we service : INDUSTRIAL EQUIPMENT CLEANING SERVICES 1. Chemical Cleaning of Boiler & Other Equipment and steam Blowing Service 2. Condenser Tube Cleaning Using Bullets 3. Hydro-Jetting/ Hydro Blasting 4. Foam Cleaning 5. Dry Ice Blasting 6. Lube Oil Flush

we service: INDUSTRIAL EQUIPMENT CLEANING SERVICES 1. Chemical Cleaning of Boiler & Other Equipment and steam Blowing Service 2. Condenser Tube Cleaning Using Bullets 3. Hydro-Jetting/ Hydro Blasting 4. Foam Cleaning 5. Dry Ice Blasting 6. Lube Oil Flushing SPECIALIZED NDT SERVICES 1. Eddy Current Testing ( ECT) 2. Helium Leak Detection Service ( HLD) 3. Acoustic Eye Ultra-Fast Tube Inspection ( AE) 4. Remote Field Eddy Current Testing ( RFECT) 5. Internal Rotary Inspection System ( IRIS) 6. Bore Scope Inspection ( BI) 7. Low Frequency Electromagnetic Technique ( LFET) 8. Long Range Ultrasonic Testing ( LRUT) 9. Pulse Eddy Current Testing ( PEC) 10. Fluorescent Leak Detection Testing ( FLDT) / Vacuum Leak Testing Method ( VLT) 11. Acoustic Emission Testing ( AET) 12. Near Field Eddy Current testing ( NFET) 13. Other NDT Services as per Customer Requirement. SPECIALIZED MECHANICAL ENGINEERING SERVICES/ PRODUCTS 1. Re-tubing 2. Valve Repair/ Refurbishment 3. Epoxy Coating/ Glass Flake / Ceramic Coating/ Thermal Spray coating. 4. Conveyor Pulleys / Idlers 5. Expansion Joints/ Bellows/ Gaskets/ Hose Assembly 6. e2 – Sorb Oil Absorption Mat SERVICES: A) Industrial Equipment cleaning service: • Pre Commissioning and Post Operational Chemical Cleaning Service of High Pressure Boilers, Pipelines, Heat Exchangers etc. • Condenser Tube Cleaning using Specially Designed Bullets / Scrapers Powered by Water Pressure • Mechanical Decoking By Pigging Of Heaters and Furnace Tubes • Foam Cleaning of Exteriors of Fin Fan Coolers and Air Cooled Condenser • Oil Flushing of Lube Oil, Seal Oil and Hydraulic Pipelines • Cleaning of Heat Exchanger Tubes, Air Fin Fan Cooler Tubes & Pipes by Hydrokinetics Technology. • Hydro-jetting / Hydro-blasting • Dry Ice Blasting B) Specialized NDT Services: • Eddy Current Testing of Non Ferrous Condenser / Heat Exchanger Tube • Helium Leak Detection Services for Condenser / Turbine’ s Negative Pressure Parts, Hydrogen Cooled Generator, Condenser Tube Leak Identification, Hydro-Carbon Line Testing at On-Shore / Off-Shore • Acoustic Eye Ultra-fast Inspection of Tubes up to 4” of Boilers / Fin Fans / Heat Exchangers • Aru-Fluorescent Leak Testing of Heat Exchanger / Condenser Tubes • Remote Field Eddy Current Testing ( RFECT) • Internal Rotary Inspection System ( IRIS) • Bore Scope Inspection • Low Frequency Electromagnetic Technique ( LFET) • Magnatic Partical Inspection ( MPI) & Other NDT services -4- C. Specialized Mechanical Engineering Services: • Re-tubing Service of Heat Exchangers, Condensers, Cooler Tubes and Air Pre-Heater Tubes. • Valve Repair / Refurbishment Service of Any Type / Class / Size of Valves. • Epoxy Coating • Glass Flake Coating • In-Situ Flange Facing of Equipments • Thermal Spray Application of Various Systems • Rubber Lagging – Pulleys • Rubber Lining – Pipes / Tanks PRODUCTS: A) Various Types of Gaskets: • Spiral Wound Gaskets • Camprofile Gaskets • Ring Type joint gaskets with API Monogram • Solid Metal Gaskets • Metal Jacketed And Heat Exchanger Gaskets of Any Shape, Size And Combinations • Graphite Steel Impregnated Gaskets Composite • Ferrule And Enveloped Gaskets • All Types Of Non-Asbestos Gaskets With SBR, NBR, Elastomers, Glass Fibre and Carbon Fibre • Flange Insulation Kit Gaskets B) Monolithic Insulation Joints C) Pipe Repair Clamps D) Valve Components E) Various Types of Hoses: • Multi Spiral Hydraulic Hoses. • Braided Hydraulic Hoses • PTFE – Hoses And Fittings • SS Corrugated Hose Assemblies And Fittings • Camlock Couplings • Rubber Hoses • High Temperature And Super High Pressure Hoses For Special Applications -5- F) Rubber Expansion Joints G) Various Types of Rubber Components: • Anti Vibration Mounts • Built-Up Rubber Hoses • Rubber Moulded Components • Rubber Sheets H) Various Types of Metal Expansion Joints: • Untied Single & Universal Expansion Joints • Tied Single And Universal Expansion Joints • Hinged Expansion Joints • Gimbal Expansion Joints • Pressure Balanced Elbow Type Expansion Joints • Inline Pressure Balanced Expansion Joints • Reinforced Expansion Joints For Very High Pressure Applications • Jacketed Expansion Joints • Insulated / Refractory Lined Expansion Joints For High Temperature Applications • Guided Expansion Joints Using Pantographic Linkages I) List of Industrial Plastic and Metallic Components: • Pipelines f Pipeline Pigs f Casing Insulators and Seals f Pipe End Caps • Condensers and heat exchangers f Tube Inserts, Liners and Plugs f Tube Liners f Tube Plugs • Nozzles for cooling towers and filter nozzles for WTP & ETP f Spray Nozzles f Blankting Balls f Filter Nozzles f Bio Tower Packings -6- • Valves and Flanges f Flange End Caps and Protectors f Bolt and Nut Protectors • Sample Cooler and Conductivity Column J) List of Fabric Expansion Joints: • Single Layer Type • Composite Type • Bolster Type f Integrally Flanged Type Expansion Joint f Belt Type Expansion Joint CHEMICAL CLEANING OF HIGH PRESSURE BOILERS, CONDENSERS, PIPELINES, HEAT EXCHANGERS ETC CONDENSER TUBE CLEANING SERVICE USING SPECIALLY DESIGNED BULLETS / SCRAPERS POWERED BY WATER PRESSURE Cooling water sources cause different tube fouling problems, affecting the heat transfer and life expectancy of Condensers and Heat Exchangers. Power Stations, Refineries, Petrochemicals & other industries in the developed countries employ “ Bullet Cleaning” as an effective and efficient method the clean the condenser tubes. We offer this Tube Cleaning Service using this unique Bullet Shot method which is the fastest, most economical, safe & environmentally friendly procedure. TECHNIQUE: Tube cleaners ( Bullets) are shot through fouled Condenser / Heat Exchanger Tubes using specially designed water guns at 15 Kg/ cm2 pressure. The Bullets moving through the tube from one end to the other, scrape off the deposits and corrosion scales. Water from the gun flushes out the scraped deposits resulting in a clean inside surface for the tube, ideally good for heat transfer. Tube cleaners, which exit at