Project Proposal

for

Establish an Industrial Predictive Maintenance and Troubleshooting Lab forProgress of Industrial Sustainability and Productivity of Bangladesh

Project Submitted By:

Saj Engineering & Trading CompanyHouse # 351 (5th Floor), Road # 07,Mirpur DOHS, Dhaka-1216.www.sajetc.com

Project DescriptionIn more than last 59 years the inspection and maintenance technologies of Powergeneration and production industry have been developed all around the world. Todetect the problem and avoid the failure of Power generation and Production plant(like power, petrochemical, fertilizer, Pharmaceuticals, Cement Plant, Aviation,Ship Building) is very important and essential to develop the Non Destructive Testing(NDT) and Condition Monitoring (including Vibration Analysis, Oil Analysis, UltrasonicAnalysis and Thermal Analysis). Most of power and process plants in Bangladesh arevery aged, maintenance cost come huge and irregular shut down they cannot produceoptimum power and production. By developed predictive maintenance concept you canminimize plant maintenance cost reduce plant irregular shut down and it help increaseplant efficiency.Object of the Project: Develop the NDT and Condition Monitoring facilities for Power Generation andproduction Plant. Make more reliable to power plant Service. Save the plant from upcoming failure. Reduce the Lube Oil Cost by increasing the interval time of oil change. Detect the engine problems by Lube Oil Analysis. Avoid the accident caused by hidden crack/damage of critical power plantequipment Reduce the maintenance cost by doing maintenance where and when required. Make the proper maintenance and inspection facility for new plant.Predictive maintenance (PdM) techniques help determine the condition of in-serviceequipment in order to predict when maintenance should be performed. This approachoffers cost savings over routine or time-based preventive maintenance, because tasksare performed only when warranted.The main value of Predicted Maintenance is to allow convenient scheduling of correctivemaintenance, and to prevent unexpected equipment failures. The key is "the rightinformation in the right time". By knowing which equipment needs maintenance,maintenance work can be better planned (spare parts, people, etc.) and what wouldhave been "unplanned stops" are transformed to shorter and fewer "planned stops",thus increasing plant availability. Other advantages include increased equipmentlifetime, increased plant safety, fewer accidents with negative impact on environment,and optimized spare parts handling.

Non-Destructive Testing is a noninvasive technique for determining the integrity of amaterial, component or structure. Because it allows inspection without interferingwith a product's final use, NDT provides an excellent balance between quality controland cost-effectiveness.Condition monitoring is the process of monitoring a parameter of condition inmachinery, such that a significant change is indicative of a developing failure. It is amajor component of Predictive Maintenance (PdM). The use of conditionalmonitoring allows maintenance to be scheduled, or other actions to be taken toavoid the consequences of failure, before the failure occurs.Condition Monitoring Parameter:1. Vibration Analysis2. Oil Analysis3. Thermal Analysis4. Laser Alignment5. Dynamic Balancing

NDT and CM for Power Generation

We provide nondestructive inspection products and solutions for key powergeneration applications, including those for fossil, nuclear, renewable energy markets,transmission and distribution. Our reliable, advanced technology inspection solutionsand support services enable power generation customers to help maximizeefficiency, minimize downtime and enhance productivity with unyielding integrity.Primary and secondary piping: To prevent leakage and failures, piping is regularlyinspected for corrosion, weld defects and gas accumulation using ultrasonics, remotevisual inspection and direct radiography systems. These same technologies are alsoused to inspect pipes, welds and vessel components to help ensure integrity.

Feed water heaters, condensers and heat exchangers Proper operation of thesecrucial components is essential for efficient operation of a power plant. Each machine isinspected internally and externally for fitness for service. Our menu-directed remotevisual inspection and eddy current systems can detect defects and cracks that causeleaks.Nuclear submarinesTo help ensure maximum safety of a submarine crew, numerous nondestructive testsare carried out to verify quality ofthe vessel girth welds, steam generator system, primary and secondary piping andreactor vessels. The submarine environment demands use of all nondestructivetechnologies to help ensure safety.Feed water heaters, condensers and heat exchangers Proper operation of thesecrucial components is essential for efficient operation of a power plant. Each machineis inspected internally and externally forfitness for service. Our menu-directed remote visual inspection and eddy currentsystems can detect defects and cracks that cause leaks.

Reactor vesselHigh-pressure boilers and vessels are kept operating safely using remote visualinspection. Regular inspection for cracks and defects help ensure safe operationand help prevent loss of structural integrity of the vessel.Nuclear fuel and fuel rodsUltrasonics, eddy current and radiography are commonly used inthe manufacturingenvironment to test rods for ovality to ensure the rods fit into a fuel cluster. A fuelassembly that does not fit precisely as designed can cause long and unacceptabledelays in a plant maintenance outage.Turbines and generatorsUsing our remote visual inspection, eddy current and ultrasonic systems, blades anddovetails found in rotating machines, such as turbines and generators, are inspectedfor cracks and defects to minimize downtime and possible injury.

