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NDT Services

NDT Services at Thal

You are well aware that R.C.F. is a giant fertilizer company in India & also has number of plants for different industrial products. We are accredited with ISO 14000 certification for our whole factory & ISO 9001 certification for our chemical group of plants. Also we are accredited with OHSAS 18001 certification.

For maximum equipment reliability & condition monitoring we have developed a well equipped NDT department along with properly trained staff. So we are able to follow "PREDICTIVE MAINTENANCE" policy in our factory. We also have very efficient workshop facilities which include CNC machines, Balancing machine etc. These two facilities have played a major role in achieving the awards


1) "THE BEST PERFORMANCE FERTILIZER COMPANY 2003-04"

2) "NATIONAL ENERGY CONSERVATION AWARD 2004"


THE LIST OF NDT SERVICES THAT RCF THAL CAN OFFER ON CHARGEABLE BASIS:

1) SERVICE: Eddy Current testing of exchanger nonferrous tubes.

Instrument: Eddy Current Testing MAD-8D machine, ECT USA make. APPLICATION: For monitoring the tubes condition of critical heat exchangers. This will give the %wall thickness reduction. Based on this data a decision can be made to plug the weak tubes so that plant breakdown can be avoided.


eddy_curr
Eddy current testing machine

2) SERVICE: Vibration analysis/ diagnosis of rotating machines.
Instrument:
1) CSI 2120-2, CSI USA.
 
 
vibration_ana
Vibration Analyzer
 
 
Application: Allows to know the exact condition of the machine. Optimum decision can be taken so that machine does not get damaged & also production loss can be avoided / minimized.

3) SERVICE: In-situ balancing of rotating machines.
Instrument: 1) CSI 2120-2, CSI USA. 2) Balance Master TK-83,84,85 Bently Nevada USA
 
balancing_mc
Balancing machine
 
 
Application: In-situ balancing of rotating machines saves lot of time & money, also improves the machine condition in minimum time & prevents further probable damages to the machine, plant etc.


4) SERVICE: a) Videoscopy b) Fibroscopy of exchanger tubes

Instrument: 1) Videoprobe XL830, Everest VIT USA 2) Diaguidescope, Dainichi Japan.

 
video_probe
Video Probe

Application: Enables to inspect inside surface condition of the tube so that exchanger process parameters, tube cleaning procedure & maintenance procedure can be correctly decided.
5) SERVICE: Thermal scanning of various process equipments.

Instrument:Thermacam E45, FLIR Sweden.

 
therma_cam
Thermacam

Application: Viewing thermal images on 2.5" LCD, scanning of temperature of any spot of the image & recording of the images on PC for record & analysis purpose.

This helps in knowing

1) The faulty electrical connections so that flash over is avoided

2) Thermal insulation condition so that it can be attended in time.

3) Steam trap passing condition etc.

6) SERVICE: Valve passing.
Instrument: SPM LDE-10. APPLICATION: Identifying passing of critical valves like antisurge valves, PSV's, control valves etc.
 
7) SERVICE: Hardness testing.
Instrument:
1) Equostat, Pulsecho System.

2) Int Hardness Tester TH130, General Instruments Mumbai.
 
Application: Gives indication of material life in high temperature service like Reformer, Cracker etc.

 

8) SERVICE: Ferrite content checking.
Instrument:
1) Ferrite meter, Dr. Foster Inst. German EEC, Mumbai.

2) Ferrite Gauge Elcometer UK model 211.


Application: Gives ferrite content in SS material.


9) Condition monitoring of critical rotary machines & thermal scanning of different mechanical & electrical equipments on periodic basis.
 
boring_mc
Boring Machine
 



THE LIST OF WORKSHOP SERVICES THAT RCF THAL CAN OFFER ON CHARGEABLE BASIS:


1) Dynamic Balancing jobs of rotating assemblies weighing up to 5500kg , diameter up to 3000mm & bearing span 4250mm.

2) Deployment of cranes on hire for capacity up to 360 MT.
cranes
Cranes

3) Heat Exchanger Re-tubing /Manufacturing in CS & SS material up to 1" tube & length up to 10,000 mm.

4) Fabrication of Low pressure storage tanks, vessels in CS & SS material up to diameter 4000mm, height 5000 mm of up to 20 mm plate thickness. 5) Manufacturing of spares for rotating assemblies of pumps i.e. shaft, sleeves, deflector etc in CS , SS material up to diameter 125 mm.

6) Overhauling of gear boxes, compressors, blowers, pumps etc.

7) Re-finning of sealing fins of rotors as well as steam glands, end seal, intermediate seals, HP/ LP inner casing of turbines etc.

8) Overhauling of valves above 6".

9) In-Situ machining by "Do all machine" up to 150 mm diameter.

10) Overhauling & testing of Safety valves, control valves and level gauges. Calibration of Pressure gauges, Electronic /Pneumatic transmitters, I / P converter, Pad type transmitters etc.

11) Calibration of Temperature gauges, Thermocouple, RTD, Pyrometers etc.

12) Repair & testing of electronic circuit boards of electronic equipment, on component level (We have 'Boardwizard' in circuit multi function tester & SMD soldering/de-soldering & Rework station installed recently.)

13) Overhauling of HT/LT motors.

14) Rewinding up to 200 HP.

15) Rewinding of Ceiling fan stators.