REPROT REF NO. R19-0104.

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Attn.: ----
Co.\ Est.: ElNahda ASEC Cement
Tel.: ----
‫ﻟﻠﻣﺿﺧﺎت و اﻟﺣﻠول اﻟﻣﺗﻛﺎﻣﻠﺔ ﻷﻧظﻣﺔ اﻟﻣﯾﺎه‬
Address: Qena governorate, El Nahda cement factory (ASEC)
Pumps and water system solutions
Date: 18\08\2019 Tel&whatapp: +201091177502
www.tiengineer.com

Subject Underground pipe leakage detection Service type (Site-Workshop) Site

Dear Sir, kindly read the following report about your pipeline:

Detection results
Point No. Value of noise Point No. Value of noise
01 5dB 21 4dB

02 5dB 22 5dB

03 5dB 23 5dB

04 5dB 24 5dB

05 5dB 25 3dB

06 8dB 26 6dB

07 8dB 27 7dB

08 5dB 28 5dB

09 5dB 29 6dB

# 6dB 30 4dB

10 5dB 31 5dB

11 7dB 32 4dB

12 3dB 33 7dB

13 12dB 34 4dB

14 8dB 35 4dB

15 5dB 36 4dB

16 8dB 37 5dB

17 5dB 38 32dB 1

18 7dB 39 4dB

19 6dB 40 4dB

20 5dB 41 3dB
*Note that the green is normal reading, yellow is detection of small leak, and red is detection of the major leakage.
*Note that the recorded values are noise in (db).
*Note that points are illustrated on the pipeline map.
*(#) is Main pipeline Between 9-10.
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 *(1) after isolation Reduced to 6dB.

Inspection results - Corrective actions (Recommendations)

*Please note that all mentioned points are illustrated on the map which placed in the attachments.
1. There are a detected leakage between points 38 and 36.
2. Pipeline between 38 and 36 had been partially isolated to insure the detection result and noticed that the jockey
pump run interval reduced from 15 minutes to more than 1.5 hours.
(Site engineers had been informed with all leakage coordination)
3. If the distance is 60 Meter for line between 38 & 36 the damaged part will be from about 7 to 12 meter from
Point 38.
4. For point 13& 14, if the distance between the 2 points is 80 Meter, the damaged part will be from about 10
meter from Point 13 to direction of 14.
5. For points 16-18-19 have a minor leakage less than 0.1 liter/hour which cannot detect the leakage place
accurately, and they may not be identified after the excavation or drilling work.
6. Recommended for the last result number 5, to check (by closing valves or other common methods) those points
every 3 months and observe the jockey operation for more early detection if the leakage increase.

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 Attachments
The pipeline as drawn and inspected in the site (points illustrated)

36

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 Live photos of the done job

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 General introduction to the ultrasonic inspection
Ultrasonic inspection and monitoring of bearings and any mechanical problem is by far the most reliable method for
detecting incipient bearing failure and conditions such as lack of lubrication. The ultrasonic warning appears prior to a
rise in temperature or an increase in low frequency vibration levels.

Ultrasonic inspection of bearings is useful in recognizing:

 The beginning of fatigue failure.

 Brinelling of bearing surfaces.
 Flooding of or lack of lubricant.

In ball bearings, as the metal in the raceway, roller or ball elements begins to fatigue, a subtle deformation begins to
occur. This deforming of the metal will produce irregular surfaces, which will cause an increase in the emission of
ultrasonic sound waves.

A change in amplitude from the original reading is an indication of incipient bearing failure. When a reading exceeds a
baseline reading by 8 dB with no substantial change in the sound quality, it can indicate lack of lubricant. If the reading
exceeds a baseline by 12 dB, it can be assumed that the bearing has entered the beginning of the failure mode. This
information was originally discovered through experimentation performed by NASA on ball bearings. In tests performed
while monitoring bearings at frequencies ranging from 24 through 50 kHz, they found that the changes in amplitude
indicate incipient (the onset of) bearing failure before any other indicators including heat and vibration changes. An
ultrasonic system based on detection and analysis of modulations of bearing resonance frequencies can provide subtle
detection capability, whereas conventional methods are incapable of detecting very slight faults. As a ball passes over a
pit or fault in the race surface, it produces an impact. A structural resonance of one of the bearing components vibrates
or "rings" by this repetitive impact. The sound produced is observed as an increase in amplitude in the monitored
ultrasonic frequencies of the bearing. The sound quality of these changes can also be heard through headphones .

Brinelling of bearing surfaces will produce a similar increase in amplitude due to the flattening process as the balls get
out of round. These flat spots also produce a repetitive ringing that is detected as an increase in amplitude of monitored
frequencies.

The ultrasonic frequencies detected by an ultrasonic translator such as the Ultraprobe®, are reproduced as audible
sounds. This "heterodyned" signal can greatly assist a user in determining bearing problems. The heterodyned signal
may be analyzed through spectral analysis software or by connecting the instrument to a vibration analyzer. When
listening, it is recommended that a user become familiar with the sounds of a good bearing.

A good bearing is heard as a rushing or hissing noise. Crackling or rough sounds indicate a bearing in the failure stage. In
certain cases a damaged ball can be heard as a clicking sound whereas a high intensity, uniform rough sound may
indicate a damaged race or uniform ball damage. Loud rushing sounds similar to the rushing sound of a good bearing
only slightly rougher can indicate lack of lubrication. Short duration increases in the flat" spot and sliding on the bearing
surfaces rather than rotating.

If any of these conditions are detected, examinations that are more frequent should be scheduled .

Data should be collected to note and trend decibel rises. In addition the bearing sound should be analyzed using
spectral analysis software or by connecting the ultrasound instrument to a vibration analyzer.

These sound qualities can often be analyzed further when recorded and played back in the UE Spectralyzer spectral
analysis software. Sound samples can be observed and heard in real time as they are played in either a spectral view or
a time series view.

For Gear Box:

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If we are comparing the two below time waveforms, you can see that there is a slight difference in the two gearboxes.
Now when you look at the time waveforms that were captured with ultrasonics the problem becomes more defined.

Gear Box 1 Gear Box2

Also the ultrasonic’s time waveforms shows the broken tooth or teeth in gearbox A. By the use of ultrasonics this
problem was caught in an earlier stage. SEE BELOW FIGURE

Gear Box A Gear Box B

And for leaks can using for early detection up-to 0.1 liter/hr

Scope of Work

Measurement of Ultrasound levels and review related to baseline level or check time signal pattern for all Pipe line Main
valves to detect any turbulent coming from Leaks.

Parameter: Sensitivity: 65 - Mode: real time - Frequency: 30KHz

Notes

…………………………………………………………….…………………………………………………………….…………………………………………………………….

Special thanks for the site engineer Mohamed Mostafa and his team, Eng.Mohamed Alsaied,
and Eng.Ahmed Ragaie for their honest cooperation to let the job success.
Thanks for our team Eng..Mahmoud Selim, Eng.Mahmoud Yousef, Eng.Ahmed Eshrah.

SIGNATURE General Manager

Mahmoud Salem Mohamed Abdulrahman
Vibration CAT IV Consultant
Ultra sound inspector CAT I

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