the other end of the condenser, are collected, cleaned and used again. Normally a bullet can be used around 20 times. This is one of the quickest methods to clean the condenser tubes with the following benefits: 1. Very limited Shut Down Time 2. Longer Tube Life 3. Improved Plant Availability 4. Improved Power Generation 5. Low Consumption of Power & Water 6. No Environmental – Pollution EXPERIENCE: We have mastered this cleaning technique over the last nine years and so far cleaned Nine million tubes successfully. Today we execute simultaneously Seven to Eight sites all across the world. Why choose us? 1. Skilled and experienced cleaning crew 2. Available 24 Hours a Day and 365 days a year 3. Instant mobilization 4. Cost effective 4 + 1 PUMP CONCEPT We are a well reputed service provider to undertake various type of cleaning in power plant, refineries, petrochemicals and other industries Special Note: We will also carry out condenser tube cleaning by bullet shot method service during partial isolation basis ( i.e.) one part of the condenser is to be given for cleaning and another part should be in running condition and vice versa. MECHANICAL DECOKING BY PIGGING OF HEATERS AND FURNACE TUBES INTRODUCTION Furnaces fundamentally serve to supply a specified quantity of heat to process fluids. Together with steam boilers they consume approximately 75% of the energy used at petroleum refineries or chemical processing plants. An important factor in the overall efficiency of a furnace is the transfer of thermal energy between the furnace tube and the process fluid. During normal operation, a layer of carbonaceous material deposits along the inner tube wall. This material dehydrogenates in the high temperature region along the tube wall, forming hard coke deposits. In addition, mineral deposits, corrosion and scale can build up along with the coke. The coke layer continuously grows in thickness, eventually requiring removal. Without any maintenance, coke restricts the flow of process fluid, causing high pressure drops across the heater. Additionally, coke deposits act as an insulator, hindering heat transfer from the tube to the process fluid. Furnaces are critical-path components in plant processes and are high energy consumers, their maintenance is therefore essential for safe and economical plant operation. Recently, developments in pigging technology have presented a technique that • completely removes all coke and scale • does not erode tubes • reduces shutdown times and costs • eliminates environmental emissions SCOPE OF WORK EXECUTION Methodology statement The Decoking Technology is applied to remove hard coke and scale from furnace tubes using pigs fitted with special cleaning appendages. The resilient and flexible pig bodies allow the pigs to navigate pipe systems that have short radius elbows, U-bends, tees and reducers, including older style fired heaters with plug headers. Decoking pigs are available in diameters ranging from ¾ ” to 60” . -15- The pigs are hydraulically driven through a furnace with water at ambient temperature. As the pig moves through the tube, the deposits are scraped from the tube surface. The removed deposits are flushed into the collection tank by the driving fluid. The pig can be driven in both directions enabling repeated cleaning in those areas where deposits are located, reducing the time required for decoking tubes exposed to flame impingement or other process upsets. Initially a flow of water is established through the furnace whereby pressure and flow conditions are measured and recorded. The actual decoking procedure begins with the displacement of a foam pig through the circuit in order to determine the extent of coking. The information gained determines the size of the first cleaning pig. As a pig is propelled through the circuit, pressure fluctuations are monitored and recorded. Pressure peaks show the location of the bends and the areas where the deposits are concentrated. In these areas the pigs can be sent back and forth, providing maximum cleaning effort where it is most required. As the decoking operation progresses, the pig size is gradually increased until all the coke and scale have been removed. Finally, similar to the start of the operation, a flow of water is established through the furnace and again pressure and flow conditions are measured and recorded in order to be able to compare ‘ before’ and ‘ after’ results. The results of the decoking operation are issued in a report showing ‘ before’ and ‘ after’ pressure graphs identified by furnace tag number, pass number, tube inside diameter, cleaning service date and duration. Resource Requirements Equipment The equipment set up for the decoking operation includes: • Double Pumper Decoking unit • Pig Launchers and Receivers • Full bore ball valves • Temporary High and Low Pressure Hoses Personnel Each crew consists of: • Supervisor and • Operators Materials & Consumables During the decoking operation we use: • Water : 5000 Liters / Hour • Diesel Fuel : 700 Liter / 12 hours • Foam Pigs • Cleaning Pigs REPORTING During execution of the Decoking Operation, ARUDRA will provide the client with regular updates of cleaning status and service performance. After completion of the Decoking Operation, ARUDRA will prepare a Service Ticket stating Location, Date and Type of Service Performed, Description of Activities and/ or Events with their respective Durations. The Service Ticket will be issued for the client’ s approval and serve as a job close out document, a copy of which will remain with the client. -17- FOAM CLEANING OF EXTERIORS OF FIN FAN COOLERS AND AIR COOLED CONDENSER In the continuous process of improving our cleaning technique, we are now happy to inform you that through our R & D efforts, we have developed “ ARUFOAM” to remove the deposit from the system. The efficiency of Fin Fan Coolers and Air Cooled Condensers gets affected over a period of time due to deposition of insects, birds dropping, coke fines and other foreign matter and for the efficient working of the Fin Fan Coolers and Air Cooled Condensers, the same have to be removed on a regular basis. To achieve the same we have developed our “ ARUFOAM” Technique. This system is designed to chemically remove accumulations