S1. The document proposes establishing an industrial predictive maintenance and troubleshooting lab in Bangladesh to help power generation and production plants minimize costs and downtime through non-destructive testing (NDT) and condition monitoring techniques. S2. The lab would develop NDT and condition monitoring facilities using methods like vibration analysis, oil analysis, ultrasonic testing, and thermal analysis to detect problems in power plants and save plants from failures. S3. This predictive maintenance approach aims to reduce maintenance costs, minimize unplanned shutdowns, and increase plant efficiency and availability.

1. Project Proposal
for
Establish an Industrial Predictive Maintenance and Troubleshooting Lab for
Progress of Industrial Sustainability and Productivity of Bangladesh
Project Submitted By:
Saj Engineering & Trading Company
House # 351 (5th Floor), Road # 07,
Mirpur DOHS, Dhaka-1216.
www.sajetc.com

2. Project Description
In more than last 59 years the inspection and maintenance technologies of Power
generation and production industry have been developed all around the world. To
detect 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, Ultrasonic
Analysis and Thermal Analysis). Most of power and process plants in Bangladesh are
very aged, maintenance cost come huge and irregular shut down they cannot produce
optimum power and production. By developed predictive maintenance concept you can
minimize plant maintenance cost reduce plant irregular shut down and it help increase
plant efficiency.
Object of the Project:
 Develop the NDT and Condition Monitoring facilities for Power Generation and
production 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 plant
equipment
 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-service
equipment in order to predict when maintenance should be performed. This approach
offers cost savings over routine or time-based preventive maintenance, because tasks
are performed only when warranted.
The main value of Predicted Maintenance is to allow convenient scheduling of corrective
maintenance, and to prevent unexpected equipment failures. The key is "the right
information in the right time". By knowing which equipment needs maintenance,
maintenance work can be better planned (spare parts, people, etc.) and what would
have been "unplanned stops" are transformed to shorter and fewer "planned stops",
thus increasing plant availability. Other advantages include increased equipment
lifetime, increased plant safety, fewer accidents with negative impact on environment,
and optimized spare parts handling.

3. Non-Destructive Testing is a noninvasive technique for determining the integrity of a
material, component or structure. Because it allows inspection without interfering
with a product's final use, NDT provides an excellent balance between quality control
and cost-effectiveness.
Condition monitoring is the process of monitoring a parameter of condition in
machinery, such that a significant change is indicative of a developing failure. It is a
major component of Predictive Maintenance (PdM). The use of conditional
monitoring allows maintenance to be scheduled, or other actions to be taken to
avoid the consequences of failure, before the failure occurs.
Condition Monitoring Parameter:
1. Vibration Analysis
2. Oil Analysis
3. Thermal Analysis
4. Laser Alignment
5. Dynamic Balancing

4. NDT and CM for Power Generation
We provide nondestructive inspection products and solutions for key power
generation applications, including those for fossil, nuclear, renewable energy markets,
transmission and distribution. Our reliable, advanced technology inspection solutions
and support services enable power generation customers to help maximize
efficiency, minimize downtime and enhance productivity with unyielding integrity.
Primary and secondary piping: To prevent leakage and failures, piping is regularly
inspected for corrosion, weld defects and gas accumulation using ultrasonics, remote
visual inspection and direct radiography systems. These same technologies are also
used to inspect pipes, welds and vessel components to help ensure integrity.
Feed water heaters, condensers and heat exchangers Proper operation of these
crucial components is essential for efficient operation of a power plant. Each machine is
inspected internally and externally for fitness for service. Ourmenu-directed remote
visual inspection and eddy current systems can detect defects and cracks that cause
leaks.
Nuclear submarines
To help ensure maximum safety of a submarine crew, numerous nondestructive tests
are carried out to verify quality of
the vessel girth welds, steam generator system, primary and secondary piping and
reactor vessels. The submarine environment demands use of all nondestructive
technologies to help ensure safety.
Feed water heaters, condensers and heat exchangers Proper operation of these
crucial components is essential for efficient operation of a power plant. Each machine
is inspected internally and externally for
fitness for service. Ourmenu-directed remote visual inspection and eddy current
systems can detect defects and cracks that cause leaks.
Reactor vessel
High-pressure boilers and vessels are kept operating safely using remote visual
inspection. Regular inspection for cracks and defects help ensure safe operation
and help prevent loss of structural integrity of the vessel.
Nuclear fuel and fuel rods
Ultrasonics, eddy current and radiography are commonly used inthe manufacturing
environment to test rods for ovality to ensure the rods fit into a fuel cluster. A fuel
assembly that does not fit precisely as designed can cause long and unacceptable
delays in a plant maintenance outage.
Turbines and generators
Using our remote visual inspection, eddy current and ultrasonic systems, blades and
dovetails found in rotating machines, such as turbines and generators, are inspected
for cracks and defects to minimize downtime and possible injury.