Reactor vesselHigh-pressure boilers and vessels are kept operating safely using remote visualinspection. Regular inspection for cracks and defects help ensure safe operationand help prevent loss of structural integrity of the vessel.Transmission and distributionRemote visual inspection of switches helps ensure compliant and safe operation ofthe substation. Digital Radiography allows for condition-based maintenance ofgas-insulated switches.Image and data sharingRhythm software ties all inspected components of the plant into one data file andhelps plant operators plan maintenance rather than react to forced outages.DICONDE compliant, this software platform is compatible with our digital radiography,phased array ultrasound, remote visual inspection and eddy current technologies.Rhythmencompasses the image management tools that help ensure thorough inspectionresults and rapid data sharing.Manufacturing power plant componentsThe very low tolerance for manufacturing defects or foreign matter inclusions inlarge forgings, such as turbine shafts or in controlling piping and vessel materials,is mitigated by using nondestructive testing systems in the manufacturing facility.Our radiography, film or digital solutions, coupled with ultrasonic, detectsvolumetric defects. Our eddy current systems are used for near surface defectdetection.Blade manufacturing for wind energyThroughout the steps of the blade manufacturing process, ultrasonic technology isused to test composite material for delaminations and defective layering to ensurequality. The bonding of portions of the blade to one another and support structures isalso monitored using ultrasonics.Transmission and distributionRemote visual inspection of switches helps ensure compliant and safe operation ofthe substation. Digital Radiography allows for condition-based maintenance ofgas-insulated switches.Wind GenerationCondition-based inspection of the gearbox in the nacelledecreases the likelihood of catastrophic failure and enablesscheduling of repairs and preventative maintenance. Our easy-to-use remote visual inspection systems require no specialtraining, while producing more uniform inspection results.

SUMMARY OF NDT AND CM METHOD AND APPLICATION

NDT and CMMethod

Area of Application Defect Identification01. Remote Visual inspection Compressor,Combustion chamber,Turbine.Heat ExchangerREACTORBoiler / CondenserValvesPressure vessel

Nick Dents ,Scratches, Corrosions.Cracks. Erosion ,Discoloration ofturbine , pipe blockage, visualizeremote area

02. Dye penetrants Any kind of surface Defect(without porous material)Metals (aluminum, copper,steel, titanium, etc.)GlassMany ceramic materialsRubberPlastics

- Casting Defect- Forging Defect- Welding surface defects- Hairline cracks- Surface porosity- Leaks in new products- Fatigue cracks on in-service components- Quench cracks- Grinding cracks- Overload and impactfractures- Porosity- Laps- Seams- Pin holes in welds- Lack of fusion or braisingalong the edge of the bondline03. Magnetic particle testing

(MT)Apply for finding Surface andSubsurface defect. Materialswith a significant, Iron, Nickelor, Cobalt content aregenerally ferromagnetic

Welding Defect (IncompleteFusion, Slag Inclusion, andPorosity, Inadequate JointPenetration, Under Cut) , Seams,Laps, Grinding cracks Quenchingcracks ,In-service damage,Fatigue , Overload cracks,Lamination04. Ultrasonic Thickness Boiler tubes, steel tank andpressure vessel - Determine Thickness ofBoiler Pipes- Oxide Scale Measurement-Viewing Cross Sectional Image ofchecking point.05. Ultrasonic FlawDetection

Defects findings of welding,crack, fatigue crack,Discontinue of metal Welding Defect and StructuralIntrigity

structure.06 Advanced UltrasonicPhased Arrays07. Radiography testing(RT)

Defect of weld joint, findingdiscontinue of metalstructure Defect of weld joint, findingdiscontinue of metal structure08. Electromagnetic or EddyCurrent

Crack finding from turbineBlade. Apply for finding Surface andSubsurface defect of turbineblade.09. Tube Inspection 5800 CondensersFeed water heatersHeat exchangersAir conditionersEddy current technique issuitable for detecting and sizingmetal discontinuities such as- Corrosion,- Erosion,- Wear,- Pitting,- Baffle cuts,- Wall loss, and- Cracks10. Hardness Testing Metallic and Non MetallicParts and equipments Determine the hardness ofparticular area.-11. XRF/PMI Known for composition ofUnknown Material andChecking Quality control, Application of XRF in PowerGeneration industry:

- Element trace,- Composition inaccuracy,- Chemical concentrationinaccuracy Corrosion,- Contamination,- Checking Quality control,12. Thermography Process PlantTank/vessel levelsMotorBearingElectrical ConnectionFuse BoxFanHigh Voltage SubstationSwitch Gear