of organic and inorganic deposits such as oils, dust, dirt and caked products formed on particularly intricate inaccessible areas that inhibit heat transfer. We apply a heavy “ SHAVING CREAM LIKE” foam into and around the Fin Fan Coolers and Air Cooled Condenser fins. In this particular application, our process primarily uses foam ridden solvents, which has high penetrating capacity combined with property to reduce the surface tension. The foam is generated in our proprietary Foam Generator ensuring consistent quality of Foam with very high HALF LIFE period. This is an important factor in Foam Cleaning technique. The surface of the Fin Fan Coolers and Air Cooled Condensers on application of the Foam ridden solvents is allowed to soak for a period of time to permit penetration thereby reducing the adherence of the deposit to the surface. Later, the surface is flushed with abundant quantity of water at low pressure to wash out the dislodged deposits. In our experience and trial studies, we found that this technique is much suitable for cleaning Fin Fan Coolers and Air Cooled Condensers where deposits get trapped in inaccessible intricate Fins spread. “ ARUFOAM” has proven to be more efficient and faster than traditional cleaning. Normal high pressure water jetting cleaning destroys the fragile fins, compacts dirt and debris into the center of the cooling unit, thus significantly reducing cooling efficiency. “ ARUFOAM” on the other hand, is a low pressure cleaning method, which gently soaks away dirt and debris throughout the entire system. Blocked fins restrict airflow through the unit causing a drop in cooler efficiency and eventually slower production. THE SALIENT FEATURES OF OUR SYSTEM ARE: 1. Biodegradable foam and hence disposal is not an issue. 2. No damage to fins as we will be operating at low pressures 3. Provides great surface contact and hence better cleaning than other conventional process. 4. No High Pressure Jetting ( which damages Fins) . 5. Very short cleaning time 6. Setup time for our equipment is less than four hours. 7. Safer for Aluminium as well as Copper Fins. 8. Firewater can be used for flushing provided the same is clear. -19- OIL FLUSHING OF LUBE OIL, SEAL OIL AND HYDRAULIC PIPELINES CLEANLINESS: Cleanliness in Hydraulic systems has received considerable attention recently. Hydraulic systems are extremely sensitive to contamination. Fluid cleanliness is of primary importance because contaminants can cause component malfunction, prevent proper valve seating, cause wear in components, and may increase the response time of servo valves and cylinders. The inside of a Hydraulic system can only be kept and clean as the fluid added to it. GENERAL CLEANING AND FLUSHING REQUIREMENTS: 1. Chemically clean and treat internal surfaces of Lube Oil, Seal Oil and Hydraulic Lines. 2. Perform Hot Oil Flushing to reach target cleanliness level. 3. Inspect and verify that the cleanliness level has been achieved. 4. Follow the proper steps when disassembling the flushing loops to prevent contaminants from re – entering the cleaned system. Seal off all openings with plugs and blind flanges with Plastic sheets. CHEMICAL CLEANING: The object for acid carrying out cleaning of Hydraulic Pipelines is to remove mill scale, oil, paint, preservatives, rust, welding slag that would have entered during assembly of new tubes and also to remove the oxides of iron. After carrying out the process, the internal surface of the system is passivated by means of protective layer to prevent further rusting and corrosion. STEP 1: DE-GREASING: De – Greasing is the process to remove Grease and oil film. STEP 2: ACID PICKLING: The purpose of carrying out Acid Pickling is to remove Mill Scales, welding slag, iron oxide etc. STEP 3: PASSIVATION: Here the aim is to form a coherent, adhesive, non-porous, thin layer of gama ferric oxide. The layer is formed under expansion and hence is passive HIGH VELOCITY HOT OIL FLUSHING On completion of the Chemical Cleaning activity we provide unique Oil Flushing service. The Oil Flushing Skid with our team of experienced technicians, provides an effective and highly economical service Onshore, Offshore and overseas, for the rapid and effective clean up of lube, seal and hydraulic oil systems. Our equipment is compact, transportable, electrically driven and configured to work in hazardous areas. After setting the system up for a High Velocity flush by removing all restrictions to flow, operational oil will be flushed through the system. This high volume of oil will remove scale and particulate from the piping and flush it back to the system where it will be filtered. Thermal shocks to the system will greatly enhance the cleaning process. Clean Oil is simply a by-product of this process. With the use of an On Line Laser Particle Counter, particle counts may be accomplished on site in a matter of minutes giving actual counts. All counts are based on particles per 100 ml, in various sizes ( i.e.) . 5-10 micron, 10-25 micron. A minimum of 100 ml of oil will be required for analysis. THE SERVICE GUARANTEES THE FOLLOWING: • Entire Oil System is Cleaned and Flushed • Oil System and the Oil becomes clean. • Reduced wear and tear of lubricated parts. • No extra flushing oil required. • Oil system will retain the natural protective oxides layer on the inner walls of the pipeline system. • Significant reduction of Filter Cartridges consumption. • Reduced operation costs. -21- CLEANING OF HEAT EXCHANGER TUBES, AIR FIN FAN COOLER TUBES BY HYDROKINETICS TECHNOLOGY We take this privilege to inform you that we have tied up with M/ s. Aimm Technologies Inc., La Marque - Texas, U.S.A, to offer the services of cleaning the fouled interior of Heat Exchanger Tubes / Air Fin Fan Cooler Tubes by way of a state-of-the-art technology called “ HYDROKINETICSTM” – a patented technique. HYDROKINETICSTM is based on induction of Sonic Resonance into the cleaning water stream. This Sonic Resonance travels through the water stream and safely transfers to the tube and the fouling material. They resonate at different frequencies because of different composition of the tube and fouling material. This causes a breaking of bond between them and allowing the fouling to be expelled quite easily