5. Reactor vessel
High-pressure boilers and vessels are kept operating safely using remote visual
inspection. Regular inspection for cracks and defects help ensure safe operation
and help prevent loss of structural integrity of the vessel.
Transmissionand distribution
Remote visualinspection ofswitcheshelps ensure compliant and safe operation of
the substation. Digital Radiography allows for condition-based maintenance of
gas-insulated switches.
Image and data sharing
Rhythm software ties all inspected components of the plant into one data file and
helps 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.
Rhythm
encompasses the image management tools that help ensure thorough inspection
results and rapid data sharing.
Manufacturing power plant components
The very low tolerance for manufacturing defects or foreign matter inclusions in
large 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, detects
volumetric defects. Our eddy current systems are used for near surface defect
detection.
Blade manufacturing for windenergy
Throughout the steps of the blade manufacturing process, ultrasonic technology is
used to test composite material for delaminations and defective layering to ensure
quality. The bonding of portions of the blade to one another and support structures is
also monitored using ultrasonics.
Transmissionand distribution
Remote visualinspection ofswitcheshelps ensure compliant and safe operation of
the substation. Digital Radiography allows for condition-based maintenance of
gas-insulated switches.
Wind Generation
Condition-based inspection of the gearbox in the nacelle
decreases the likelihood of catastrophic failure and enables
scheduling of repairs and preventative maintenance. Oureasy-
to-use remote visual inspection systems require no special
training, while producing more uniform inspection results.

6. SUMMARY OF NDT AND CM METHOD AND APPLICATION
NDT and CM
Method
Area of Application Defect Identification
01. Remote Visual inspection Compressor,
Combustion chamber,
Turbine.
Heat Exchanger
REACTOR
Boiler / Condenser
Valves
Pressure vessel
Nick Dents ,Scratches, Corrosions.
Cracks. Erosion ,Discoloration of
turbine , pipe blockage, visualize
remote area
02. Dye penetrants Any kind of surface Defect
(without porous material)
Metals (aluminum, copper,
steel, titanium, etc.)
Glass
Many ceramic materials
Rubber
Plastics
- 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
03. Magnetic particle testing
(MT)
Apply for finding Surface and
Subsurface defect. Materials
with a significant, Iron, Nickel
or, Cobalt content are
generally ferromagnetic
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
04. Ultrasonic Thickness Boiler tubes, steel tank and
pressure vessel
- Determine Thickness of
Boiler Pipes
- Oxide Scale Measurement
-Viewing Cross Sectional Image of
checking point.
05. Ultrasonic Flaw
Detection
Defects findings of welding,
crack, fatigue crack,
Discontinue of metal
Welding Defect and Structural
Intrigity

