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General Information

Date of Inspection: 18~19 March 2013


Place of Inspection:
o Wingles,France
Participants:
o Our Company
o GEA
o LLOYDS
Our Engineers:
o Ashik Ahmed- SectionManager
o Kh. Md. Ruhul Amin - Project Engineer (Mech)
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

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
List of Final Deliverables
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
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 000m manufacturing site
Key Customers of GEA:-
Fin orientation of GEA Heaters

The most commonly used fines


are spiral/circular type.

GEA used plate type fin


arrangement for our heaters.
PoluAl XT coating of the bundle for
higher mechanical resistance and
lower roughness.
Aluminum Fin Corrosion
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:

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

A hydrostatic test is a way in which pressure vessels such


as pipelines, plumbing, cylinders, heat exchangers, boilers &
fuel tanks can be tested for strength and leaks. The test
involves filling the vessel or pipe system with a liquid,
usually water, which may be dyed to aid in visual leak
detection, and pressurization of the vessel to the specified test
pressure. Pressure tightness can be tested by shutting off the
supply valve and observing whether there is a pressure loss.
Inspection
I) Pressure Test
Pressure Test

Heat Exchangers got Pressurized up to 22.5 Barg


Pressurized Water from Pump 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.

Water To Pumps Water Tank


Inspection
II) 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
Inspection
III) Nozzle Check
GEA manufactured nozzle flanges in accordance with European
standard, EN 1092 instead of Our Companys 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 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 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
I. Pre-cleaning:
The test surface should be cleaned
to remove any dirt, paint, oil, grease or any
loose scale that could either keep penetrant out
of a defect, or cause irrelevant or false indications.

II. Application of Penetrant:


The penetrant is then applied to
the surface of the item being tested.
The penetrant is allowed "dwell time
to soak into any flaws (generally 5 to 30 minutes).

III. Application of Developer


After excess penetrant has been removed
developer is applied to the sample piece e.
Developer agent is applied to draw
the penetrant from the discontinuities.
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

Austenitic Stainless Steel


It is a nickel Chromium alloy. Chromium content 16~24 %,
Ni content 8~14% ,carbon percentage 0.08~0.25%.
It is non magnetic so we can easily identify it by holding
magnet on its body.
It is most widely used .SS 304,304L, 316,316L are
most commonly used austenitic stainless steel.

Ferretic Stainless Steel


It contains Chromium 12~27%.
Carbon contains 0.08~0.2%.It is magnetic.
It is widely used in kitchen equipments, dairy machines,
furnace parts, etc.
SS 430,405,409,434 & 436 are Ferretic ss.

Martensitic Stainless Steel


It contains Chromium 12~18% & Carbon contains 0.15~1.2%.
It is magnetic.
It is widely used in surgical equipments, compressor
& turbine parts, valves, etc.
SS403,410,410S,416,420,431 are a Martensitic SS.
Inspection of Welds
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.
Checking of name plate
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.
Packing List Checking
Equipment No 2-E-601C 2-E-613 2-E-614 Image

Equipment Fluidization Atomization First Bed Cooler


Name Air Heater Air Heater Air Heater

Counter Flange
02 02 02

No of Bolts 66+10% Spare 54+10% Spare 34+10% Spare =


(M10x 40mm) =75 x 2 = 150 =60 x 2 = 12 38x 2 = 76

No of Nuts 75 x 2 = 150 60 x 2 = 120 38x 2 = 76

Washer ,M10 150 x 2 = 300 120 x 2 = 240 76 x 2 = 152

Gasket 13 x2 = 26 m 10 x2 = 20 m 6 x 2 = 12 m
(17 x 6
Garlock)
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.
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)
Standard Pitch Dimension
Standard Bolt Head Size for Metric Bolts

The normal spanner /bolt head size is 1.5 times of the bolt
dia.
Seaworthy Wooden Crate Inspection

Our Company Representatives had visited the GEA crate


manufacturing unit to inspect the crate for the Heaters.
The wooden plys of crate are under fabrication & the overall
quality was found satisfactory.
The crate are strong enough to place overheads crates .
Closing Meeting
Meeting ended with signing of
Inspection Documents
GEAs MOM signing
Our Companys MOM signing
MOM GEA.pdf

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