out of the tubes. We are pioneers in this technique and have an excellent track record of Cleaning the Heat Exchanger Tubes / Air Fin Fan Cooler Tubes, which are severely fouled to the extent of being totally blocked. HYDROKINETICSTM is superior, faster, eco-friendly, more effective, and much safer than any available conventional method for routine tube cleaning jobs. In addition, HYDROKINETICSTM can be a real time-money saver, doing jobs that cannot be accomplished by hydro-blasting, lancing, drilling, baking, acidizing etc. -22- HYDROKINETICS CLEANING OF HEAT EXCHANGERS / AIR FIN FAN COOLERS HYDRO-JETTING / HYDRO-BLASTING Arudra Engineers Private Limited is a Multi – Disciplined Engineering Company with its strength lying in Industrial Cleaning, Industrial Inspection, Mechanical Maintenance and Project Contract Activities. The company has gained Enormous Experience in Hydro Jetting / Water Jetting for various Industrial applications. Hydro-Jetting / Water Jetting have contributed to the use of water as a tool for De-Scaling. Hydro Jetting / Water Jetting equipment consists of a High Pressure Plunger Pumps driven by Electric or Diesel Engine driven depending on your requirements. Why Hydro – Jetting? • Cleans the Pipe Line or Tube to its fullest capacity. • Prevent damage to Property or Equipment due to rust formation. • Superior to Rodding. • Reduce emergency Drain Problems. • Reduce the chance of losing business revenue in a commercial setting. Hydro-Jetting/ Water Jetting is used in various industries are listed below: ™ Power Plant ™ Petrochemical & Fertilizer Units ™ Refineries And Specialty Chemicals ™ Sugar Mills, Paper & Pulp Industry ™ Cement Plant ™ Offshore / Marine / Oilfields ™ Aluminum Plant ™ Food Processing ™ Pipe Industry ™ Automotive / Pharmaceuticals AC ELECTRIC DRIVEN PUMP DIESEL ENGINE DRIVEN PUMP -24- DRY ICE BLASTING FOR HRSG What is DRY ICE BLASTING? • Dry Ice blasting is similar to conventional shot blasting except that the shot is replaced by pellets of Dry Ice which literally disappear as soon as the cleaning cycle is complete. • Dry Ice Pellets are accelerated at high velocities using the required quantity and quality air and allowed to impact and clean the surface. • The process provides a dry and abrasion free clean surface. 1 : : Kinetic Effect 2 : : Thermal Effect Dry Ice pellets are accelerated by Dry Ice penetrates and generates a compressed air to high velocities thus sudden local temperature decrease on impacting the layer and provoking both the dirt layer and the substrate. fractures. The different materials contract unequally so that the adherence between them diminishes. The layer cracks even more and begins to loosen off the substrate. 3 : : Sublimation 4 : : After Dry Ice Blasting After making impact, the dry ice turns The substrate is clean and completely from solid form into gaseous form, expanding intact. its volume by a factor of 700. The expansion acts as an explosion that completely detaches the layer from the substrate. -25- : Benefits No waste disposal: The system produces no waste products. Only the coating that has been removed remains to be disposed of, and this can usually be swept or vacuumed from the floor. Non-abrasive: Dry Ice blasting is non abrasive. Since surfaces are treated extremely gently, wear and tear resulting from the use of steel brushes and scrapers – or from other blasting media – is avoided. Lower costs: Reduced downtime periods. Increased production capacity. Improved product quality. On site cleaning without dismantling. Reduced payroll costs of cleaning and maintenance. Environmentally friendly: Dry Ice blasting is completely non-toxic and no hazardous chemicals are used. Costs connected with the disposal of blasting media, chemicals or solvents are saved. Lower costs: Adding up all these factors will clearly indicate that the investment will pay off within a very short time. EDDY CURRENT TESTING OF NON FERROUS CONDENSER / HEAT EXCHANGER TUBES Eddy Current Testing service is a Non-Destructive Testing ( NDT) that aims detection and characterization of Defects / Flaws / Discontinuities in a material ( Tubes) without impairing the intended use of the material ( Tubes) . Eddy Current Testing ( ECT) is an Electro Magnetic NDT technique widely used in Power Plants ( Nuclear, Thermal, Gas Turbine) , Petrochemical, Refineries and other Industries where Tubular Heat Exchangers, Coolers, Condensers are available. The above test is not a volumetric technique. This is a surface technique and can readily detect very shallow surface defects ( Fatigue Crack, Inter-Granular Stress Corrosion Cracks etc) , Sub- Surface Defects ( Inclusions, Voids etc.) within a depth of say 6 mm. It can also identify Pitting, Cracking, Microbiological induced Corrosion Damage, Support Wear, Erosion etc. It can easily identify material discontinuities in new tubes also. Eddy Current Testing is a high speed, highly sensitive, versatile and reliable NDT technique. We will be employing INSIS-EC advanced Multi-Frequency Eddy Current Test System for inservice inspection of tubes with a Multiple Sensor and Frequency channels. This new instrument allows Inspection of a large variety of materials and provides documentation of the inspection all in one unit. The equipment is built with a unique Parallel Processor Architecture centered on an embedded Pentium Processor. Extensive Data-Acquisition, Archival, Data Analysis as well as reporting software is available. Our Engineers are well trained in carrying out the test at site and interpret the results accurately, depicting the actual condition of the tubes based on the test results, particularly very competent in resolving between defects and non-relevant indications. The jobs will be carried out by Level-II Certified Engineers. BENEFITS 1. Helps in Condenser Tubes Replacement Planning Activity 2. Assessment of the life of the Tubes 3. Avoid unnecessary Shutdown due to Tube Leakages -30- INSIS – EC Multi - Frequency Eddy Current Machine. Reference Standard: Eddy Current Testing works on the principles of electro magnetic induction. Conventional eddy current testing as per ASTM – section – V, Article 08 & ASTM – section V, Article 08 – Appendix 1, is used for inspection of non-ferromagnetic