7. structure.
06 Advanced Ultrasonic
Phased Arrays
07. Radiography testing
(RT)
Defect of weld joint, finding
discontinue of metal
structure
Defect of weld joint, finding
discontinue of metal structure
08. Electromagnetic or Eddy
Current
Crack finding from turbine
Blade.
Apply for finding Surface and
Subsurface defect of turbine
blade.
09. Tube Inspection 5800 Condensers
Feed water heaters
Heat exchangers
Air conditioners
Eddy current technique is
suitable for detecting and sizing
metal discontinuities such as
- Corrosion,
- Erosion,
- Wear,
- Pitting,
- Baffle cuts,
- Wall loss, and
- Cracks
10. Hardness Testing Metallic and Non Metallic
Parts and equipments
Determine the hardness of
particular area.
-
11. XRF/PMI Known for composition of
Unknown Material and
Checking Quality control,
Application of XRF in Power
Generation industry:
- Element trace,
- Composition inaccuracy,
- Chemical concentration
inaccuracy Corrosion,
- Contamination,
- Checking Quality control,
12. Thermography Process Plant
Tank/vessel levels
Motor
Bearing
Electrical Connection
Fuse Box
Fan
High Voltage Substation
Switch Gear
Hot spot, cold spot, slack/loose
connectors, overheated motor
bearing, substation hot spot,
loose connection, damaged or
missing insulation
13. Vibration Analyzer Turbine
Generator
Pump
Motor
FD Fan
ID Fan
Gear
Routine Vibration Analysis,
Leaser Shaft Alignment,
Dynamic Mass Balancing
Bum Test
Motor Current Analysis
Transient Analysis
Over Speed Protection System
14. Vibration Meter and
Bearing Checker
Vibration Meter Bearing
Checker allows operators to
Listen sound pattern of Bearing ,
help determine of looseness,

8. quickly and easily check
machine and bearing
condition. Operators can also
“listen” to the pattern of the
vibration on the bearing by
using the audio output and
standard headphones.
resonance, Unbalance,
Misalignment and Cane measure
of Vibrate rate.
15. Lube Oil Testing Engine
Bearing
Gear
Turbine
Compressor
Lube condition, lubricant
degradation, lubricant
contamination, viscosity index,
lubrication failure, fatigue,
bearing fatigue, TBN, TAN,
Particle count, particle shape
analysis, elemental analysis.
16. UE System (Leak
Detector)
Valve leak
Tank
Steam Traps
Bearing
Lubrication Failure
Fans
Switchgear
Transformer
Relays
Breaker
Compressed and vacuum leak,
lubrication problem, bearing
faults, corona, arcing, tracking,
17. Guided Wave System
(Ultrawave LRT)
18. High Speed Camera
01.
Remote Visual Inspection (RVI) :
Remote means inaccessible, where you cannot reach by naked eye. Some tools will help
you 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 to
detect and examine a variety of visible flaws; such as cracks, corrosion, contamination,
structural integrity, and other discontinuities. Remote visual inspections also often
provide supplemental information for other NDT methods. Remote Visual Inspection is
by far the most common and relatively simple NDT technique. Visual Testing (VT) is
usually the first choice of any inspection as it offers an immediate and less costly
approach as compared to other NDT methods.
Area of Application:
- Gas,Steam & Wind turbines
- Compressor,
- Combustion chamber,
- Heat Exchanger
- Boiler / Condenser
- Valves

9. - Pressure vessel
- Electrical generators & transformers
- Sanitary piping & tubing
- Boiler water piping & components
- Nuclear reactor heads, reactor coolant pumps, demineralizers, containment
structure, & 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, Incomplete
Penetration , Concavity , Convexity , Excess Penetrate , Nick Dents, Scratches, Corrosions.
Cracks, Erosion, Discoloration of turbine, pipe blockage, visualize remote area
Tools Used for RV :
1. Borescope
2. Fiberscope
3. Videoscope/Endoscope
02.
Dye penetrant inspection (DPI),

10. 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 non-porous 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.
Materials that are commonly inspected using LPI include the following:
- Metals (aluminum, copper, steel, titanium, etc.)
- Glass
- Many ceramic materials
- Rubber
- Plastics
Liquid penetrant inspection can only be used to inspect for
flaws that break the surface of the sample. Some of these flaws are
listed 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 Testingis done for surface defects finding.
For this testing user
usedthe Magnaflux
made following
products:
1. Cleaner,
2. Penetrant
3. Developer.
03.
Magnetic Particle Testing:

