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CORE SERVICE OFFERINGS

Conventional NDT

RADIOGRAPHY TESTING

TCR Engineering offers Automated Radiographic Testing (ART) for circumferential butt welds in cross-country and City Gas Distribution (CGD) internal pipelines using advanced crawler systems. This technology enables efficient, high-precision detection of both surface and subsurface defects in welds through external X-ray or Gamma ray radiation. Our crawler-based ART solution ensures reliable and comprehensive weld inspections, helping to maintain pipeline integrity and compliance with industry standards, while minimizing operational downtime.

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TCR Engineering also specializes in Gamma Ray Radiographic Testing, which uses gamma radiation to inspect welds and detect internal defects in pipelines. Gamma rays, emitted from a radioactive isotope source such as Iridium-192 or Cobalt-60, have the ability to penetrate thick materials, making them highly effective for inspecting dense pipeline welds. This method is ideal for locations where access to electrical power for X-ray equipment is limited, as gamma ray testing does not require an external power source. Gamma radiation provides high-resolution imaging of both surface and subsurface flaws, ensuring precise identification of any anomalies that could compromise the integrity of the pipeline. Combining gamma ray technology with our crawler systems allows for comprehensive and efficient inspection of welds in cross-country and CGD station piping works.

ULTRASONIC TESTING

Ultrasonic methods of NDT employs the use of beams of sound waves (vibrations) of short wavelength and high frequency that is transmitted from a probe and detected by the same or other probes. Usually, pulsed beams of ultrasound are used and in the simplest instruments a single, handheld probe is placed on the specimen surface.


An oscilloscope display with a time base shows the time it takes for an ultrasonic pulse to travel to a reflector (a flaw, the back surface or other free surfaces) in terms of distance traveled across the oscilloscope screen. The height of the reflected pulse is related to the flaw size as seen from the transmitter probe. The relationship of flaw size, distance and reflectivity are complex, and a considerable skill is required to interpret the display.

 

At TCR, complex multi-probe systems are also used with mechanical probe movement and digitization of signals, followed by computer interpretation.

Ultrasonic examinations are performed for the detection and sizing of internal defects, flaws or discontinuities in piping, castings, forgings, weldments or other components. 

 

TCR has in-house capability to undertake Automated UT using Time of Flight Diffraction technique (ToFD) and Phased Array (PaUT) in India for piping, pressure vessels and as per API 650 appendix U for storage tanks.

PORTABLE HARDNESS

As per ASTM E110, the testing is done by TCR for on-site applications as well as for very large samples. TCR’s portable hardness unit performs the hardness testing by applying a 5 kg vickers load indenter and electronically converting the values to a preferred scale

NDT SOLUTION

In-Situ Metallography

TCR Engineering under the NDT service performs In-Situ Metallography to determine in-service degradation of critical components of process and plants operating under high temperature, high-pressure and corrosive atmospheres. The technique enables real-time component condition monitoring and health assessments. TCR’s Metallurgists have strong experience in the interpretation of microstructures and have more than 15,000 replica microstructure interpretations, logged and captured in its proprietary database. These databases contain extensive information from various plants, captured over the course of four decades of service. The database also includes rare collections of varying microstructure damage levels from various industries such as power, oil and gas, petrochemical, fertilizers among others.

The In-Situ Metallography team at TCR is highly skilled in the art of replica preparation. TCR has custom-developed special purpose in-situ polishing devices that assist in metallographic polishing under difficult locations and allows the field services team to carry out high-quality replication even on warm components.

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TCR provides microstructure survey for critical components viz., Boilers, Pipelines, Reactors and Vessels for monitoring and health assessments. TCR has developed a databank of critical components of process plant equipment by periodical monitoring for preventive maintenance and planning for inventory control. With this, TCR can provide suggestions on repair and welding of used components of process plants.

In-situ Metallography and replication is used for microstructural analysis while examining large components that cannot be easily moved or destructive sample preparation is difficult or not permissible. The testing allows quick on-site evaluation of a component’s metallurgical and heat treatment condition and assists investigators while carrying out a remaining life assessment study or a failure analysis project.

Metallography Replica Interpretation

TCR, at their material testing laboratories in Mumbai and Baroda, has a state-of-the-art Inverted Metallurgical Microscope, GX5, from Olympus Corporation, Japan. This Inverted Metallurgical Microscope allows expert metallurgists at TCR to perform Volume Fraction Measurement by point count method as per E-562 used for Duplex Steel and Carbide Morphology Distribution as per STAHL-EISEN-PRUFBLATT 1520 (SEP-1520) German chart for checking microstructures.
 
At material testing laboratories in Mumbai and Baroda, India, TCR has a state-of-the-art Inverted Metallurgical Microscope, GX51, from Olympus Corporation, Japan. This Inverted Metallurgical Microscope allows expert metallurgists at TCR to perform Volume Fraction Measurement by point count method as per E-562 used for Duplex Steel and Carbide Morphology Distribution as per STAHL-EISEN-PRUFBLATT 1520 (SEP-1520) German chart for checking microstructure.