tubing such as stainless steel, titanium, copper brass, cupro-nickel alloys, etc. EDDY CURRENT TESTING OF NON - FERROUS TUBES We will undertake Eddy Current Testing of Non-ferrous tubes. With respect to Eddy Current Testing ( ECT) , it is a Non Destructive Testing procedure that aims to detect shallow surface defects, fatigue crack, inter-granular stress corrosion cracks and microbiological induced corrosion damage etc. Our Engineers are level II certified engineers and they are very competent in analyzing the test results. We will follow the reference standard for Eddy Current Testing as per ASTM-Section-V, Article 08 & ASTM – Section V, Article 08 – Appendix 1 is used for inspection of non-ferromagnetic tubing such as stainless steel, titanium, copper brass, cupro-nickel alloys, etc. Preliminary report will be given after completion of the job. Final detailed report along with colour coding will be submitted in two weeks time. -31- Advantages of Eddy Current Testing: 1. Assessment of your life of the condenser tubes in terms thinning wall reduction. 2. Avoid unnecessary shutdown due to tube leakage and hence big cost saving. 3. Helps in Condenser Tubes Replacement Planning Activity. Special Note: We are glad to inform that we will carry out Eddy Current Testing of Loose Condenser Tubes, prior to insertion in to the Condenser Tubes Hole. This will ensure the healthiness of the tubes and this is very important especially if the condenser tubes are procured and kept in yard for a long time in open atmosphere. * * * * * * * * * * -32- HELIUM LEAK DETECTION FOR CONDENSER / TURBINE’ S NEGATIVE PRESSURE PARTS, HYDROGEN COOLED GENERATOR, CONDENSER TUBE LEAK IDENTIFICATION, HYDRO-CARBON LINE TESTING AT ON-SHORE / OFF SHORE Introducing a state-of-the-art inspection technique to detect leaks in the negative pressure parts of Steam Condensers, in technical tie-up with M/ s.American Efficiency Services, LLC, Maryland, USA. Air-in-leakage is one of the worst obstacles of the Condenser’ s vacuum system, which undermines the performance of the equipment. Air-in-leak results in blanketing tube surface from the steam side thereby reducing heat transfer efficiency, as air is a bad conductor of heat. Also the back pressure increase due to air in leakage causes an increase in dissolved oxygen in the condensate resulting in deposition in water wall and super heater tubes of the Boiler, turbine blades thereby leading to generation loss, extra fuel consumption etc. Portable Helium Leak Detector Hence an early detection of leaks and arresting them would definitely improve the performance of the condenser. It is very important that the negative pressure part system of the condenser / turbine should not be neglected at any cost. WORKING PRINCIPLE OF OUR HELIUM LEAK DETECTION TECHNIQUE Our procedure involves spraying of a tracer gas – Helium on all the suspect areas. Helium being a lighter gas than air, gets sucked into the system due to difference in pressure in case a leaking spot is present. Helium which got sucked into the negative side of the Condenser is then sucked out through the air removal system along with the non-condensables and a sample of this ejected mixture is passed through our Mass Spectrometer to identify presence of Helium. As the Spectrometer is extremely sensitive, even minute leaks can be identified instantaneously. We will categorize the leaks as Small, Medium, Large and Very Large. This classification will help in planning the maintenance program. Benefits: • On line Job Testing • Increases Condenser Efficiency and hence Power Plant efficiency • Minimizes corrosive dissolved oxygen to get carried into the boiler system Mechanical Pump -33- IDENTIFYING TUBE LEAKS IN CONDENSERS / HEAT EXCHANGERS Our system can very effectively identify tube leaks also. The procedure adopted here is that Helium gas is sprayed into the tubes and if a leak is present, it will be carried over into the steam side of the Condenser, which is under vacuum condition and then get ejected out through the ejector / vacuum pump, where the ejected gases are tested for presence of helium using the sensitive spectrometer. The advantage of Helium Leak Detection is that, the check for tube leaks can be done by reducing the load of the machine and isolating one half of the condenser at a time. The test can also be conducted off-line, but the vacuum on the steam side should be maintained using the vacuum pumps. Chart Recorder HELIUM LEAK DETECTION TESTING BY POSITIVE PRESSURE METHOD We also offer service of testing of minute leaks using Helium gas for equipments like Columns, Reactors, Pipelines and Oil Platforms by positive pressure method. Typically, in these cases, we pressurize the equipment / pipeline with Nitrogen / Helium in the ratio of 90: 10 to the testing pressure required by the client and check for leaks in all probable areas. Even minute leaks can be identified using our Sensitive Helium Spectrometer. We have undertaken such jobs for two new offshore platforms top sides, a flare platform and an interconnecting Bridge for L & T Ltd., Hazira. Our Engineers are well trained in carrying out the test and to interpret the results accurately. The job will be carried out by ASNT Level II Certified Engineers. Helium Leak Detection Testing for following applications: • On Shore • Off Shore • Hydro Carbon Lines • Valve Tube Testing using Helium • Hydrogen Cooled Generator • Critical Heat Exchanger Leak Testing -34- ACOUSTIC EYE – ULTRA FAST INSPECTION OF TUBES UP TO 4” FOR BOILERS, AIR PREHEATERS, FIN FANS, HEAT EXCHANGER AND REACTOR TUBES In our constant urge to offer more services, encompassing latest techniques to our esteemed clients, we have added “ Acoustic Eye” . This works on the principle of " Acoustic Pulse Reflectometry ( APR) Technology" . Acoustic Pulse Reflectometry ( APR) is based on the measurement of one-dimensional acoustic waves propagating in tubes. Any change in the cross sectional area in the tubular system creates a reflection, which is then recorded and analyzed in order to detect defects. Our innovative tube inspection solution is designed specifically for detecting faults commonly found in industrial tube systems: Leaks, Increases in Internal Diameter caused by Wall Loss, and Full