11. Detecting Crack by make magnetize certain area, surface and subsurface defect
identification is convenient by this test. A material is considered ferromagnetic if it can
be magnetized. Materials with a significant, Iron, Nickel or, Cobalt content are generally
ferromagnetic.
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 inspection
methods.
- Fast method of inspection and indications are visible directly on the specimen
surface.
- Considered low cost compared to many other NDT methods.
- Is a very portable inspection method especially when used with battery powered
equipment.
Magnetic Particle Testing Products: User use following equipment for MPI Test
1. Magnetic Yoke
2. Magnetic Particle Magnetic Bench
3. Black Light (UV)
4. Residual Field Indicator/ Pie Gauge
5. Black Ink (7HF)
6. White Contrast Paint(WCP)
7. Fluorescent Bath (14 AM)
04.
Ultrasonic Thickness Gages:
Using principle of ultrasound a small machine
can measure thickness of metallic or non
metallic pipe, tank, steel structure just touch

12. from one side. This gages help quality control, reliability, and condition monitoring in a
cost-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 pieces
where 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 image
together.
- 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 later
post analysis & tracking.
- Apart from detecting wall loss the system is capable of detecting hydrogen
damage, pitting & caustic gouging (by measuring signal attenuation) which is not
detected with conventional means.
Tools:
Ultrasonic Thickness Gages:
1. Ultrasonic Thickness Gage (With Coating Thickness measurement option)
2. Ultrasonic Corrosion Thickness Gage
3. Ultrasonic Precision Thickness Gage
4. Ultrasonic Bond Tester
5. Pet Bottle Thickness Gage
6. Thickness Gage Transducer/Probes and Accessories
05.

13. Ultrasonic Flaw Detection ( Conventional):
In ultrasonic testing, high frequency sound waves created by a vibrated crystal in probe
are transmitted into a material to detect imperfections or to locate changes in material
properties. The most commonly used ultrasonic testing technique is pulse echo where-
by sound is introduced into a test object and reflections (echoes) from internal
imperfections or the part's geometrical surfaces are returned to a receiver. This method
is very sensitive to detect crack type defects but requires extensive training for operator
to 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 defects
Test results known immediately
High penetration capability
Requires access from only one surface
06.
Advanced Ultrasonic Phased Arrays:
Phased array Ultrasonics (PA) is an advanced method of ultrasonic testing that has
applications in medical imaging and industrial nondestructive testing. Common
applications are to noninvasively examine the heart or to find flaws in manufactured
materials such as welds. Ultrasonic test instruments have been used in industrial
applications for more than sixty years. Since the 1940s, Conventional UT used single
element transducer Phased array system use multi element transducer. So PA scanning
speed is much higher and accurate than conventional.
Phased array is widely used in several industrial sectors, such as construction or power
generation. This method is an advanced NDT method that is used to detect component
failures i.e. cracks or flaws and thereby determine component quality. Phased array can
be used for the following industrial purposes:
 Inspection of Welds
 Thickness measurements
 Corrosion inspection
 Flaw detection
 Detect hidden cracks,
 Voids,
 Porosity,

14.  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 by
Advanced Ultrasonic Phased Array
01. Supar Heater Tube 02. Water wall Tube 03. Tube to Connect Ceiling Super Heater
Header To Boiler Dram, 04. Condenser Tube 05. Over Heated Convective Supper Heater
06. 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 Products
Radiography is the most commonly known non-destructive test method. Radiography
can be used to obtain permanent image of surface and sub-surface (embedded)
discontinuities. The same discontinuities can be radiographed again after a period of
service life and the radiographs can be compared to measure the change in the size and
shape of the discontinuity. There are numerous applications of radiography in
engineering applications.
Some of the common uses are detection of surface and subsurface features of interest in
welded parts, castings, forgings, wall thickness measurement, corrosion mapping,
detection of blockages inside sealed equipment, detection of reinforcing material in
concrete slabs, measuring bulk density of materials measuring porosity in concrete etc.
The conventional film radiography is the most sensitive test method. On the contrary
digital or computed radiography have certain advantages over conventional film
radiography.

