Wednesday, January 23, 2008

Castings and Forgings Third Party Source Inspection in India

TCR has inspection engineers that are well experienced in performing
inspections on Forgings, having done the same for a number of companies as
per international quality standards. Our engineers can fill your status
reports, corrective action reports and send the same via email upon
completion of the inspection activity. Our on-site inspection team members
are mobile and can be sent across any place in India.

The inspection engineer that are assigned to a Client's account have a
degree in engineering and strong experience in forgings and castings. He/She
has inspected forgings and castings for international buyers like yours and
is well versed with reporting standards.

Payment terms are at the end of 10 days of inspection work or completion of
the project (whichever is earlier). Payment can be made via electronic wire
transfer or credit card (using paypal).

- In order to ensure tolerances, we require Clients to furnish us with
engineering drawings, jigs and gauges as necessary. Typically we will
require your supplier to provide our inspection engineer with a Dial Vernier
(to measure thickness, diameter, length, width etc.), Radius Measuring
device (digital) to determine exact radius as well as a Angle measuring
device to measure angles and not just compare them. Should your supplier not
have any of these tools, please let us know of the same so that alternate
arrangements can be made.

- Clients must let TCR know regarding how is their supplier in India
measuring angles in Forgings currently? TCR inspectors can measure angle by
laying it out on a table and using a protractor with a sine bar. In the TCR
lab in Mumbai we have Micrometers, vernier caliper, height gauge, dial gauge
set up, pillar gauge, radius gauges, angle gauge and shadowgraph (wherever
feasible).

- Clients are advised to check with their Supplier if CMM and Shadowgraph
facilities are available. If not, TCR inspectors can measure using CMM and
Shadowgraph.

- If a shadowgraph measurement is needed, our inspection engineer will send
the sample to our lab in Mumbai where we will need to make a tracing of
various radius and do the matching which will initially be time consuming.
This will cover all dimensions and the cost per piece would be very
reasonable. Please note that we may have to make certain set up and
therefore it may take longer for the first batch. Once the setup is made
measurements will be faster for the next batch onwards. In case of sending
samples to our lab there will be a shipping charge per piece that will be
billed at actual as well. If this method is used the TCR inspection engineer
will do an on-site visual dimension check and can then send a few pieces
(number of pieces to be defined as per your guidelines) over to our
laboratory in Mumbai, India. Upon completion of in-depth dimension checking
these pieces will be sent back with our inspection stamp back to your
supplier. TCR inspection engineer will make a return visit during a loading
audit.

- With regards to measurement using CMM, TCR can quote on a cost only after
we have checked the sample forging as the cost will depend on time consumed.


- TCR inspectors can perform a loading audit as well. Clients are advised to
share their parameters for the shipping audit.

- Clients must share the production schedule defined with their supplier and
provide the inspection dates determined currently.

Please note that Founded in 1973, TCR Engineering Services, is an ISO 17025
accredited independent Material Testing Laboratory, Third Party Inspection
and Quality Assurance Company located in India. Currently a market leader in
India, based in Navi Mumbai, TCR is slowly strengthening its Middle Eastern
presence with recent openings of new offices in Kuwait and Al-Jubail, Saudi
Arabia. The company also has representative offices in Malaysia and
Washington DC, USA.

The services TCR provides include Mechanical Testing, Chemical Analysis,
Positive Material Identification (PMI including onsite carbon detection),
Non Destructive Testing (UT, DP, MP, PT, Automated UT using ToFD, Helium
Leak Detection, Ferrite Measurement, Portable Hardness), Metallography,
Welder Qualification (as per ASTM, ASME and API), RoHS Compliance Testing,
in-situ Metallography (with SEM and EDAX), Corrosion Testing (including
HIC/SSC), Risk Based Inspection as per API 581, Failure Analysis, Fitness
for Service as per API 579, Vendor Evaluation, Factory Audits, Third Party
Inspection, Metallurgical Product Evaluation, Post Weld Heat Treatment,
Manpower Deployment, Training, Engineering Research and Consultancy using
NDT Level III and AWS/CSWIP inspectors.