TCR Engineering Services has undertaken In-situ Metallography projects at major plants of reputed clients including, Alstom Projects India Limited, Vadodara (Worked on more than 20 RLA projects), BARC (Mumbai), Heavy Water Board (Mumbai), BARC, Reliance Industries Limited (Jamnagar and Hazira), SPIC-SMO, Gujarat Electricity Board, Ahmedabad Electricity Board, GSFC Limited, GNFC Limited, IOCL (Vadodara), L & T, Hindustan Lever Limited (9 Boiler RLA Work), Narmada Chematur Petrochemicals Limited, Bharuch and many more.

TYPES OF EQUIPMENT

At TCR, the following sets of In-Situ Metallography kits and equipment are available:

  • Insipol 2000 And Advanced Electrolytic Flow Type Polisher And Etcher

  • Portable Rough Grinder With Self-Adhesive Papers

  • Portable Fine Polishing (Mini Grinder)

  • Portable Microscope Capable Up To 400X Magnification

  • Replica Kit: Used With Specialized Plastic Based Slides For Replica Preservation (For Longer Durability And Ease Of Handling On Site)

 

KEY INFORMATION FOR REPLICATION INTERPRETATION

  • Objective Of In-Situ Metallography - Condition Assessment, Fire/Damage Assessment, Remaining Life Assessment, Or Baseline Data Generation

  • Material of Construction with Exact Specification

  • Location of Replication with Sketch

  • Process Parameters and Design Parameters

  • Service Life of The Component at the Time of Replication

  • Any History Of Previous Failures at the Location of Replication

DYE PENETRANT

With the dye penetrant method, a penetrating liquid is applied to the surface of the component in order to enter the discontinuity or crack. Subsequently, after clearing the excess penetrant from the surface, the penetrant that exudes or is drawn back out of the crack, is observed.

 

Liquid penetrant testing is applied to any non-porous clean material, metallic or non-metallic, but is unsuitable for dirty or very rough surfaces. Penetrants can contain a dye to make the indication visible under white light, or a fluorescent material that fluoresces under the suitable ultra-violet light. Fluorescent penetrants are usually used when maximum flaw sensitivity is required.

TCR can detect cracks as narrow as 150 nanometers using this method. 

MAGNETIC PARTICLE INSPECTION

The Magnetic Particle Inspection method of Non-Destructive testing is a used by TCR for locating surface and subsurface discontinuities in ferromagnetic material.

 

Depending on its operation on the face when the material or part under test is magnetized, discontinuities that lie in a direction generally transverse to the direction of the magnetic field. This causes a leakage field, and therefore, the presence of the discontinuity is detected by using finely divided ferromagnetic particles applied over the surface, some of these particles being gathered and held by the leakage field. This magnetically held collection of particles forms an outline of the discontinuity and indicates its location, size, shape and extent.

At TCR, dry magnetic particle examinations and wet fluorescent magnetic particle examinations are performed on ferromagnetic materials to detect surface and slightly subsurface discontinuities.

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Specialized wet fluorescent magnetic particle techniques are available for black light internal examinations of equipment through borescopes.

Positive Material Identification (PMI)

​The PMI division at TCR Engineering Services has an expert engineering and inspection workforce to undertake incoming material inspection and can provide on-site alloy verification for quality control and stock control purposes. TCR can analyze both melt and weld for comprehensive maintenance assessment.


TCR provides PMI services to a number of metal producers, foundries, metal fabricators, scrap yards, scrap traders in the industry, electric utility companies, fossil and nuclear power plants, refining and petrochemical industry, construction engineering, and the Chemical process industry.  


The range of equipment available at TCR for undertaking Positive Material Identification (PMI) is unparalleled in India. TCR’s on-site inspection and the testing team has over 12 highly sophisticated Portable Alloy Analyzer Spectrometers which can in-situ non-destructively and accurately measure the chemical composition of materials. Using these spectrometers, TCR’s engineers can provide elemental identification and quantitative determination regardless of form, size, and shape. No samples need to be cut for PMI.  TCR can also deploy the portable optical emission spectrometer that can detect C, S, P, Mn and Si. Elements that can be identified using PMI include Ti, V, Cr, Mn, Co, Fe, Cu, Zn, Ni, Se, Nb, and Mo.


The team also conducts positive material identification test to detect Carbon composition using a portable optical emission spectrometer. The portable optical emission analyzer is designed to identify all the key elements in metals, especially where highest accuracy, analysis of light elements (like C, Al, S, P, Mg, Si) or sorting of low alloys and aluminum is needed. For example, it is ideal for separation of 316 H (>0.04% C) and 316 L (<0.03% C).


Using portable XRF analyzers, TCR offers scrap traders in India all the necessary data needed to take fast, informed decisions about material purchases along with the input and speed required to sort large quantities of materials, and hence utilize sales opportunities efficiently. Inspection services team of TCR supports the recycle and resell scrap traders in enhancing their profit margins by measuring precious metals in electronics - Pt, Ir, Ru, Rh, Pd.  TCR also supports a scrap trader to perform scrap classification service efficiently. From titanium alloys to stainless steels to nickel superalloys to red metals to exotics, TCR can quickly provide fast, reliable results that the industry demands.

