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TCR Advanced Engineering Pvt. Ltd.

TCR has global expertise in life enhancement of different boiler and turbine by integrating knowledge of metallurgical degradation, corrosion and life-limiting factors

Product, Service

India

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Overview

TCR Advanced Engineering is a service partner of TCR Engineering Services, a very reputed company established way back in 1973 by the great visionary late Sh. V. K. Bafna. TCR Advanced Engineering provides technical services in the area corrosion and metallurgy to the industries not only at Vadodara, a hub for chemical and petrochemical & fertilizer industries but also organizations world around. Company has a set-up comprising full-fledged advanced metallography and material characterization facilities at Vadodara, Gujarat.

TCR Advanced through its team of experts offers specialized services in the field of metallography and failure Investigation. The company provides asset integrity management, failure investigation of industrial plants and equipment, In-situ metallography, assessment of in-service degradation, components / parts indigenization, selection of materials, remaining life assessment (RLA) and fitness for service (FFS). TCR Advanced Engineering has a competent team of metallurgical and mechanical engineers, technicians and field staff working for in-house as well as on-site testing and investigation.

Mr. Paresh U. Haribhakti (Managing Director) who is a Metallurgical Engineer and holds Master degree in Material Technology heads the company. He is having vast experience of more than a two decades in the field of R & D activities, failure investigation, damage assessments and RLA studies at global level. TCR Advanced has set up a full-fledged advanced testing division at Vadodara to meet with the industries requirements for testing and material characterization such as raw material testing, material identification, microstructure examination for evaluation of material processing, chemical properties & physical properties of metallic materials. The testing division of TCR Advanced is NABL accredited as per international standard ISO/IEC-17025.

Products & Services
Failure Investigation

Failure Analysis Objectives
The first step in managing the actual failure analysis effort is to determine what you expect from the final outcome. During TCR's initial meetings with the client we develop a charter that clearly delineates the terminal objective of the analysis. This is further enhanced through the development of critical success factors that outlines whether the terminal objectives have been obtained. At TCR Advanced, we adopt a disciplined vertical problem solving methodology used to determine levels of root causes of specific failure events.

Failure Analysis Procedure
Cause of failure is determined using state-of-art analytical and mechanical testing procedures and often includes testing under simulated service conditions. A combination of analysis and physical testing defines the problem and helps in providing recommendations for the solution.

Cause of failure is determined using state-of-art analytical and mechanical testing procedures and often includes testing under simulated service conditions. A combination of analysis and physical testing defines the problem and helps in providing recommendations for the solution.In the course of the various steps listed below preliminary conclusions are often formulated. If the probable fundamental cause of the metallurgical failure becomes evident early in the examination, the rest of the investigation focuses on confirming the probable cause and eliminating other possibilities. The metallurgical failure analyst compiles the results of preliminary conclusions carefully considering all aspects of the failure including visual examination of a fracture surface, the inspection of a metallographic specimen, and the history of similar failures. The complete evaluation sequence is summarized as under:

  • Collection of background data and selection of samples
  • Preliminary examination of the failed part
  • Complete metallurgical analysis of failed material
  • A thorough examination of the failed part including Macroscopic and Microscopic examination and analysis (electron microscopy, if needed)

If necessary tests may also include Weld Examination, Case Depth, Decarburization Measurement, Coating/Plating Evaluation, Surface Evaluation and/or Grain Size Determination
Chemical analysis (bulk, local, surface corrosion products, deposits or coating and microprobe analysis)
Tests to simulate environmental and physical stress that may have played a role in the failure analysis of fracture mechanics.
Selection and testing of alternative products and/or procedures that will significantly improve performance On-site evaluation and consulting services and Formulation of conclusions and writing the report

In-situ metallography

In-situ metallography is performed for following areas :

  • To find out in-service degradation of critical components of the process plants operating under high temperature /high pressure/ corrosive atmosphere.
  • Damage assessment of fire affected equipment of the plants.
    Microstructural survey for critical components viz., Boilers, Pipelines, Reactors and Vessels for condition monitoring / health assessment.
  • To develop a data bank of critical components for equipment of process plant by periodical monitoring for preventive maintenance and planning for inventory control.
  • To provide suggestions on the welding of components of process plants.
  • To check the quality of the microstructure of components for intended service before put in to use.
Remaining Life Assessment (RLA)

The Salient Features Involved are:

UNDERSTANDING THE ACTUAL DEGRADATION MECHANISM

  • High cycle fatigue
  • Low cycle fatigue
  • Thermal fatigue
  • Thermo mechanical fatigue
  • Wear
  • Thermal aging
  • Creep
  • Embitterment
  • Corrosion

VISUAL EXAMINATION

  • NDT involving In-situ Metallography, Ultrasonic Testing, Magnetic Particle Inspection, DP Test, Ferrite Measurement.

STRESS ANALYSIS

  • Stress analysis is carried out to know the strength of the material.

NON DESTRUCTIVE TESTING :

  • NDT inspection data provide good insite to the component integrity.
  • LABORATORY TESTING : Laboratory testing of cut samples provide valuable information about the material soundness.
  • JUDGMENT OF FITNESS OF THE EQUIPMENT : Based on available data, a judgement about the fitness of the equipment: If required, repairing of the equipment is suggested, for life extension.
  • JUDGMENT OF REMAINING LIFE BASED ON ANALYSIS : Finally, the estimation for remaining life is carried out.

Often the physical properties are verified and tests like stress-rupture, that are not so common are conducted. Having ascertained the extent of degradation, judgment on the remaining life is made. In addition to this, periodic inspection procedures are formulated and followed to monitor the health of the equipment during the course of operation. RLA is done based on life limiting factors like corrosion, creep and microstructure degradation with respect to time. There are different approaches available to assess the remaining life based on thermal cycles, creep calculation and fatigues cycles. Based on these aspects, the remaining life is ascertained with integration of rate of degradation v/s available material properties.

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