The TCR Inspection team looks forward to working on third party inspection
work all over India. Please visit www.tcreng.com to know more.

Friday, January 18, 2008

Third Party Inspection in India

TCR Engineering Services, is an ISO 17025 accredited independent Material Testing Laboratory, Third Party Inspection and Quality Assurance Company located in India.

Typically TCR inspectors undertake:

· Review of suppliers internal records, test certificates for identified stages in the approved Quality Plan or material procurement for verifying conformance of requirements of the equipment's / systems as per Purchase Orders, agreed Technical Specifications / approved drawings / data sheets, approved Quality Plan and other documents available with the contractor.

· Carry out stage and final inspection at works as per above documents. Inspection could be by TCR alone or along with Customer's representatives.

· Verification of calibration status of all the inspection, test and measuring instruments used for inspection.

· Preparation and submission of Inspection Reports in the prescribed format along with the necessary supporting documents such as Stage Inspection Reports / Test Certificates, etc. as per approved technical documentation and approved quality plans.

· Identify any deviations to our requirements and indicate along with supplier the proposed corrective actions.

· The Inspection reports along with all the necessary supporting documents such as Stage Inspection reports / Test certificates, etc. shall be sent through courier immediately to your office by email

TCR undertakes Independent, third party inspection and quality assurance services, including Factory Audits, OEM Development, Raw Material Inspection, Initial Production Check, In-Production Check, Random Inspection and Loading Supervision directly on-site at a given vendor / supplier location in India.

TCR's independent, third-party quality assurance services results in improved product quality, with a reduction in customer complaints, noncompliance and product recalls. TCR Engineering Services Factory Audit service verifies the capability of a manufacturer to meet contract conditions for quality, quantity and delivery terms. Such assessments are often tailor-made as per a client's needs and requirements. By availing of this service, TCR eliminates the need for a client to be present on-site at the manufacturer's plant or factory.

Please download TCR’s Brochure, Service Descriptions, and Technical White papers from: http://www.tcreng.com/download/

PMI with carbon detection in India

TCR Engineering Services in India has the portable optical emission spectrometer, ARC-MET 8000. The portable Optical Emission analyzer is designed to identify all the key elements in metals - especially where highest accuracy and/or the analysis of light elements like C, Al, S, P, Mg, Si is needed and when sorting low alloys and aluminums. It is ideal, for example, for separation of 316 H (>0.04% C) and 316 L (<0.03% C).

 

Using the portable Optical emission spectrometer, Arc Met 8000 the experienced technicians from TCR can analyze Carbon in SS wherever they can get a good 25 x 25mm flat surface. Please note that ArcMet cannot be used for smaller size pipes and fittings.  Its best performance is for larger than 50 NB size. 

 

For optical emissions based PMI, the inspectors from TCR will need 99.9% pure argon gas as well.

 

It is important to note that for use of portable OES, surfaces need to be grinded and flattened to at least a 20mm x 20mm size in order to generate a spark from the OES. If the samples presented to TCR operator do not permit them being flattened than it may not be possible with the portable OES. Due to the weight and the expensive nature of the OES machine, TCR does recommend that her operator use this machine at high altitudes. The machine cannot be used on a scaffolding unless proper platform arrangements are made. Grinding will be needed to be done on all surface which are to be tested by the portable OES and hence the part should be big enough.