or Partial Blockages. Building upon APR technology, Acoustic Eye has engineered a series of breakthrough algorithms that enable the system to isolate, and then identify the above faults automatically. Currently, the most commonly used techniques for inspecting tubes found in heat exchangers are based on invasive testing. Eddy current, Magnetic Flux Leakage, Iris Tube Inspection and Ultrasound-based methods all require a probe to be traversed throughout the entire length of each tube being examined. Acoustic Eye, utilizes non-invasive APR technology to create a “ virtual probe” , which can navigate bends, coils, elbows, fittings, etc. without difficulty. This technology lets you test any tube from a single point outside the tube in less than 10 seconds, saving considerable time and resources. Acoustic Eye can be used to inspect all types of Tube Materials like Ferrous, Non Ferrous Plastic & Composite Tubes to name a few Acoustic Eye can be used successfully on. Straight Tubes, U Tubes, Spiral Tubes & Finned Tubes to name a few * * * * * * * * * * * * -35- ARU-FLUORESCENT LEAK TESTING Prior to the commencement of the leak detection test, stop cooling water supply to the condenser. Drain the waterbox. Open the manhole doors form both the sides. Dry the tubes as much as possible. To detect the leak, the steam space has to be filled with water. But prior to filling operation the condenser has to be gagged by immobilizing the spring supports. Fill the steam space with demineralised water upto the top manhole cover. Add the required quantity of ARUFLUORESCENT powder in the water already filled in the steam space. To ensure thorough mixing, run condensate pump on recirculation for a while. Allow the water to remain in the condenser for 4 hrs. for better penetration, enabling detection of minute leakages too. Inspect the condenser thoroughly from cooling water side for leaks, scanning with the aid of a specialized ultra violet lamp. Mark the location and the tube ( s) where fluorescence is spotted. After the completion of the test, drain the water and rinse the steam side. Fill the condenser HOTWELL with demineralised water upto the normal level. Box up water side. BENEFITS OF ARU-FLUORESCENT LEAK DETECTION TESTING 1. Fast, easy and accurate find multiple and intermittent leaks at the speed of light. 2. Find all leaks – the first time, every time. 3. Economical to use. 4. Eco-friendly service. 5. No harm to System and Manpower Absolute Safe. 6. Cuts loss of excessive fluid. 7. Perfect for preventative Maintenance. 8. Decreases equipment downtime. 9. With detection of Leak Tubes and Rectification of the same Condenser Efficiency will go up. 10. System can be normalized with in few hours after the job completed. -36- LEAK TUBE ARU-FLUORESCENT POWDER MIXING WITH WATER REMOTE FIELD EDDY CURRENT TECHNIQUE ( RFECT) The Remote Field Eddy Current ( RFECT) is a variation of Eddy Current send-receive probe technique. The RFECT technique allows the use of the differential- and absolute mode. This technique is capable for the detection of localised defects with the differential mode and gradual defects with the absolute mode. The detector coils are separated by a distance equivalent to two or three times the tube diameter. The receiving coils sense the flux lines that cross the tube wall twice. Remote field has an equal sensitivity to internal and external indications while the phase shift is directly proportional to wall loss. Diagram 1 shows the principle of this technique. The signal phase can be use to identify the defect depth, whereas the signal amplitude identifies the defect volume. The receiver coil receives in the remote area the remaining energy path field lines passing trough the wall over distance. Although these field lines are of low strength, dedicated amplifiers used allow the analysis of the received induction very well. Debris or external electrical noise might induce noise signal which could influence the defect signal strength. As the Remote Field principle works in low frequencies ( typical 10Hz -1kHz) , the inspection speed is therefore limited. The technique allows the designing of probes for u-bend inspection, which are generally possible for running u-bends with the radius from ~ 15 x I inner tube diameter. The signal analysis of the RFET technique is shown in Diagram 2 and 3. The differential mode is used for local defects while the absolute mode is used for gradual defects ( thinning) . The frequency is adapted to the material and wall thickness and the signal amplitude shows the volume of the defects. Diagram Remote Field Eddy Current Examination Method: Advantages 1. Can inspect ferromagnetic tubes up to 3.5 inches in diameter with 0.125 inches wall thickness. 2. Inspection speed ( up to approx. 40 feet per minute) . 3. Can detect large-area discontinuities such as steam erosion and baffle wear. 4. Amplitude changes in the signals sensed are not speed-sensitive. 5. Permanent records can be obtained on test results. Limitations 1. Some limitation to distinguishing ID from OD defects. 2. Evaluation of small flaws such as pits can be difficult. 3. Impingement erosion and wall loss detectability is limited to approximately 20% and greater. 4. Requires high inspection skills for data analysis and evaluation. 5. Instrumentation and test probes can be very expensive. 6. Tubes must be cleaned. 7. Flexible probes can not be used to inspect and travel through U-bend areas. 