15. ,.
Radiography setup is following
1. X-Ray Generator
2. X-Ray Generator for Crawler
3. X-Ray Control Unit
4. Gamma-Projector
5. Computed RadiographyScanner
6. Radiation Survey Meter
7. Densitometer
8. X-Ray Film
9. RT Accessories
08. Eddy Current:
Eddy-current test uses electromagnetic induction to detect flaws in conductive
materials. The eddy current test set-up consists of a circular coil which is placed on the
test surface. The alternating current in the coil generates changing magnetic field which
interacts with the conductive test surface and generates eddy current. The flow of eddy
current can be disrupted due to change in resistivity or conductivity, magnetic
permeability, any physical discontinuities. The change in eddy current flow and a
corresponding 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 the
material, the surfaces need minimum preparation. The biggest advantage of the eddy
current test method is that is can be employed to determine surface flaws on painted or
coated surface. Eddy current flaw detection is commonly used in the aerospace industry,
crane industry, concrete pumping industry and other general industries where the
protective surface coating cannot be removed.
The crane industry and crane owners benefits most from the application of eddy current
test method to detect surface flaws underneath the protective coating (paint ). The
exorbitant cost of paint removal and repainting is eliminated by applying eddy current
flaw detection method as compared to magnetic particle test. It is also useful for making
electrical conductivity and coating thickness measurements. Eddy current test is
commonly 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

16. conductive material makes it useful in wide range of applications such as conductivity
measurement, sorting of material, assessment of heat treatment condition, sorting of
materials on the basis of hardness and strength, thickness measurement of thin
components.
09.
MULTISCAN5800 TUBE INSPECTION SYSTEM:
Eddy Currents are most effectively used to check for cracking located at the surface
and sub-surface of metals such as tubes. A number of main areas have been identified
where cracking occurs are Eddy current inspections form a vital part of checking
power plant for the cracks and faults that can lead to serious accidents. As many of
the 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 Current
Magnetic Flux Leakage
Remote Field
IRIS Ultrasound
Area of Application MultiScan5800:
Condensers
Feed water heaters
Heat exchangers
Air conditioners
Eddy current technique is suitable for detecting and sizing metal discontinuities
such as
Corrosion,
Erosion,
Wear,
Pitting,
Baffle cuts,
Wall loss, and cracks
10.

17. Hardness Tester:
Hardness Testing is a widely used method for determining hardness of materials using
test methods such as Vickers, Brinell, Knoop, Rockwell, Shore and IRHD. Portable
hardness testers come in a variety of types with the ability to test most metals, alloys
and 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 rubbers
to engineering alloys designed for use in the most arduous conditions or most severe
operating environments.
Model:…………testers are very precise, easy to operate and are used to identify and
classify parts in stock, measure in areas with limited access, control large and/or heavy
parts 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" (or
fluorescent) 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 of
petrochemical processing and power generation facilities. X-ray diffraction (XRD) and X-
ray fluorescence (XRF) analyzers are used for incoming material verification, safety
assurance, PMI, and maintenance.
Application of XRF in Power Generation industry:
- Element trace,
- Composition inaccuracy,
- Chemical concentration inaccuracy Corrosion,
- Contamination,
- Checking Quality control,
- Instrumental sensitivity.

18. 12.
Infrared Thermography:
Infrared thermography is one of the most cost effective and proven predictive
maintenance technology available to quickly, accurately and safely locate problems
prior to failure.
We provide thermography services for predictive and preventive analysis in all types of
industries. A trained technician brings the right thermography camera to conduct a
comprehensive thermographic survey quickly and accurately. They report the concern
areas and vulnerable spots immediately so that you can take corrective actions based on
the severity of the problem.
Benefits of Thermography
Reduction of production losses due to unplanned downtime
Reduced maintenance and repair costs
Increased equipment life
Increased Mean-Time-Between-Failures (MTBF)
Increased productivity and profitability
13.