 

To avail of TCR’s positive material identification (PMI) services with onsite carbon analysis, please visit www.tcreng.com

 

Wednesday, January 16, 2008

Replica Analysis

A number of companies all over the world send their Replica’s originated from the Metallography Replication (MR) / in-situ metallography activity to the labs of TCR for analysis. Customers are advised to send the following data for correct interpretation of replica microstructure.:

 

·         Purpose of evaluation

·         Exact location with sketch of equipment

·         Etchant used

·         Method of preparation: Manual/Electrolytic

·         Material of construction

·         Process parameters like temperature and pressure

·         Fluid handled

·         Service life of the component

 

 

Monday, January 14, 2008

Risk Based Inspection in India

PP SIMTECH (UK) has partnered with TCR Engineering Services, India's leading Material Testing, QA and Inspection Company. The joint venture has resulted in formation of TCR PP SIMTECH Pvt. Ltd. Based in Navi Mumbai and Vadodara (India), TCR PP SIMTECH will implement reliable and proven Risk based Inspection (RBI) technology process incorporating the key guidelines given in API 580/581 and UK HSE. PP SIMTECH has successfully implemented RBI at BP, Dow Chemicals, GPIC, ADNOC-Fertil, Norsk Hydro, BASF, and INEOS.

 

TCR PP SIMTECH will ensure reliable assessment and calculation of risk profile of items in a plant, based on its "active" and "potential" Damage Mechanism ensuring that the resulting inspection interval for the item is reliably optimized in a safe and cost-effective manner.

 

rbiAsyst™ is a fully auditable & transparent software system developed by PP SIMTECH, is designed to facilitate the RBI team study and successful implementation of RBI technology process at a plant site.

 

Speaking at the company formation, Mr. V.K. Bafna, Director, TCR PP SIMTECH said, "Effective use of RBI will allow Petrochemical, Power, Fertilizer and Oil/Gas companies in India to have an inspection which includes an increase in plant availability and cost saving, minimum duration of shutdowns, change in inspection strategies and intervals and improved safety compliance. The RBI team study will also improves the team working and communication between all plant departments."

 

Mr. Ron Selva, director TCR PP SIMTECH, said, "The RBI team study facilitated by TCR PP SIMTECH and rbiAsyst™ software provides all plant management and operations team a reliable method to identify and resolve complex item technical issues associated with static equipment including reactors, furnaces, strippers, distillation columns, heat exchangers, pressure vessels, reformers, boilers, fired heaters with associated items such as interconnected piping and storage tanks."

 

The TCR PP SIMTECH team includes Mechanical Engineers, Metallurgists, Corrosion Engineers, NDT Experts, RBI Experts and Project Managers and provides plants with RBI, Fitness-For-Service (API 579), Material Damage Mechanisms Assessment, Metallurgical Investigation & Failure Analysis and In-service Inspection.

 

The TCR PP SIMTECH approach to risk-based inspection is based on a strong co-operation between the plant personnel and TCR PP SIMTECH experts. The adopted process of guided expert judgment is based on operational experiences and sound technical basis for the evaluation of possible degradation mechanisms.

 

For more information about risk based inspection, analytical and material testing facilities at TCR Engineering Services and her associate companies in Mumbai, Vadodara, Navi Mumbai, Saudi Arabia, Kuwait, Malaysia and USA, please visit www.tcreng.com.

 

For more details on PP SIMTECH, based in UK, please visit www.ppsimtech.com.

Saturday, January 12, 2008

TCR Advanced Engineering

TCR Advanced is NABL (National Accreditation Board for Testing and Calibration Laboratories – Ministry of Science and Technology, Govt. of India) in the field of Chemical and Mechanical Testing. It is a service partner of TCR Engineering Services Pvt. Ltd. Mumbai, a company established since 1973, an old reputed organization.

 

Our Vadodara lab address is as under:

 

TCR Advanced Engineering Pvt. Ltd.,

36/2/9, Abhishek Complex, GIDC Estate,

Makarpura, Vadodara-390010, Gujarat INDIA

Research Division : +91 265 2657233

Testing Division :  + 91 265 2634375,

Telefax:+ 91 265 2643024Mobile: 093762 55165,  093762 55166,

Email : tcradvanced@tcradvanced.com

Web site:   www.tcradvanced.com

 

TCR Advanced Engineering Pvt. Ltd. has been established to cater for advanced metallurgical needs of the Industries at Vadodara a hub of chemical and petrochemical industries. Company has set-up full-fledged advanced Metallography laboratory facilities at Vadodara, Gujarat. TCR ADVANCED offers specializing services in the field of Metallography, The company provides services such as Failure Investigations, In-situ Metallography for process related equipment’s in-service degradation, Indigenization of the components, Selection of materials of constructions, Third party Inspection services, Weld repair solution etc.