Hot spot, cold spot, slack/looseconnectors, overheated motorbearing, substation hot spot,loose connection, damaged ormissing insulation

13. Vibration Analyzer TurbineGeneratorPumpMotorFD FanID FanGear

Routine Vibration Analysis,Leaser Shaft Alignment,Dynamic Mass BalancingBum TestMotor Current AnalysisTransient AnalysisOver Speed Protection System14. Vibration Meter andBearing Checker Vibration Meter BearingChecker allows operators to Listen sound pattern of Bearing ,help determine of looseness,

quickly and easily checkmachine and bearingcondition. Operators can also“listen” to the pattern of thevibration on the bearing byusing the audio output andstandard headphones.

resonance, Unbalance,Misalignment and Cane measureof Vibrate rate.

15. Lube Oil Testing EngineBearingGearTurbineCompressorLube condition, lubricantdegradation, lubricantcontamination, viscosity index,lubrication failure, fatigue,bearing fatigue, TBN, TAN,Particle count, particle shapeanalysis, elemental analysis.16. UE System (LeakDetector) Valve leakTankSteam TrapsBearingLubrication FailureFansSwitchgearTransformerRelaysBreaker

Compressed and vacuum leak,lubrication problem, bearingfaults, corona, arcing, tracking,

17. Guided Wave System(Ultrawave LRT)18. High Speed Camera01.Remote Visual Inspection (RVI) :Remote means inaccessible, where you cannot reach by naked eye. Some tools will helpyou look remote zoon where you desire to look without open or disassemble or destroy.Remote Visual Inspection (RVI) is a Non-Destructive Testing (NDT) technique used todetect and examine a variety of visible flaws; such as cracks, corrosion, contamination,structural integrity, and other discontinuities. Remote visual inspections also oftenprovide supplemental information for other NDT methods. Remote Visual Inspection isby far the most common and relatively simple NDT technique. Visual Testing (VT) isusually the first choice of any inspection as it offers an immediate and less costlyapproach as compared to other NDT methods.Area of Application:- Gas,Steam & Wind turbines- Compressor,- Combustion chamber,- Heat Exchanger- Boiler / Condenser- Valves

- Pressure vessel- Electrical generators & transformers- Sanitary piping & tubing- Boiler water piping & components- Nuclear reactor heads, reactor coolant pumps, demineralizers, containmentstructure, & other components- Piping systems such as service water, fire protection, oil, coal handling, steam,boiler, feed water, & other piping- Condenser, feed water heaters, steam generators, & other heat exchangers- Foreign material search & retrieval.- Surveillance, covert Operations, search & rescue tasks etc.

Objet for Borescopic Inspection:Find the welding defect of Discolor , Groove , Undercut ,Crack ,Porosity, IncompletePenetration , Concavity , Convexity , Excess Penetrate , Nick Dents, Scratches, Corrosions.Cracks, Erosion, Discoloration of turbine, pipe blockage, visualize remote areaTools Used for RV :1. Borescope2. Fiberscope3. Videoscope/Endoscope02.

Dye penetrant inspection (DPI),

Dye penetrant inspection (DPI), also called liquid penetrant inspection (LPI) orpenetrant testing (PT), is a widely applied and low-cost inspection method used tolocate surface-breaking defects in all non-porous materials (metals, plastics, orceramics). The penetrant may be applied to all non-ferrous materials and ferrousmaterials, although for ferrous components magnetic-particle inspection is often usedinstead for its subsurface detection capability.Materials that are commonly inspected using LPI include the following:- Metals (aluminum, copper, steel, titanium, etc.)- Glass- Many ceramic materials- Rubber- PlasticsLiquid penetrant inspection can only be used to inspect forflaws that break the surface of the sample. Some of these flaws arelisted below:

- Casting defect- Forging defect- Welding surface defects- Hairline cracks- Surface porosity- Leaks in new products- Fatigue cracks on in-service components- Quench cracks- Grinding cracks- Overload and impact fractures- Porosity- Laps- Seams- Pin holes in welds- Lack of fusion or braising along the edge of the bond line

Tools:Dye Pretrant Testing is done for surface defects finding.For this testing userused the Magnafluxmade followingproducts:1. Cleaner,2. Penetrant3. Developer.03.Magnetic Particle Testing:

Detecting Crack by make magnetize certain area, surface and subsurface defectidentification is convenient by this test. A material is considered ferromagnetic if it canbe magnetized. Materials with a significant, Iron, Nickel or, Cobalt content are generallyferromagnetic.What types of defect we can detect by use this method:Welding Defect

- Incomplete Fusion,- Slag Inclusion and Porosity,- Inadequate Joint Penetration,- Under Cut) ,- Seams,- Laps,- Grinding cracks ,- Quenching cracks ,- In-service damage ,- Fatigue ,- Overload cracks,- Lamination

Advantages of Magnetic Particle Inspection:

- You can detect both surface and near sub-surface defects.- Can inspect parts with irregular shapes easily.- Precleaning of components is not as critical as it is for some other inspectionmethods.- Fast method of inspection and indications are visible directly on the specimensurface.- Considered low cost compared to many other NDT methods.- Is a very portable inspection method especially when used with battery poweredequipment.