8. Inaccuracy in test results could occur if a discontinuity encountered differs in geometry from calibration discontinuities. * * * * * * * * * * -40- INTERNAL ROTARY INSPECTION SYSTEM OF CONDENSER / GENERATOR TUBES ( IRIS) The Internal Rotary Inspection System ( IRIS) is an ultrasonic technique well suited for Petroleum and Oil plant tube inspections. The technique uses an ultrasonic beam to scan the internal surface of the tune in heli coidal patterns, ensuring that the full length of the tube is tested. R/ D Tech tube inspection systems monitor the front wall echoes in order to measure the tube wall thickness. The internal rotary inspection system probe operates in pulse echo mode to measure wall thickness, material loss, the defect orientation within the range of 0.5 in. to 3 in. ID. the IRIS probe consists of an ultrasonic transducer firing in the axial direction of the tube. A mirror mounted on a water propelled turbine deflects the ultrasonic beam in order to obtain a normal incidence wave on the internal wall of the tube. Because the mirror revolves about the axis, the entire circumference of the tube is examined. A complete IRIS probe includes the cable, centring unit, a turbine, and a transducer. The ultrasonic beam maps out a spiral along the tube length. If the probe pulling speed is sufficiently slow, taking into account the inspection sampling parameters, 100 % coverage of the tube surface is achieved. PURPOSE: The purpose of the inspection was to determine the integrity of the tubing and to monitor the general condition of the tubing for all given bundles. TUBE IDENTIFICATION AND SCANNING DIRECTION: In Order to identify and locate each tube and thereby create full traceability, the grid coordinates of row & column were used. Rows are numbered from top to bottom and column left to right. Scanning was done from Outlet Section head side to Inlet Section of the equipment. -41- BORE SCOPE INSPECTION INTRODUCTION: Fiberoptics Inspection ( Boroscopy) is a remote visual examination technique / tool for determining the presence of internal defects including internal cracks, intensity of corrosion or erosion, oxidation or internal deposits, degree of damage, pitting and presence of foreign objects etc. in any directly inaccessible area of component through Inspection hole, tube cutting opening and its other integral parts etc. Boiler high pressure parts were subjected to remote visual inspection i.e. Fiberscopy. Based on the specific requirements of the client, the general objectives of this inspection were as below: 1. To examine the condition of internal surface of pressure parts. 2. To determine the presence of internal defects including cracks, intensity of erosion, corrosion, pitting or presence of foreign objects such as dust agglomerates, welding / grinding chips, other extraneous matter in the locations for examination. BORE SCOPE EQUIPMENT: -42- LOW FREQUENCY ELECTROMAGNETIC TECHNIQUE BASED FALCON 2000 SYSTEM FOR INSPECTION OF ABOVE GROUND STORAGE TANK ( LFET) Over the years ultrasonic thickness measurement and selective coupon evaluation were the techniques used for condition monitoring of tank floor plates which never gave the complete picture of the corrosion pattern taking place causing leakages during operation. Thorough scanning of each and every plate is now possible using Falcon 2000 system, which consists of Jr. and Sr. scanners along with custom made softwarefor online detection of the flaws. 100% tankfloor plates scanning ( except welds) can be done to detect flaws from soil side and product side. The scanning is based on Low Frequency Electromagnetic Technique. A low frequency electromagnetic field is injected into the plate using an external horseshoe shaped driver coil placed in such a manner that the return magnetic field is through the area to be tested as shown in figure - 1. A flaw distorts the magnetic flux lines, which is sensed by sensors. The extent of defect is measured by observing the change in phase and/ or amplitude. The flaws detected by LFET during the scanning can be further verified using ultrasonic testing. Low frequency ( < 30 Hz) is used on carbon steel plates because of high magnetic permeability and conductivity of carbon steel, which greatly resist the penetration of higher frequencies in the metal. With low frequencies the penetration is more uniform throughout the wall thickness and defects on both the top and bottom sides of the plate can be seen. By using very low frequency the system can penetrate through coatings like epoxy, fiberglass, rubber, cement lining etc having thickness up to 5mm with excellent results and can also penetrate above 5mm with slight loss in sensitivity. -43- ASSOCIATED EQUIPMENTS: i.Falcon 2000 Sr. / Jr. System: Most advanced and compact system for inspection of Above Ground Storage Tank Plates. PC based modular electronics uses digital processing to provide Real Time data, high-resolution color graphics with 3D display. Trolley mounted integrated system consisting of a. Senior Floor Scanner – 32 channel ( 64 Sensors) b. Junior handheld scanner – 16 channel ( 16 Sensors) c. Electronic box d. Laptop computer loaded with software FALCON 2000 SENIOR. Falcon Integrated system for one man operation -44- FALCON 2000 Junior Falcon 2000 Jr. Hand scanner used for scanning hard to reach areas -45- RETUBING SERVICE OF HEAT EXCHANGERS, CONDENSERS, COOLER TUBES AND AIR PRE-HEATER TUBES Apart from the various Industrial services we offer Re-tubing service of Heat Exchangers, Condenser, Cooler Tubes and Air Pre-heater Tubes.. We offer this service for both “ U” Tube and Straight Tube equipments. We have highly qualified, skilled and experienced Engineers and Technicians to carry out removal of Old Tubes, Surface Preparation of Tube Sheets, Insertion of New Tubes, Flaring, Bell Mouth etc to the customer’ s requirement. The job can be undertaken by us in short notice. We have undertaken jobs with various metallurgical combinations of Tubes and Tube Plates. The replacement of tubes can be undertaken either totally or partially for Surface Condensers, Heat Exchangers, Coolers etc depending on the customer’ s requirement. We are well equipped with required Tools & Tackles to handle jobs of this nature on a turnkey basis with professional touch. We are also in a position to supply Tubes and undertake Replacement of Tubes on Turnkey basis. -46- VALVE REPAIR / REFURBISHMENT SERVICE OF ANY TYPE / CLASS / SIZE OF VALVES We offer Valve Repair / Refurbishment Service of any Type / Class / Size of Valves. Valve Repair / Refurbishment: Valves are key assets in your business. Ensuring they work correctly is central to keeping your entire process flowing freely. Valve Reconditioning can improve both Safety and Efficiency, save Money by stopping leakages. We expertly refurbish all types and makes of Valves. This work is carried out by skilled craftsmen at our dedicated workshop or at site. Every item is fully inspected at every stage. It is then tested before we return it to you. Arudra offers a complete Valve Refurbishment