 

TCR Advanced Engineering has a competent team of metallurgical engineers, technicians and other field staff working for catering the need of Metallography and testing work. Mr. Paresh U. Haribhakti (Managing Director) who is a Metallurgical Engineer and holds Master degree in ‘Material Technology’ heads the company. He is having more than decade experience in the field R & D activities, Failure Investigations, Damage Assessments and RLA studies at India's largest fertilizers and petrochemical complex GSFC Ltd., Vadodara. 

 

TCR Advanced has set up a fully fledged TESTING Division to meet the  need of routine testing such as raw material testing, Material Identification, Microstructure examination for evaluation of material processing, chemical properties  & physical properties of metallic materials.

 

Following tests services are offered from TCR Advanced Engineering Pvt. Ltd.:

 

·         Chemical Analysis (Wet & Spectro)

·         Physical Testing (Hardness, Tensile, Bend, Welder procedure qualification, Impact)

·         Inter Granular Corrosion Test

·         Microstructure Examination

·         Failure investigation of critical components/equipment.

·         In-situ Metallography [Replica-Test](won the national prize of IIM-1998)

·         Damage assessment of the components through in-situ Metallography and condition monitoring of the critical equipment and vessels of the process plants.

·         Indigenization of the components

·         Selection of materials of construction

·         Weld corrosion problems

·         Positive identification of materials (PMI) at site.

 

I also request you to visit www.tcradvanced.com for further information.

Inspection of Cranes

TCR Engineering Services in India, has a defined quality assurance practice for inspection of cranes which includes Design Consideration such as Determination of stress Analysis, Load capacity and material strength as well as creating the Welding procedure.

 

We will propose to depute an experienced Mechanical Engineer who will work out load distribution on various members of cranes along with our expert Welding Engineer to inspect the welding.

 

We also propose to get following NDT done to ensure good and sound weld quality.

 

Fluorescent Magnetic Particle Test

D P Test

Ultrasonic Test

 

TCR is also in process of putting up system for actual stress measurement by STRAIN GUAGE Method and we can work out ways to make measurement of actual stress present in a member at a particular spot.  This facility is expected to be installed by Mid February.

Thursday, January 10, 2008

Ultrasonic Corrosion Mapping in India

TCR Engineering Services in India, NDT service offering includes  detecting loss of thickness from the ID area at various points are suspected to be "High-Risk." TCR can determine thickness loss on internal surface of piping due to corrosion and stagnant of fluids, and on outer radius of elbows due to erosion or corrosion in downstream piping in refineries using a time tested good solution of Ultrasonic Corrosion Mapping with UT flaw detector. We can scan the pipe bands adjacent to weld joints and complete OD surface of elbows, Tees and reducers. TCR also provides Ultrasonic Corrosion Mapping with Ultrasonic Flaw Detector at Adjacent to Weld joints (To access minimum remaining thickness of pipeline).  This is the good practice and followed by ARAMCO in KSA and KOC, KNPC in Kuwait. 

 

TCR can make the quality procedure for the same with good reporting format and can submit the same for your approval if needed.

 

TCR works with EPOCH LT and Krautkrammer machines for Ultrasonic flaw detection. TCR also has two Olympus Omniscan MX with automated corrosion mapping kit and ToFD and Phased Array capabilities.

 

Founded in 1973, TCR Engineering Services, is an ISO 17025 accredited independent Material Testing Laboratory and Quality Assurance Company located in India. Currently a market leader in India, based in Navi Mumbai, TCR is slowly strengthening it's Middle Eastern presence with recent openings of new offices in Malaysia, Kuwait and Al-Jubail, Saudi Arabia.