19. Vibration Analysis Technology:
Vibration is the first indication of a machine's health. Of all the predictive
maintenance (PM) technologies, vibration analysis is the best measure of machine
health. Vibration can alert us to so many different conditions that may indicate
potential machine failures
Area of Application:
Turbine
Generator
Compressor
Pump
Motor
FD Fan
ID Fan
Gear
Type of Application:
Routine Vibration Analysis,
Leaser Shaft Alignment,
Dynamic Mass Balancing
Bum Test
Motor Current Analysis
Transient Analysis
Over Speed Protection System
Tools:
For Vibration Analysis we have the following system
Portable Vibration Meter
Portable Vibration Analysis System
12/24 Channel VibrationAnalyzer
Online Vibration Monitoring System
(Protection and Prediction Rack)
Dynamic Balancing System
Laser Alignment System
Over Speed Protection System
Wireless Transmitter (Vibration, Pressure, Temp, Cavity, PH, Flow, Level etc.)
Field Communicator
Motor Current Analysis System
Vibration Strobe Light
Analysis Software (AMS-Suite)
14.
Vibrat
ion
Meter
and

20. Bearing Checker: Vibration Meter Bearing Checker allows operators to quickly and
easily check machine and bearing condition. Operators can also “listen” to the pattern of
the 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 at
what's in the oil Oil is the lifeblood of equipment and oil analysis provides answers
to machinery health. It is as like as medical blood test, where we can know about
our diseases from our blood. It is an integral part of the maintenance plan for power
plants, manufacturing plants,trucking companies, construction, equipment,
aircraft,refrigeration, systems,processing, chemical plants and etc
Lube Oil Analysis is the great important for Power Generation Industry. An effective oil
analysis program will keep important assets such as Engines, Gearboxes, Hydraulic
systems, Turbines, Compressors, Generators and any other oil-wetted machinery in
operation 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 SpectroscopySample
Preparation Systemfor Large Wear Particle Analysis
2. Automatic Sample Processer
3. Fuel Dilution Meter (Fuel Sniffer)
4. Ferrography Laboratoryfor Wear Particle Analysis
5. Portable Fluid Condition Monitor
6. FTIR Oil Analyser for Oil Degradation & Contamination
Measurement
7. Portable Fluid Condition Monitor

21. 8. Particle Size, Count and Shape Analyzer
9. RDE Atomic Emission Spectrometer
10. Oil Analysis Spectrometer for Predictive Maintenance
11. Portable Kinematic Viscometer
12. Automatic
Kinematic
Viscosity
Measurement
of Used and
New Oil
FluidScan Q1000 (Handheld Lubricant Condition Monitoring):
Measures key oil condition parameters including:
i. Total Base Number (TBN) ii. Total Acid Number (TAN) iii. Oxidation iv. Nitration
v. Sulfation vi. Incorrect lubricant vii. Additive viii. Glycol/Antifreeze ix. Water x.
FAME xi. Glycerin xii. Fuel Dilution in Hydraulic Fluids
SpectroVisc Q3000:measurements for high accuracy kinematic viscosity.
Spectro LNF Q200 (Direct Imaging Particle Analyser):
i. Particle size distribution ii. Particle shape map
Spectroil Q100: Analyse32 Elements in PPM.

22. 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 can
speed up the inspection process and help inspectors determine effective follow-
up actions for mechanical, electrical and leak applications. Locating sources of
energy waste, identifying failure conditions in electrical and mechanical systems all
contribute to helping improve the bottom line. In some cases it can be a dramatic
improvement.
For Ultrasonic Leak detection & Predictive Maintenance we have the following system:
1. Ultrasound and Leak Detection
2. Ultrasound and Mechanical Inspection
3. Ultrasound and Electrical Inspection
4. Ultrasound and Steam Trap
5. Ultrasound and Valve Inspection
TYPICAL APPLICATIONS:
Pressure/vacuum leaks (turbulence)
Compressed air
Oxygen
Hydrogen etc.
Heat exchangers
Boilers
Condensers
Tanks
Pipes
Valves
Steam traps
Electric equipment
(Arcing/tracking/corona)
Switchgear
Transformers
Insulators
Potheads
Junction boxes
Circuit breakers
MECHANICAL INSPECTION
Bearings
Lack of lubrication/failure
Pumps
Motors
Gears/gear boxes
Fans
Compressors
Conveyers
Automotive
Rail roads
Marine

23. Aviation
17.
Guided wave technology: Guided wave technology for detect
corrosion and metal loss up to 600 feet long pipe from single
point.
We are pleased to inform about Guided Wave technology. Worldwide this technology
is using for confirm integrity of buried, coated, insulated pipe lines.
Guided wave technology is a nondestructive testing method used to locate potential
degradation, 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 insulation
removal.
 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.