Magnetic Particle Testing Products: User use following equipment for MPI Test

1. Magnetic Yoke2. Magnetic Particle Magnetic Bench3. Black Light (UV)4. Residual Field Indicator/ Pie Gauge5. Black Ink (7HF)6. White Contrast Paint(WCP)7. Fluorescent Bath (14 AM)04.

Ultrasonic Thickness Gages:Using principle of ultrasound a small machinecan measure thickness of metallic or nonmetallic pipe, tank, steel structure just touch

from one side. This gages help quality control, reliability, and condition monitoring in acost-effective and user-friendly way.Area of Application: Ultrasonic gages require access to only one side of pipes, tanks,tubing, containers, hollow castings, large metal or plastic sheets, and other test pieceswhere the inside surface is impossible or difficult to reach. , including metals,composites, fiberglass, ceramics, and rubber.Benefits:

- Machine show metal thickness, paint thickness and cross sectional imagetogether.- Internal oxide and scale measurement- External and Internal corrosion- No cutting or sectioning of parts is required, saving scrap and labor costs..- The system saves a complete record of each tube & the whole boiler for laterpost analysis & tracking.- Apart from detecting wall loss the system is capable of detecting hydrogendamage, pitting & caustic gouging (by measuring signal attenuation) which is notdetected with conventional means.Tools:

Ultrasonic Thickness Gages:1. Ultrasonic Thickness Gage (With Coating Thickness measurement option)2. Ultrasonic Corrosion Thickness Gage3. Ultrasonic Precision Thickness Gage4. Ultrasonic Bond Tester5. Pet Bottle Thickness Gage6. Thickness Gage Transducer/Probes and Accessories

05.

Ultrasonic Flaw Detection ( Conventional):In ultrasonic testing, high frequency sound waves created by a vibrated crystal in probeare transmitted into a material to detect imperfections or to locate changes in materialproperties. The most commonly used ultrasonic testing technique is pulse echo where-by sound is introduced into a test object and reflections (echoes) from internalimperfections or the part's geometrical surfaces are returned to a receiver. This methodis very sensitive to detect crack type defects but requires extensive training for operatorto interpret the result.Applications:Most weld discontinuities including

- Cracks,- Slag,- Lack of fusion,- Lack of bond,- Accurate thickness measurement possible- To measure intergranular corrosion quantitatively

Advantages :Most sensitive to planar type defectsTest results known immediatelyHigh penetration capabilityRequires access from only one surface06.Advanced Ultrasonic Phased Arrays:

Phased array Ultrasonics (PA) is an advanced method of ultrasonic testing that hasapplications in medical imaging and industrial nondestructive testing. Commonapplications are to noninvasively examine the heart or to find flaws in manufacturedmaterials such as welds. Ultrasonic test instruments have been used in industrialapplications for more than sixty years. Since the 1940s, Conventional UT used singleelement transducer Phased array system use multi element transducer. So PA scanningspeed is much higher and accurate than conventional.Phased array is widely used in several industrial sectors, such as construction or powergeneration. This method is an advanced NDT method that is used to detect componentfailures i.e. cracks or flaws and thereby determine component quality. Phased array canbe used for the following industrial purposes: Inspection of Welds Thickness measurements Corrosion inspection Flaw detection Detect hidden cracks, Voids, Porosity,

Other internal discontinuities in metals, Composites, plastics, and ceramics, as well as to measure thickness and Analyze material properties.Area of Inspection for power plant: We inspected following component and zone byAdvanced Ultrasonic Phased Array01. Supar Heater Tube 02. Water wall Tube 03. Tube to Connect Ceiling Super HeaterHeader To Boiler Dram, 04. Condenser Tube 05. Over Heated Convective Supper Heater06. Platen To Platen Tube 07. Deaerator 08. Valve Joints 09. Down Commar Line 10.Economizer Tube 11. Economizer to Boiler Dram Line 12. Boiler Dram Outlet Line 13.Ceiling Super Heater Tube 14. Main Steam Line [Tube to Steam Collector Line] 15.Injection Tube 16. Ceiling Super Heater Header to Boiler Dram

07.

