Severe Crack found Turbine Nozzle of Alstom 34.5MW Turbine after the Endoscopy Inspection.
- 45. Dye Penetrant Testing Service
- 47. Vibration Analysis and Dynamic Balancing
- 50. See the Image See the Temperature, See the Temperature See the Problem. Infrared & Thermal Testing See the Image See the Temperature, See the Temperature See the Problem.
- 53. IR Thermography at Sangu Gas Field
- 55. Mechanical Application A- Over heating bearing & shaft B- Blockage in process line C- Conveyor belt failure
- 56. IR Thermography at Garments Industry
- 57. 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
- 59. Ultrasonic Thickness Gagging Service
- 60. CONVENTIONAL ULTRASONIC TESTING SERVICE
- 61. Advanced Phased Array Ultrasonic Application at Present in Bangladesh Advanced Phased Array Ultrasonic Application at Present in Bangladesh
- 63. What we see in Medical Ultrasonic Test
- 64. What is the Difference in Medical Ultrasonogram and Phased Array Ultrasonic Test? Nothing Special, Both are Phased Array Ultrasonic Test Medical Industrial
- 66. WELDING AREA OF STRUCTUREWELDING AREA OF STRUCTURE Web Butt Joint Flange Butt Joint
- 68. PAU in Shipbuilding Industry
- 70. Ghorashal Power Plant Unit -2 Clint: Technoprome Export ,Russia Ghorashal Power Plant Unit -2 Clint: Technoprome Export ,Russia
- 73. Restoration of 190 MW Meghnaghat Power Plant
- 74. GAS Pipe Line Inspection
- 75. Shahbagpur Gas Process Plant, BAPEX
- 76. Pipe Line is our Next Target…
- 77. 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 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
- 85. XRF Analyzer
- 87. Vibration Analysis and Dynamic Mass Balancing
- 89. 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)
- 90. 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 …………………………………
- 91. SAJ Upcoming Services i. Ultrasonic Predictive Maintenance ii. Laser Alignment iii. XRF Service i. Ultrasonic Predictive Maintenance ii. Laser Alignment iii. XRF Service
- 92. NDT and CM Concept Sharing with Future User (PMRE , Department BUET)
- 93. Department of IP, SUST
- 94. NDT and CM concept share with Industrial Service Engineers
- 99. TRANINING
- 100. Basic Vibration Analysis Training at Meghnaghat Power Limited,
- 101. NDT Product Training at Ghorashal Training Center, BPDB, Palash, Narsingdi
- 102. Videoscope Operational Training at Biman Bangladesh Airlines
- 103. Vibration Analysis ISO Category Level-I Training at Chevron Bangladesh
- 104. Vibration Analysis Training at KAFCO
- 107. PAUT Operational Training at DUET
- 108. SEMINARSEMINAR
- 110. Rana Plaza , Savar
- 111. We are experience d in our field, Let us help you Thank You We are experience d in our field, Let us help you Thank You