24. 18.
When moving from reactive maintenance to predictive maintenance, it is crucial that
breakdowns are really understood. One of the basic analysis techniques is to use high-speed
cameras in order to characterize events which happen too fast to see, e.g., during
production. Similar to in science, with a pre- or post-triggering capability the camera can
simply record continuously as the mechanic waits for the breakdown to happen, following
which a trigger signal (internal or external) will stop the recording and allow the investigator
to save a given time interval prior to the trigger (determined by frame rate, image size, and
memory capacity during continuous recording). Some software allows viewing the issues in
real time, by displaying only a subset of recorded frames, minimizing file size and watch time
issues by eliminating useless frames before or after the sequence of interest.
Budgetary Price Idea for following System:
NDT and CM
Method
Area of Application Equipment Details Total Price
BD Taka
01. Remote Visual
inspection
Compressor,
Combustion chamber,
Turbine.
Heat Exchanger
REACTOR
Boiler / Condenser
Valves
Pressure vessel
Name: Industrial
Endoscope/Videoscope
Model: IPLEX FX (9.5
M length)
Manufacturer:
Olympus
Country of Origin:
Japan
02. Dye penetrants Any kind of surface Defect
(without porous material)
Metals (aluminum, copper,
steel, titanium, etc.)
Glass
Many ceramic materials
Rubber
Name: DPT Chemicals
Manufacturer:
Magnaflux, India
1. Cleaner,
2. Penetrant

25. Plastics 3. Developer.
03. Magnetic particle
testing (MT)
a. Apply for finding Surface
and Subsurface defect.
Materials with a significant,
Iron, Nickel or, Cobalt
content are generally
ferromagnetic
Name: Portable
Magnetic Particle
Inspection Kit (Yoke)
Model: Y-7
Manufacturer:
Magnaflux
Country of Origin:
India
b. Name: Magnetic
Particle Inspection
Bench
Model: CBAT-60D
AC/FWDC
Manufacturer:
Magnaflux
Country of Origin:
India
c. NameModel: :
Magnetic Particle
Inspection System
Manufacturer: : P-15
Portable Power Pac
Magnaflux
Country of Origin:
India
04. Ultrasonic
Thickness Gage
with different
option
Boiler tubes, steel tank and
pressure vessel
Name: Ultrasonic
Thickness Gage
Model: 38 DL Plus
Manufacturer:
Olympus
Country of Origin:
USA
05. Ultrasonic Flaw
Detection
Defects findings of welding,
crack, fatigue crack,
Discontinue of metal
structure.
Name: Ultrasonic Flaw
Detector
Model: EPOCH 600
Manufacturer:
Olympus
Country of Origin:
USA
06 Advanced
Ultrasonic Phased
Arrays
Name: Ultrasonic
Phased Array Flaw
Detector
Model: OmniScan SX
Manufacturer:
Olympus
Country of Origin:
USA
07. Radiography Defect of weld joint, Name: Portable X-Ray

26. testing (RT) finding discontinue of
metal structure
Generator
Model: Site X
Manufacturer: ICM X-
Ray
Country of Origin:
Belgium
08. Electromagnetic
or Eddy Current
Crack finding from turbine
Blade.
Name: Portable Eddy
Current Flaw Detector
Model: Nortec 500S
Manufacturer:
Olympus
Country of Origin:
Canada
09. Tube Inspection
System 5800MS
Condensers
Feed water heaters
Heat exchangers
Air conditioners
Name : Tube
Inspection System
Model: MS 5800
Manufacturer:
Olympus
Country of Origin:
Canada
10. Portable
Hardness Testing
Hardness Test for Metallic
and Non Metallic Parts and
equipments
Name : Portable
Hardness Tester
Model: DynaPOCKET
Manufacturer: GE
Country of Origin:
Germany
11. XRF/PMI Known for composition of
Unknown Material
Name : Handheld XRF
Model: DELTA
Premium
Manufacturer:
Olympus
Country of Origin:
USA
12. Thermography Process Plant
Tank/vessel levels
Motor
Bearing
Electrical Connection
Fuse Box
Fan
High Voltage Substation
Switch Gear
Name: Portable
Thermal Imaging
Camera
Model: Fluke Ti 32
Manufacturer: Spectro
Inc.
Country of Origin:
USA
13. 24 channel
Vibration
Analyzer
-Transient Vibration
Analysis for entire
machines or group of
machine
- Transient Analysis for
turbo machinery startup,
coast down and
production state
monitoring
Name: CSI 2600
Machinery Health
Expert
Model: CSI 2600
Manufacturer:
Emerson
Country of Origin:
USA