Radiography Testing ProductsRadiography is the most commonly known non-destructive test method. Radiographycan be used to obtain permanent image of surface and sub-surface (embedded)discontinuities. The same discontinuities can be radiographed again after a period ofservice life and the radiographs can be compared to measure the change in the size andshape of the discontinuity. There are numerous applications of radiography inengineering applications.Some of the common uses are detection of surface and subsurface features of interest inwelded parts, castings, forgings, wall thickness measurement, corrosion mapping,detection of blockages inside sealed equipment, detection of reinforcing material inconcrete slabs, measuring bulk density of materials measuring porosity in concrete etc.The conventional film radiography is the most sensitive test method. On the contrarydigital or computed radiography have certain advantages over conventional filmradiography.

,.Radiography setup is following1. X-Ray Generator2. X-Ray Generator for Crawler3. X-Ray Control Unit4. Gamma-Projector5. Computed Radiography Scanner6. Radiation Survey Meter7. Densitometer8. X-Ray Film9. RT Accessories

08. Eddy Current:Eddy-current test uses electromagnetic induction to detect flaws in conductivematerials. The eddy current test set-up consists of a circular coil which is placed on thetest surface. The alternating current in the coil generates changing magnetic field whichinteracts with the conductive test surface and generates eddy current. The flow of eddycurrent can be disrupted due to change in resistivity or conductivity, magneticpermeability, any physical discontinuities. The change in eddy current flow and acorresponding change in the phase and amplitude is measured against known values.Eddy current test method can detect very small cracks in or near the surface of thematerial, the surfaces need minimum preparation. The biggest advantage of the eddycurrent test method is that is can be employed to determine surface flaws on painted orcoated surface. Eddy current flaw detection is commonly used in the aerospace industry,crane industry, concrete pumping industry and other general industries where theprotective surface coating cannot be removed.The crane industry and crane owners benefits most from the application of eddy currenttest method to detect surface flaws underneath the protective coating (paint ). Theexorbitant cost of paint removal and repainting is eliminated by applying eddy currentflaw detection method as compared to magnetic particle test. It is also useful for makingelectrical conductivity and coating thickness measurements. Eddy current test iscommonly employed for rapid thickness testing of coatings - conductive and non-conductive.The principle of eddy current test which measures the change in resistivity in the

conductive material makes it useful in wide range of applications such as conductivitymeasurement, sorting of material, assessment of heat treatment condition, sorting ofmaterials on the basis of hardness and strength, thickness measurement of thincomponents.09.MULTISCAN5800 TUBE INSPECTION SYSTEM:

Eddy Currents are most effectively used to check for cracking located at the surfaceand sub-surface of metals such as tubes. A number of main areas have been identifiedwhere cracking occurs are Eddy current inspections form a vital part of checkingpower plant for the cracks and faults that can lead to serious accidents. As many ofthe cracks appearing in power plant are fatigue induced and thus surface- breaking,it is important to employ eddy current inspection methods in order to detect them.MultiScan5800 have following four type of test facility.Eddy CurrentMagnetic Flux LeakageRemote FieldIRIS UltrasoundArea of Application MultiScan5800:CondensersFeed water heatersHeat exchangersAir conditionersEddy current technique is suitable for detecting and sizing metal discontinuitiessuch asCorrosion,Erosion,Wear,Pitting,Baffle cuts,Wall loss, and cracks

10.

Hardness Tester:Hardness Testing is a widely used method for determining hardness of materials usingtest methods such as Vickers, Brinell, Knoop, Rockwell, Shore and IRHD. Portablehardness testers come in a variety of types with the ability to test most metals, alloysand plastics ranging from soft polymers, steel, cast steel, alloy tool steel, stainless steel,grey cast iron, spheroid iron, cast aluminum, brass, bronze and wrought copper rubbersto engineering alloys designed for use in the most arduous conditions or most severeoperating environments.Model:…………testers are very precise, easy to operate and are used to identify andclassify parts in stock, measure in areas with limited access, control large and/or heavyparts on-site and to conduct tests during production.

11.

XRF X-RAY FLUORESCENCE/PMI (POSITIVE MATERIALS IDENTIFIER):XRF means X-ray fluorescence. XRF is the emission of characteristic "secondary" (orfluorescent) X-ray from a material that has been excited by bombarding with high-energy X-rays.Material tracking and confirmation is critical to the production and maintenance ofpetrochemical processing and power generation facilities. X-ray diffraction (XRD) and X-ray fluorescence (XRF) analyzers are used for incoming material verification, safetyassurance, PMI, and maintenance.Application of XRF in Power Generation industry:- Element trace,- Composition inaccuracy,- Chemical concentration inaccuracy Corrosion,- Contamination,- Checking Quality control,- Instrumental sensitivity.

12.Infrared Thermography:Infrared thermography is one of the most cost effective and proven predictivemaintenance technology available to quickly, accurately and safely locate problemsprior to failure.We provide thermography services for predictive and preventive analysis in all types ofindustries. A trained technician brings the right thermography camera to conduct acomprehensive thermographic survey quickly and accurately. They report the concernareas and vulnerable spots immediately so that you can take corrective actions based onthe severity of the problem.Benefits of ThermographyReduction of production losses due to unplanned downtimeReduced maintenance and repair costsIncreased equipment lifeIncreased Mean-Time-Between-Failures (MTBF)Increased productivity and profitability

13.

