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CORE SERVICE OFFERINGS

Consulting - Root Cause Failure Analysis, FFS and RLA

TCR's dedicated engineering and metallurgical consulting team in India is the perfect partner for solving plant and product quality problems. With several years of experience, TCR’s advisory team supports welding engineering, corrosion, material selection queries and heat treatment problems as well. TCR’s in-depth engineering consulting services ensure that clients produce the best possible product right from the initial product design to the final production. 

CORE SERVICE OFFERINGS

Failure and Root Cause Analysis

TCR prides itself for its deep knowledge and has garnered best practices from success stories compiled from over 8000 failure investigation assignments, which include major projects in manufacturing and metallurgical failures on ASME boilers, pressure vessels, gas turbine engine components, oil and gas transmission pipelines, food processing equipment, heat exchangers, medical supplies, refineries, petrochemical plants, aircraft/aerospace, offshore structures, industrial machinery, weldments and ships.

The Failure Analysis Team’s strength lies in the evaluation of high temperature and high-pressure failures. The Failure Analysis Team at TCR Engineering has experience in the materials space, failure analysis, metallurgical, welding, quality assurance, and forensic engineering fields. The analysis is conducted by engineers holding advanced degrees in metallurgy, mechanical, civil, chemical, and electrical engineering.

 

TCR Engineering works with clients to draw up a plan for failure analysis to efficiently conduct the investigation. A large amount of time and effort is spent in carefully considering the background of failure and studying the general features before the actual investigation begins. The cause of failure is determined using state-of-the-art analytical and mechanical procedures that often includes simulated service testing. Analysis and physical testing, when combined together, locates problems and provides recommendations for effective solutions. 
 

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 on 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 considers all aspects of failure including visual examination of a fracture surface, the inspection of a single metallographic specimen and the history of similar failures.

 

The complete evaluation sequence to conduct a Failure Analysis is summarized as under: 
 

Evaluation Sequence for Conducting Failure analysis

  1. Collection of Background Data and Selection of Samples

  2. Preliminary Examination of the Failed Part 

  3. Complete Metallurgical Analysis of Failed Material 

  4. A Thorough Examination of the Failed Part including Macroscopic and Microscopic Examination and Analysis (Electron Microscopy, If Needed) Tests, If necessary may also include Weld Examination, Case Depth, Decarburization Measurement, Coating/Plating Evaluation, Surface Evaluation and/or Grain Size Determination 

  5. 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 

  6. Analysis Of Fracture Mechanics

  7. Selection and Testing of Alternative Products and/or Procedures That Will Significantly Improve Performance

  8. On-Site Evaluation and Consulting Services and Formulation Of Conclusions and Writing the Report (Including Recommendations)

Failure Investigation Report

The investigation team produces detailed written reports to ensure clients fully understand the implications and can independently examine the conclusions:

  1. Description of the Failed Component

  2. Service Condition at the Time of Failure

  3. Prior Service History

  4. Manufacturing and Processing History of Component

  5. Mechanical and Metallurgical Study of Failure

  6. Metallurgical Evaluation of Quality

  7. Summary of Failure Causing Mechanism

  8. Recommendations for Prevention of Similar Failures

  9. Latest Inspection Solutions

CORE SERVICE OFFERINGS

Fitness for Service

TCR undertakes Fitness For Service (FFS) Assessment based on Level 2 and 3 of BS 7910 standards and API 579. Our fracture mechanics methodology and its application have been successfully proven worldwide across industries, including nuclear pressure vessels to high consequence items in the exploration, refining, petrochemical and construction industry.

A process, plant, and equipment are often exposed to corrosive environments and/or elevated temperatures. Under these conditions, the material used in the equipment can degrade or age with time. Important equipment such as pressure vessels, piping, and storage tanks become older, the plant operator must decide if they can continue to operate safely and reliably to avoid injuries to personnel and public, environmental damage, and unexpected shutdowns. Fitness for service assessment procedures provide a means for helping the plant operator make these decisions on established engineering principles. 
 

Fitness for service assessment is a multidisciplinary engineering analysis that ensures all process and plant equipment such as pressure vessels, piping, and tanks operate safely and reliably for the desired period of operation and until the next turnaround or planned shutdown occurs in the future. API Recommended Practice 579 provides a general procedure for assessing fitness for service. This assessment procedure evaluates the remaining strength of the equipment in its current state, which may have degraded from its original condition. Common degradation mechanisms include corrosion, localized corrosion, pitting and crevice corrosion, hydrogen attack, embrittlement, fatigue, high-temperature creep and mechanical distortion. Methods for evaluating the strength and remaining service life of equipment containing these types of degradation are presented and reviewed

Common Reasons for Assessing The Fitness for Service of Equipment Include:

  • Discovery Of A Flaw Such As A Locally Thin Area (LTA) or Crack

  • Failure to Meet Current Design Standards

  • Plans for Operating Under More Severe Conditions than Originally Expected

Outcome of Fitness for Service Assessment

  • Decision to Run, Alter, Repair, Monitor, or Replace the Equipment

  • Guidance on Inspection Interval for the Equipment

Fitness for Service Assessment uses Analytical Methods to Evaluate Flaws, Damage and Material Aging Based On:

  • Stress Analysis may be performed using Standard Handbook or Design Code Formulas or by means of Finite Element Analysis (FEA). With modern computer technology, the use of FEA is quite common. 

  • Fitness for Service Assessment requires both, knowledge of past operating conditions and a forecast of future operating conditions. Interaction with operations personnel is required to obtain this data

  • Non-Destructive Examination (NDE): NDE is used to locate, size and characterize flaws

  •  Material Properties: The material properties include information on material damage mechanisms and behavior in the service environment, especially on the effects of corrosion and temperature
     

TECHNICAL CAPABILITIES

Asset Integrity Consulting Assistance


TCR's consulting team has deep engineering expertise and has access to a state-of-the-art material testing laboratory that enables them to uncover the root cause of failure and recommend the best solution to prevent recurrence. TCR Engineering provides consulting assistance in several areas that include:

  • Determining the Right Material for a Product

  • Corrosion Engineering, Corrosion Testing and Corrosion Investigations

  • Metallurgical Failure Analysis and Welding Evaluations

  • Investigate the Effect of Environmental Conditions on a Product or Material

  • Manage Quality Control Projects

  • Prepare Material and Process Specifications for In-House Quality Control

  • Compare Vendor or Competitive Products

  • Estimate the Remaining Service Life of a Product or Machine Component

  • Develop Non-Destructive Testing (NDT) Plan and TOFD/ Phased Array Procedures

  • Identify Equivalents between Indian and Foreign Specifications

  • Assist to Solve Product Quality Problems

  • Assist in Cost-Benefit Analysis Post Failure Analysis

  • Expert Witness and Opinion Assistance in Case of Trade Conflicts, Materials Disputes and Litigation Issues

  • Creating a Custom Metallurgical Image Analysis Software

  • Ensure Product Compliance with Rohs and WEEE

The consulting practice additionally offers advanced services that include:

  • Finite Element Analysis and Stress Analysis

  • Advanced Materials and Processes

  • Fractography

  • Surface Engineering 

  • Tribology

  • Welding esp. repair welding and cast iron welding

  • Atomized Powder Production (Technology, QA, Application wise Requirements of Powders)

  • Life Cycle Analysis and Engineering Asset Management

  • Global Warming-Role of Tribology & Surface Engineering

  • Thermal Spraying

  • CAD/CAM Modeling

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