A wide range of alloys can be analyzed on site using PMI including::

  • Carbon and Low Alloy Steels 

  • Copper Alloys

  • Stainless and High Alloy Steels 

  • Aluminum Alloys

  • Nickel Alloys 

  • Austenitics Duplex and Super

  • Titanium Alloys 

  • Zirconium Alloys

 

TCR Engineering's PMI equipment includes

 

  • Portable X-Ray Florescence (XRF) Spectro​

  • Portable Optical Emission Spectrometer (OES) 

 

TCR’s Positive Material Identification service is fast becoming an integral part of the safety management process in petroleum refining, petrochemical, and electric power generation industries. TCR has provided PMI services to over 700 projects including major oil and petrochemical installations in India, Kuwait, Kingdom of Saudi Arabia and other parts of Middle East.

 

Some PMI projects were undertaken in conjunction with the third-party inspection of EIL, Lloyds, KTI, TUV, DNV & BARC.

PAINT & COATING THICKNESS

TCR undertakes inspection of paint and/or coating, applied to metal surfaces. The paint and coating inspection team at TCR is fully equipped and has at its disposal, Wet paint thickness gauge(s), Dry paint film thickness gauge(s), Holiday detector(s), Hygrometer with Dew Point calculator and Metal surface thermometer.
 

The expert paint and coating inspectors at TCR are responsible for monitoring and verifying to ensure that all the work inspected comprehensively conforms with the requirements of the relevant code, specification and/or standard with respect to the paint/coating procedure, the physical application as well as the physical examination, including testing.

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Senior TCR paint inspectors are qualified BGas (British Gas Corporation) and are NACE certified. The inspectors are responsible for verifying the following requirements:

  • The Blasting and Coating Materials ​

  • The Blasting and Coating Equipment 

  • The Temperature and Humidity 

  • The Surface Condition 

  • The Application Procedure

TCR's expert inspectors are responsible for the preparation of precise, yet comprehensive records that include all critical aspects of:  

  • Materials Control and Identification

  • Climatic Conditions and Surface Condition

  • Details Of Abrasive(S) and Application Procedure

  •  Abrasive/Wire Brush Standard

  • Details Of Coating and Application Procedure

  • Equipment Calibration

  •  Inspection Results

Thickness Measurement 

1

Piping

For all on-site piping, corrosion loops are the basis for carrying out thickness survey whereas, for offsite and tank farm piping, special loops are made for thickness monitoring:

  • Each corrosion loop (for on-site piping) have a combined isometric where Thickness Management Locations (TML) are serially marked

  • If any base readings are taken before commissioning, it is done with random values measured on the components

  • Routine, on stream or shutdown thickness measurement at these locations, is done in the form of a scanning. The scanning format is in a grid of size 1.5” x 1.5”, with each component marked with chalk before thickness scanning

  • Out of all the locations, few TMLs are identified for regular scanning. The selected TMLs are identified by the inspection engineer, based on the probability of corrosion at these locations (as compared to other locations in the loop) and accessibility considerations.

  • Respective maintenance departments provide access to ladders, scaffolding or portable trolleys for thickness scanning. In case corrosion is observed in these TMLs, then other TMLs in the loop are included for thickness scanning

2

Hot Tap Locations

In case of thickness survey of equipment and piping for hot tap locations, following steps are undertaken:

  • The maintenance team marks the location of the new nozzle as per the exact type and dimensions of the component to be welded on the parent pipe

  • The Inspection engineer verifies the type of component to be welded viz. weldolet, pipe of pipe connection, a nozzle with reinforcement pad, split sleeve nozzle etc. The Inspection engineer marks the centerline of the proposed weld joint: A width of 1.5” to 2” shall be marked on either side of the proposed weld centerline. A close thickness survey is undertaken along the centerline and on either side and the minimum thickness measured is reported in the hot tap file.

 

If the thickness measurement is comparable to nominal or previously measured values (if available at the same locations or at different locations in the same pipe), then it could be assumed that there is no corrosion at the location.

 

If the thickness measurement indicates severe corrosion, and thickness measured is very close to the minimum allowable for hot tapping, then hot tapping should be avoided at the location, as it will be difficult to pick up a thickness point with minimum thickness through this procedure.

 

Minimum thickness required for hot tapping is 4.8mm. If the pipe is corroded and actual thickness is in the range of 6 – 8mm, then alternate methods should be used to check the pipe thickness and certify the same fit for the hot tap.

3

Thickness Locations In Tanks

  • In case of storage tanks, the thickness is measured from outside first, followed by shell course from the bottom

  • In all the other shell courses, the thickness is measured along the staircases. Few thickness points are taken near the weld and few at the center of the shell course plate

  • In case of roof plates, the thickness is measured on each plate, with two thickness points at the center of each plate and one thickness point at the corner of each plate

  • In case of bottom plates, thickness measurement is possible only during an internal inspection. Under this, the thickness is measured on each plate, with two thickness points at the center of each plate and one thickness point at the corner of each plate

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