 

Our service offerings include Mechanical Testing, Chemical Analysis, Positive Material Identification (PMI including onsite carbon detection), Non Destructive Testing (Conventional NDT including Automated UT using ToFD and Thermography), Helium Leak Detection, Vendor Evaluation, Factory Audits, Welder Qualification (as per ASTM, ASME and API), Third Party Inspection, in-situ Metallography (with SEM and EDAX), RoHS Compliance Testing, Corrosion Testing (including HIC/SSC), Failure Analysis, Risk Based Inspection, Metallurgical Product Evaluation, Heat Treatment, Manpower Deployment, Training, Engineering Research and Consultancy using NDT Level III and AWS/CSWIP inspectors.

 

Over 2000+ customers worldwide use TCR´s services to dramatically improve and certify their products, validate material quality, ensure innovation in the marketplace, and to achieve significant competitive advantages. As a result, these companies are bringing the right products to market, at the right time, at the right cost.

 

TCR in India is the back-end material and metallurgical testing house for a number of global companies including Reliance, L&T, Godrej, HPCL, IOC, Haliburton, Chevron, Schlumberger, Caterpillar, Enerflex, Elliott, Sinopec and others. TCR’s strengths in performing HIC and SSC corrosion tests as per NACE TM 0177 and TM 0284 for sour gas applications helps a number of companies in the middle east. TCR also performs in-depth salt spray tests, failure investigations, SEM, micro and macro examinations, in-situ metallography, hot temperature tensile (upto 850 degree C) and impact (upto -196 degree C). The range of chemical analysis spectrometers (OES, AA, ICP, GDS, CS Analyser, wet chemistry lab) at TCR is unparallel in the region it operates.

 

Saturday, January 05, 2008

Expansion of Engineering Consulting

TCR Engineering Services, India’s leading material testing, inspection and quality assurance company has expanded its engineering consulting practice with the addition of new senior level professionals in the company. As a result, the engineering consulting practice, based in Mumbai can now also undertake:

- Advanced materials & processes

- Surface Engineering

- Tribology

- Welding esp. repair welding and cast iron welding

- Thermal Spraying

- Atomised Powder Production(technology,QA,applicationwise requirements of powders),including making  complete project report and market survey report for Indian market.

- Life Cycle Analysis and Engineering Asset Management

- Failure Analysis & Product Liability

- Global Warming--Role of Tribology & Surface Engineering

 

TCR's dedicated engineering and metallurgical consulting team in India is a perfect partner for solving manufacturing and product quality problems. Several senior consultants with many years´ experience are available to help and advice on corrosion or materials selection queries. The metallurgical consulting team also advise on welding engineering, heat treatment problems, verifying product integrity, measuring performance and determining end of life to enhance product performance and quality.

 

From initial product design, through final production, TCR in-depth engineering consulting services ensures that clients are producing the best possible product. The cost for engineering consulting service is billed on a per hour basis.

 

The above listed services are in addition to the existing services provided by the engineering consulting team. For more details, please visit http://www.tcreng.com/services/engineering-consulting-metallurgy.shtml

 

Wednesday, January 02, 2008

NDT Inspection of Reformer Tubes

TCR has secured a project to undertake NDT Inspection of 200 Reformer Tubes at a very prestigious client in India. As part of this project, the NDT Services division will depute Engineer / Technicians along with Instruments and Consumables at the site location.

 

As part of the project, a Sr. Inspection Engineer from TCR will conduct in-depth visual examination and then proceed to take measurement of OD at every 3 meters and at ends in two places perpendicular to each other, i.e. at 8 locations on a 9 meter long tube for each of the 200 tubes. Ultrasonic  thickness  measurement  at  12,3,6  &  9  O’Clock position at both ends and 3m from each end, i.e. at 16 points on each of 200 tubes. Portable hardness measurement at all 200 tubes at 3 locations on each tube. Ferrite measurement at 3 locations on each tube. In-situ  metallography  at  10  locations  selected  by  the Client’s officers out of 200 tubes.

 

All TCR personnel will carry all safety gadgets etc. with insurance etc.