A Sample Presentation of Air Heater Inspection

1. Prepared by
Thanks & Best Regards,
Ashik Ahmed
Section Manager
Technical Services
Multinational Fertilizer Company
Tel.: +880 31 618972~4; Ext.: 2237 (Office)
Mobile: +880 1730059920

2. General Information
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Date of Inspection: 18~19 March 2013
Place of Inspection:
o Wingles,France
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Participants:
o Our Company
o GEA
o LLOYD’S
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Our Engineers:
o Ashik Ahmed- SectionManager
o Kh. Md. Ruhul Amin - Project Engineer (Mech)

3. Inspected Items & Shop Inspection Basis
Fluidization Air Heater: 2-E-601C
Atomization Air Heater: 2-E-614
First Bed Cooler Air Heater: 2-E-613
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Quality Plan for Heater Inspection(Rev. B, 08-Oct2012)-Delivered by GEA & Approved by our company
All Documents approved by Our Company prior to
shop test

4. List of Final Deliverables
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Mill test certificates of all materials.
Welding procedure Specifications
Welding procedure qualification record.
Welder performance qualification.
Certificate of calibration of instruments, i.e pressure gauges
Updated data sheets
Updated GADs
End of manufacturing report
Installation instruction of heaters
Certificate for crates materials
Packing List
Passivation of welding
Fluorescein test report on tube sheet
NDT reports
Pressure drop & heat capacity assurance documents

5. Presentation on GEA Heaters
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After Introduction a brief presentation was done by GEA regarding their
company.
Mr. Sebastien Le Moignic had carried out the presentation.
GEA,Wingles were established on 1950 then on 1978 it was Acquisition
by GEA
200 employees are now working on a 50 000m² manufacturing site

6. Key Customers of GEA:-

7. Fin orientation of GEA Heaters

8. Aluminum Fin Corrosion

9. The GEA solution against corrosion:
PoluAl XT.pdf
The protection of the Heat Exchanger
against corrosion risks due to the
environment must take into account
the following parameters:
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Thermal transfer
Resistance to Ultraviolet's
Thickness
Adhesion to the fins
Superficial tension and roughness
Flexibility (dilatations)
Mechanical resistance
Chemical resistance

10. The PoluAl XT® coating
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KAFCO asked GEA about remedy if the coating damaged.
GEA informed that, palual is a product from “Blygold”. If any
maintenance of the coating is required than KAFCO can communicate
with the company, procure and apply the product in accordance with
their instruction.
GEA provided the brochure of “Blygold”
Polual is used on HVAC system of Palm Island & Burj Dubai

11. Inspection
I) Pressure Test

12. Inspection
I) Pressure Test

13. Pressure Test
Pressurized Water from Pump
Heat Exchangers got
pressurized
Pressurized up to 22.5 Barg
I) The heat exchangers were
kept pressurized for 04
Hours.
II) No leakage/Pressure
drop was observed during
that time.
III) The pressure gauges are
checked & found
certification during the test
date.
Water To Pumps
Water Tank

14. Inspection
II) Dimensional Check
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During visual inspection of three heaters, some minor
discrepancies were found which will not affect installation
of air pre heaters. GEA informed that they will update the
GAD according to measurement found during visual
inspection. GEA also has to correct the date of “Year build”
in nameplate of GAD

15. Inspection
III) Nozzle Check
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GEA manufactured nozzle flanges in accordance with European
standard, EN 1092 instead of Our Company’s specified standard
B16.5.
Then these two standards were compared and found that they are not
compatible.
In this regard GEA proposed that they can supply the counter flanges
for the nozzle flanges.

16. PT Report Review
Penetrant test report of the welding joints of all the three air
heaters were checked & found OK.
No flaws were found & as well as the procedure was found
OK.
 Dye penetrant inspection (DPI), also called liquid
penetrant inspection (LPI) or penetrant testing (PT), is a
widely applied and low-cost inspection method used to
locate surface-breaking defects in all nonporous materials
(metals, plastics, or ceramics). The penetrant may be applied
to all non-ferrous materials and ferrous materials; although
for ferrous components magnetic particle inspection is
often used instead for its subsurface detection capability.

17. PT Test Procedure
1. Section of material with a surfacebreaking crack that is not visible to the
naked eye.
2. Penetrant is applied to the surface.
3. Excess penetrant is removed.
4. Developer is applied, rendering the
crack visible
Sample Cleaner ,Penetrant &
Developer Bottles

18. PT Test Procedure

19. Mill test certificates of all materials
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The material composition of the used materials are checked
and found OK.
The punched heat number on material body is counter
checked with the Mill test certificate.
Our heaters are made of austenitic stainless steel SS
316L.Which is non magnetic & have very well resistance to
corrosion.

20. Stainless steel differs from carbon steel by the amount of chromium present. Unprotected carbon steel rusts readily when
exposed to air and moisture. This iron oxide film (the rust) is active and accelerates corrosion by forming more iron oxide, and
due to the greater volume of the iron oxide this tends to flake and fall away. Stainless steels contain sufficient chromium
(12%) to form a passive film of chromium oxide, which prevents further surface corrosion and blocks corrosion from spreading
into the metal's internal structure, and due to the similar size of the steel and oxide ions they bond very strongly and remain
attached to the surface.
There are three types of stainless steel:
SS Material Properties from Marks' Standard Handbook For Mechanical Engineers-10Th.pdf

21. Inspection of Welds
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WPS,WPQR & Welder performance qualification reports had reviewed &
found OK.The documents will be sent to site during shipment of the Heater
crate.
Definition & sample WPS,WPQR & Welder performance is attached herewith
for your understanding:Welding Procedure Qualification (WPS)Welding Procedure Qualification.pdf
WPS provides in detail the required welding variables for specific application to
assure repeatability by properly trained welders.
Welding Procedure Qualification Records Welding Procedure Qualification.pdf
A record of welding variables used to produce an acceptable test weldment
and the results of tests conducted on the weldment to qualify a Welding
Procedure Specification.
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Welder Performance Qualifications Welder Performance Qualification.pdf
A test administered to a welder to determine the welder's capacity to perform a
specific welding application. Welder performance qualification tests are specific
to a WPS.
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100% visual inspection of welds had been done & no defects were found.

22. Checking of name plate
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The name plates were checked & found OK. Only some
discrepancy found on the GAD & GEA correct the date of
“Year build” in nameplate of GAD.

23. Packing List Checking

24. Determine the diameter of the bolt is found from
first number.
For example, if the metric bolt was M10x1.5x 6g x
40, means :M :- ISO Metric Thread
10 : - Bolt Diameter (mm)
1.5:- Pitch (mm)
6g:- Fit Symbol
40:- 40 mm Length
Metric thread angle is 60◦ & Thread Gauge is used
to measure the thread.

25. SS Bolt Head Numbering System
The head for the austenitic stainless steel has some properties .
A- Means the Steel Composition Type(Austenitic)
2- Alloy group designation(18-8)
70- Strength properties (700 MPa)

26. Standard Pitch Dimension

27. Standard Bolt Head Size for Metric Bolts
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The normal spanner /bolt head size is 1.5 times of the bolt
dia.

28. Seaworthy Wooden Crate Inspection
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Our Company Representatives had visited the GEA crate
manufacturing unit to inspect the crate for the Heaters.
The wooden ply’s of crate are under fabrication & the overall
quality was found satisfactory.
The crate are strong enough to place overheads crates .

29. Closing Meeting
Meeting ended with signing of
Inspection Documents
 GEA’s MOM signing
 Our Company’s MOM signing
MOM GEA.pdf
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30. Thank You
Any Question Please?