Service with an emphasis on quick turnaround. The assemblies are fully disassembled, inspected, reassembled and tested to meet relevant industry standards. All defective parts are replaced within this process. Replacing valves is expensive, which is why it is important to entrust your valves to a company with expertise and comprehensive facility for Valve Repair / Refurbishment. Arudra Strength: Arudra Repairs and Reconditions almost any Size, Type and Make of Valve, Onsite, In Shop and on Budget. We Meet Your Needs Anywhere Anytime. We have state of art tools and tackles, specially designed lapping machine suitable upto 30” for Gate Valve and upto 16” for Globe and Safety Valve. Some of the basic Types of Valves that we refurbish: Ball Valve, Butterfly Valve, Check Valve, Choke Valve, Diaphragm Valve, Gate Valve, Globe Valve, Knife Valve, Needle Valve, Pinch Valve, Piston Valve, Plug Valve, Poppet Valve, Safety Valve etc. Some of the Industries we are focusing on are -47- Thermal Power Plants, Hydro Power Plants, Nuclear Power Plants, Offshore and Onshore Oil and Gas Production, Offshore and Onshore Oil and Gas Drilling, FPSO, Oil Refineries, Oil & Gas Transportation Pipelines, LNG Plants, Petrochemical Plants, Chemical Plants, LPG Bottling Plants, Cement Plants, Fertilizer Plants, Food Processing Plants, Sugar Plants, Brewery & Distillery Plants, Soap & Detergent Plants, Solvent Extraction Plants, Pharmaceutical Plants, Pulp and Paper Plants, Steel Plants, Mining, Slurry & Ash Handling Plants, Water Treatment Plants, Desalination Plants, Effluent Treatment Plants, Sewage Treatment Plants, HVAC, Ship Yards, Marine and Naval Crafts, Cryogenic Plants, Textile Plants, Dyes & Intermediate Plants, Paint & Varnish Plants and Municipalities and Public Facilities etc. -48- PROTECTIVE COATING OF CONDENSER TUBE SHEET, WATER BOX AND OTHER EQUIPMENTS / SYSTEMS ( SOLID EPOXY / GLASS FLAKE / CERAMIC / OTHER TYPE OF COATING AS PER CUSTOMER REQUIREMENT) We offer Solid Epoxy coating of condenser tube sheet and water box in the above sector. We have well trained man power to perform Solid Epoxy Coating of Condenser with high quality material. We have completed Solid Epoxy Coating of Condenser Tube Sheet at Essar Power, Vedanta Aluminum and AES, Srilanka and Tata Power Ltd. Jojobera and Petro Vietnam with great success. The advantage of Solid Epoxy Coating of Condenser Tube Sheet is to avoid corrosion and erosion problem as well as water seepage at shell side of condenser. Our coating ensures trouble free system and avoids unnecessary shutdown. ADVANTAGES OF SOLID EPOXY COATING AT TUBE SHEET AREA • We will overcome corrosion and erosion problem with our Solid Epoxy coating system. • In proper expansion of tube to tube sheet will be protected. • Water seepage in tube to tube sheet area will be controlled through this coating system. • Protection of tube sheet by the use of this solid epoxy coating system and hence the life of tube sheet is enhanced. • Since the coating solution includes anti-fungal element the formation of fungus, algae growth in the tube sheet area which is detrimental to the tube sheet is completely eliminated. BEFORE SAND BLASTING -49- AFTER SAND BLASTING AFTER COATING -50- IN-SITU FLANGE FACING In-situ Flange Facing is the process of Resurfacing Flanges by Machining to ensure a Perfect Seal when Assembled. The newly Machined Surface then allows for an Improved Seal. In-situ Flange Facing helps to keep your plant running efficiently and safely. Arudra’ s In-situ Flange Facers save time and money by doing repairs On-site and In-place. Arudra' s In-situ Flange Facing machines are equipped with options like Milling Head, Grinders or Single Point Tooling depending on the job to be performed. We can provide any type of Surface Finish you require. Arudra is equipped with a full line of In-situ Flange Facers that can handle 50 mm to 3000 mm in diameter and larger upon request. We will be bringing the Flange Facing machines, Mounting Fixtures, Accessories and other Tools & Tackles required to carry out the job. Some of the areas where In-situ Flange Facing Services could be used are Raised Face Flanges, Flat Face Flanges, RTJ Flanges, Re-Face Valve Seats & Compressors, Lens Ring Flanges, Tube Sheet Re-facing in Heat Exchangers, Shells, Man Ways, Pivot Bearing Faces on Heavy Equipment, Turbine Casings, Pressure Vessels, Process Reactors, Coupling Flanges, Hand Holes, Ring Groove, Diesel Engine Liners, Engine Block Landing Surfaces, Slewing Ring Landing Faces, Leaking Mating Surfaces, Pump Bases, Crane Pedestals, Channel Heads, Swicel Ring Flanges etc. All machining is done to industry standards and specifications. We serve a variety of industries including Marine, Oil Refineries, Oil & Gas, Petrochemical, Power Plants, Steel, Mining, Cement, Paper, Sugar, Fertilizer, Chemical and Other allied Industries. BENEFIT OF IN-SITU FLANGE FACING • Helps to run your plant safely and efficiently • Saves Time and Money • Helps to avoid unnecessary shutdown • Fast response • Always available, 24/ 7 service • No need to cut out & Re-weld the Flange Note: We have In-situ Flange Facers that can handle 50mm to 3000 mm in diameter and larger upon request. -51- IN-SITU FLANGE FACING PHOTOS -52- THERMAL SPRAY APPLICATION OF VARIOUS SYSTEMS In our constant urge to offer more services to our esteemed clients, we have added “ THERMAL SPRAY” applications to our portfolio. We provide thermal spray for various applications mainly to protect the system from erosion and corrosion point of view. We will undertake Thermal spray application with various materials like Aluminium, Zinc, stainless steel, copper etc., as per customer requirement. We have well trained engineers and technicians to undertake the job with high Quality. We are glad to inform you that, we have done Thermal Spray of Aluminized coating at HPCL OUR VARIOUS CUSTOMERS ¾ Power Plant ¾ Petrochemical & Fertilizer Units ¾ Refineries And Specialty Chemicals ¾ Sugar Mills, Paper & Pulp Industry ¾ Cement Plant ¾ Offshore / Marine / Oilfields ¾ Aluminum Plant ¾ Food Processing ¾ Pipe Industry ¾ Automotive / Pharmaceuticals ¾ EPC / TA Contractors ¾ O& M Contractors please contact : saleskehan@ gmail.com fax 62215602582 081316302360 081807489548