Presentation on Air Heater Inspection

Prepared byThanks & Best Regards,Ashik AhmedSection ManagerTechnical Services Multinational Fertilizer CompanyTel.: +880 31 618972~4; Ext.: 2237 (Office)Mobile: +880 1730059920

General Information Date of Inspection: 18~19 March 2013 Place of Inspection:

o Wingles,France Participants:

o Our Companyo GEAo LLOYD’S

Our Engineers: o Ashik Ahmed- SectionManagero Kh. Md. Ruhul Amin - Project Engineer

(Mech)

Inspected Items & Shop Inspection Basis

Fluidization Air Heater: 2-E-601CAtomization Air Heater: 2-E-614First Bed Cooler Air Heater: 2-E-613

Quality Plan for Heater Inspection(Rev. B, 08-Oct-2012)-Delivered by GEA & Approved by our company

All Documents approved by Our Company prior to shop test

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

List of Final Deliverables

Presentation on GEA Heaters 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

Key Customers of GEA:-

Fin orientation of GEA Heaters

Aluminum Fin Corrosion

The protection of the Heat Exchanger against corrosion risks due to the environment must take into account the following parameters:

Thermal transfer Resistance to Ultraviolet's Thickness Adhesion to the fins Superficial tension and roughness Flexibility (dilatations) Mechanical resistance Chemical resistance

The GEA solution against corrosion:PoluAl XT.pdf

The PoluAl XT® coating

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

Inspection I) Pressure Test

Inspection I) Pressure Test

Pressurized Water from Pump

Water Tank

Pressurized up to 22.5 Barg

Water To Pumps

Pressure TestPressure Test

Heat Exchangers got pressurized

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.

InspectionII) Dimensional Check

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

InspectionIII) Nozzle Check

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.

PT Report ReviewPenetrant 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 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.

PT Test Procedure

1. Section of material with a surface-breaking 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

PT Test Procedure

Mill test certificates of all materials

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.

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

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.

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.

100% visual inspection of welds had been done & no defects were found.

Inspection of Welds

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.

Checking of name plate

Packing List Checking

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 Thread10 : - Bolt Diameter (mm)1.5:- Pitch (mm)6g:- Fit Symbol40:- 40 mm Length Metric thread angle is 60◦ & Thread Gauge is used to measure the thread.

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)

SS Bolt Head Numbering System

Standard Pitch Dimension

The normal spanner /bolt head size is 1.5 times of the bolt dia.

Standard Bolt Head Size for Metric Bolts

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 .

Seaworthy Wooden Crate Inspection

Closing Meeting

Meeting ended with signing of Inspection Documents

GEA’s MOM signing Our Company’s MOM signingMOM GEA.pdf

Any Question Please?

Thank You