Vibration Analysis Technology:Vibration is the first indication of a machine's health. Of all the predictivemaintenance (PM) technologies, vibration analysis is the best measure of machinehealth. Vibration can alert us to so many different conditions that may indicatepotential machine failuresArea of Application:TurbineGeneratorCompressorPumpMotorFD FanID FanGearType of Application:Routine Vibration Analysis,Leaser Shaft Alignment,Dynamic Mass BalancingBum TestMotor Current AnalysisTransient AnalysisOver Speed Protection SystemTools:For Vibration Analysis we have the following systemPortable Vibration MeterPortable Vibration Analysis System12/24 Channel Vibration AnalyzerOnline Vibration Monitoring System(Protection and Prediction Rack)Dynamic Balancing SystemLaser Alignment SystemOver Speed Protection SystemWireless Transmitter (Vibration, Pressure, Temp, Cavity, PH, Flow, Level etc.)Field CommunicatorMotor Current Analysis SystemVibration Strobe LightAnalysis Software (AMS-Suite)

14.VibrationMeterand

Bearing Checker: Vibration Meter Bearing Checker allows operators to quickly andeasily check machine and bearing condition. Operators can also “listen” to the pattern ofthe vibration on the bearing by using the audio output and standard headphones.

15.Lube Oil Analysis:Oil analysis is a quick, nondestructive way to gauge the health , of an engine by looking atwhat's in the oil Oil is the lifeblood of equipment and oil analysis provides answersto machinery health. It is as like as medical blood test, where we can know aboutour diseases from our blood. It is an integral part of the maintenance plan for powerplants, manufacturing plants,trucking companies, construction, equipment,aircraft,refrigeration, systems,processing, chemical plants and etcLube Oil Analysis is the great important for Power Generation Industry. An effective oilanalysis program will keep important assets such as Engines, Gearboxes, Hydraulicsystems, Turbines, Compressors, Generators and any other oil-wetted machinery inoperation by reducing unexpected failures and costly unscheduled down time.Benefits of Lube Oil Analysis:- Convenience of on-site analysis.- Immediate feedback on critical properties.- Extension of oil change intervals.- Reduction in operational and maintenance cost.- Elimination of catastrophic equipment failure.Oil Analysis Technology:For Oil Analysis we have the following system:1. Automated Rotrode Filter Spectroscopy SamplePreparation System for Large Wear Particle Analysis2. Automatic Sample Processer3. Fuel Dilution Meter (Fuel Sniffer)4. Ferrography Laboratory for Wear Particle Analysis5. Portable Fluid Condition Monitor6. FTIR Oil Analyser for Oil Degradation & ContaminationMeasurement7. Portable Fluid Condition Monitor

8. Particle Size, Count and Shape Analyzer9. RDE Atomic Emission Spectrometer10. Oil Analysis Spectrometer for Predictive Maintenance11. Portable Kinematic Viscometer12. AutomaticKinematicViscosityMeasurementof Used andNew OilFluidScan Q1000 (Handheld Lubricant Condition Monitoring):Measures key oil condition parameters including:i. Total Base Number (TBN) ii. Total Acid Number (TAN) iii. Oxidation iv. Nitrationv. Sulfation vi. Incorrect lubricant vii. Additive viii. Glycol/Antifreeze ix. Water x.FAME xi. Glycerin xii. Fuel Dilution in Hydraulic FluidsSpectroVisc Q3000:measurements for high accuracy kinematic viscosity.Spectro LNF Q200 (Direct Imaging Particle Analyser):i. Particle size distribution ii. Particle shape mapSpectroil Q100: Analyse32 Elements in PPM.

16.Ultrasonic Leak Detection & Ultrasonic Predictive Maintenance:Ultrasound inspection offers a unique position for condition monitoring as both a“stand-alone” inspection technology and as an effective screening tool that canspeed up the inspection process and help inspectors determine effective follow-up actions for mechanical, electrical and leak applications. Locating sources ofenergy waste, identifying failure conditions in electrical and mechanical systems allcontribute to helping improve the bottom line. In some cases it can be a dramaticimprovement.For Ultrasonic Leak detection & Predictive Maintenance we have the following system:1. Ultrasound and Leak Detection2. Ultrasound and Mechanical Inspection3. Ultrasound and Electrical Inspection4. Ultrasound and Steam Trap5. Ultrasound and Valve InspectionTYPICAL APPLICATIONS:Pressure/vacuum leaks (turbulence)Compressed airOxygenHydrogen etc.Heat exchangersBoilersCondensersTanksPipesValvesSteam trapsElectric equipment(Arcing/tracking/corona)SwitchgearTransformersInsulatorsPotheadsJunction boxesCircuit breakersMECHANICAL INSPECTIONBearingsLack of lubrication/failurePumpsMotorsGears/gear boxesFansCompressorsConveyersAutomotiveRail roadsMarine

Aviation17.Guided wave technology: Guided wave technology for detectcorrosion and metal loss up to 600 feet long pipe from singlepoint.