27. Routine Vibration Analysis,
-Leaser Shaft Alignment,
-Dynamic Mass Balancing
-Bum Test
-Motor Current Analysis
-Transient Analysis
-Over Speed Protection
System
Turbine
Generator
Pump
Motor
FD Fan
ID Fan
Gear
14. Vibration Meter
and Bearing
Checker
Purpose: Vibration Meter
Bearing Checker allows
operators to quickly and
easily check machine and
bearing condition.
Operators can also “listen”
to the pattern of the
vibration on the bearing by
using the audio output and
standard headphones.
Name : Overall
vibration checker
Model: 1850 Overall
vibration checker
Manufacturer:
Emerson Process
management
Country of Origin:USA
15. Lube Oil Testing Engine
Bearing
Gear
Turbine
Compressor
a. Portable Viscometer for
onsite viscosity
measurement without any
solvents.
Name: Portable
Solvent-Free Kinematic
Viscometer
Model: SpectroVisc
Q3000
Manufacturer: Spectro
Inc.
Country of Origin:
USA
b. FT-IR Oil Analyzer which
is specifically designed for
the molecular analysis of
lubricating oil to determine
Name: FT-IR Oil
Analyzer

28. oil degradation and
contamination.
It is used to check Total
Acid Number (TAN), Total
Base Number (TBN),
Water, Oxidation, Nitration,
Sulfation, Coolant, Fuel
dilution, Soot and Wear
additive depletion
Model: Q1000
Manufacturer: Spectro
Inc.
Country of Origin:
USA
c. Wear Particle Counter +
Particle Shape Analyzer +
Dynamic Viscometer in
one unit. Particle counting
is required for checking the
lube oil cleanliness, how
much wear is mixed with
oil. With particle shape
analysis it is possible to
determine the proble.
Name: Combined
Particle Counter,
Particle Shape
Classifier, and
Viscometer
Model: LNF-Q200
Manufacturer: Spectro
Inc.
Country of Origin:
USA
d. Oil Analysis
Spectrometer is required
for elemental analysis
which can detect the origin
of wear particle. It is
required for the
simultaneous analysis of
wear metals, contaminants
and additives in lubricants
It can detect up to 32
elements which include:
Aluminum (Al), Barium
(Ba), Boron (B), Cadmium
(Cd), Calcium (Ca),
Chromium (Cr), Copper
(Cu), Iron (Fe), Lead (Pb),
Magnesium (Mg),
Name: Spectroil Q100
Bench-Top
Spectrometer
Model: Q100
Manufacturer: Spectro
Inc.
Country of Origin:
USA

29. 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 (Leak
Detector)
Valve leak
Tank
Steam Traps
Bearing
Lubrication Failure
Fans
Switchgear
Transformer
Relays
Breaker
Name: Portable
Ultrasound Leak
Detector
Model: LNF-Q200
Manufacturer: UA
System, Inc
Country of Origin:
USA
17. Guided Wave
System
(Ultrawave LRT)
 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
insulation removal.
 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.
Name: Guided Wave
System
Model: Ultrawave LRT
Manufacturer: Olympus
Country of Origin: USA

30. 18. High Speed
Camera
Document Prepared by:
Ferdous Kabir
Marketing Manager
(ASNT NDT Level-II UT, RT, PT and ISO Level-II MT)
Saj Engineering & Trading Company
House# 351(5th Floor), Road# 05,
DOHS, Mirpur
Dhaka-1216
Bangladesh
Tel# +88-8080693, 8080682
Fax# +88-02-8000401
Cell# +88-01817-094194
Email: ferdous@sajetc.com
http://www.sajetc.com