We are pleased to inform about Guided Wave technology. Worldwide this technologyis using for confirm integrity of buried, coated, insulated pipe lines.

Guided wave technology is a nondestructive testing method used to locate potentialdegradation, such as internal or external corrosion and metal loss.

Advantages of Guided Waves

High productivity inspection with long-range coverage and rapid screening. Ability to scan pipes with limited access, such as buried, coated, insulated and

through wall pipes, leading to cost reduction for excavation and insulationremoval.

100% screening coverage of pipe wall. Cost effective solution for pipe integrity management programs. In-service inspection (no production shutdown). Inspection lengths range up to 182 meters (600 feet) for single point.

18.

When moving from reactive maintenance to predictive maintenance, it is crucial thatbreakdowns are really understood. One of the basic analysis techniques is to use high-speedcameras in order to characterize events which happen too fast to see, e.g., duringproduction. Similar to in science, with a pre- or post-triggering capability the camera cansimply record continuously as the mechanic waits for the breakdown to happen, followingwhich a trigger signal (internal or external) will stop the recording and allow the investigatorto save a given time interval prior to the trigger (determined by frame rate, image size, andmemory capacity during continuous recording). Some software allows viewing the issues inreal time, by displaying only a subset of recorded frames, minimizing file size and watch timeissues by eliminating useless frames before or after the sequence of interest.

Budgetary Price Idea for following System:

NDT and CMMethod

Area of Application Equipment Details Total PriceBD Taka01. Remote Visual

inspectionCompressor,Combustion chamber,Turbine.Heat ExchangerREACTORBoiler / CondenserValvesPressure vessel

Name: IndustrialEndoscope/VideoscopeModel: IPLEX FX (9.5M length)Manufacturer:OlympusCountry of Origin:Japan02. Dye penetrants Any kind of surface Defect(without porous material)Metals (aluminum, copper,steel, titanium, etc.)GlassMany ceramic materialsRubber

Name: DPT ChemicalsManufacturer:Magnaflux, India1. Cleaner,2. Penetrant

Plastics 3. Developer.03. Magnetic particletesting (MT)a. Apply for finding Surfaceand Subsurface defect.Materials with a significant,Iron, Nickel or, Cobaltcontent are generallyferromagnetic

Name: PortableMagnetic ParticleInspection Kit (Yoke)Model: Y-7Manufacturer:MagnafluxCountry of Origin:Indiab. Name: MagneticParticle InspectionBenchModel: CBAT-60DAC/FWDCManufacturer:MagnafluxCountry of Origin:Indiac. NameModel: :Magnetic ParticleInspection SystemManufacturer: : P-15Portable Power PacMagnafluxCountry of Origin:India04. UltrasonicThickness Gagewith differentoption

Boiler tubes, steel tank andpressure vessel Name: UltrasonicThickness GageModel: 38 DL PlusManufacturer:OlympusCountry of Origin:USA05. Ultrasonic Flaw

DetectionDefects findings of welding,crack, fatigue crack,Discontinue of metalstructure.

Name: Ultrasonic FlawDetectorModel: EPOCH 600Manufacturer:OlympusCountry of Origin:USA06 AdvancedUltrasonic PhasedArrays Name: UltrasonicPhased Array FlawDetectorModel: OmniScan SXManufacturer:OlympusCountry of Origin:USA07. Radiography Defect of weld joint, Name: Portable X-Ray

testing (RT) finding discontinue ofmetal structure GeneratorModel: Site XManufacturer: ICM X-RayCountry of Origin:Belgium08. Electromagnetic

or Eddy CurrentCrack finding from turbineBlade. Name: Portable EddyCurrent Flaw Detector

Model: Nortec 500SManufacturer:OlympusCountry of Origin:Canada09. Tube InspectionSystem 5800MS CondensersFeed water heatersHeat exchangersAir conditionersName : TubeInspection SystemModel: MS 5800Manufacturer:OlympusCountry of Origin:Canada10. PortableHardness Testing Hardness Test for Metallicand Non Metallic Parts andequipments Name : PortableHardness TesterModel: DynaPOCKETManufacturer: GECountry of Origin:Germany11. XRF/PMI Known for composition ofUnknown Material Name : Handheld XRFModel: DELTAPremiumManufacturer:OlympusCountry of Origin:USA12. Thermography Process PlantTank/vessel levelsMotorBearingElectrical ConnectionFuse BoxFanHigh Voltage SubstationSwitch Gear

Name: PortableThermal ImagingCameraModel: Fluke Ti 32Manufacturer: SpectroInc.Country of Origin:USA

13. 24 channelVibrationAnalyzer -Transient VibrationAnalysis for entiremachines or group ofmachine- Transient Analysis forturbo machinery startup,coast down andproduction statemonitoring

Name: CSI 2600Machinery HealthExpertModel: CSI 2600Manufacturer:EmersonCountry of Origin:USA

Routine Vibration Analysis,-Leaser Shaft Alignment,-Dynamic Mass Balancing-Bum Test-Motor Current Analysis-Transient Analysis-Over Speed ProtectionSystemTurbineGeneratorPumpMotorFD FanID FanGear14. Vibration Meterand BearingChecker Purpose: Vibration MeterBearing Checker allowsoperators to quickly andeasily check machine andbearing condition.Operators can also “listen”to the pattern of thevibration on the bearing byusing the audio output andstandard headphones.

Name : Overallvibration checkerModel: 1850 Overallvibration checkerManufacturer:Emerson ProcessmanagementCountry of Origin:USA

15. Lube Oil Testing EngineBearingGearTurbineCompressora. Portable Viscometer foronsite viscositymeasurement without anysolvents.Name: PortableSolvent-Free KinematicViscometerModel: SpectroViscQ3000Manufacturer: SpectroInc.Country of Origin:USAb. FT-IR Oil Analyzer whichis specifically designed forthe molecular analysis oflubricating oil to determineName: FT-IR OilAnalyzer

oil degradation andcontamination.It is used to check TotalAcid Number (TAN), TotalBase Number (TBN),Water, Oxidation, Nitration,Sulfation, Coolant, Fueldilution, Soot and Wearadditive depletion

Model: Q1000Manufacturer: SpectroInc.Country of Origin:USA

c. Wear Particle Counter +Particle Shape Analyzer +Dynamic Viscometer inone unit. Particle countingis required for checking thelube oil cleanliness, howmuch wear is mixed withoil. With particle shapeanalysis it is possible todetermine the proble.

Name: CombinedParticle Counter,Particle ShapeClassifier, andViscometerModel: LNF-Q200Manufacturer: SpectroInc.Country of Origin:USA

d. Oil AnalysisSpectrometer is requiredfor elemental analysiswhich can detect the originof wear particle. It isrequired for thesimultaneous analysis ofwear metals, contaminantsand additives in lubricantsIt can detect up to 32elements which include:Aluminum (Al), Barium(Ba), Boron (B), Cadmium(Cd), Calcium (Ca),Chromium (Cr), Copper(Cu), Iron (Fe), Lead (Pb),Magnesium (Mg),

Name: Spectroil Q100Bench-TopSpectrometerModel: Q100Manufacturer: SpectroInc.Country of Origin:USA

Manganese (Mn),Molybdenum (Mo), Nickel(Ni), Phosphorus (P),Potassium (K), Silicon (Si),Silver (Ag), Sodium (Na),Tin (Sn), Titanium (Ti),Vanadium (V), Zinc (Zn),Carbon (C), Hydrogen (H),Antimony (Sb), Bismuth(Bi), Arsenic (As), Indium(In), Cobalt (Co), Zirconium(Zr), Tungsten (W),Strontium (Sr), Lithium(Li), Cerium (Ce)16. UE System (LeakDetector) Valve leakTankSteam TrapsBearingLubrication FailureFansSwitchgearTransformerRelaysBreaker

Name: PortableUltrasound LeakDetectorModel: LNF-Q200Manufacturer: UASystem, IncCountry of Origin:USA

17. Guided WaveSystem(Ultrawave LRT) High productivityinspection with long-range coverage and rapidscreening. Ability to scan pipeswith limited access, suchas buried, coated,insulated and throughwall pipes, leading tocost reduction forexcavation andinsulation removal. 100% screeningcoverage of pipe wall. Cost effective solutionfor pipe integritymanagement programs. In-service inspection(no productionshutdown). Inspection lengthsrange up to 182 meters(600 feet) for singlepoint.

Name: Guided WaveSystemModel: Ultrawave LRTManufacturer: OlympusCountry of Origin: USA

18. High SpeedCamera

Document Prepared by:

Ferdous KabirMarketing Manager(ASNT NDT Level-II UT, RT, PT and ISO Level-II MT)

Saj Engineering & Trading CompanyHouse# 351(5th Floor), Road# 05,DOHS, MirpurDhaka-1216Bangladesh

Tel# +88-8080693, 8080682Fax# +88-02-8000401Cell# +88-01817-094194

Email: ferdous@sajetc.comhttp://www.sajetc.com