TCR Engineering- Company Profile

offshore QA department. The client begins, the second fourth is billed whenis required to provide TCR inspectors TCR presents potential candidateswith medical insurance except for and the remaining balance is due uponeye refraction, eye glasses, dental completion of the assignment.treatment, plastic surgery, artificiallimb etc. The client is not responsible Should a candidate placed by TCR onfor any treatment that includes chronic a retained search be terminated fordiseases such as Cancer, AIDS and cause within 6 months of placement,Hepatitis or other such diseases that TCR guarantees to provide arequire long term treatment. replacement.RETAINER PROJECTS PROCESS KICK-OFFTCR provides solutions with dedicated TCR provides priority handling to allefforts to address specific needs and client assignments. After a thoroughfill a position or staff the entire project understanding of client’s businesswithin a specific and critical time operation and their specific needs,frame. For such projects, TCR charges TCR will locate, screen, interview anda fee equivalent to 25% of the placed select the right candidate that will becandidates first Years ‘Anticipated ideal for the requirements.Annual Salary’, that includes bonusesand/or premiums. A retainer fee ischarged for consulting services thatare not contingent on the hiring of acandidate. One-fourth of the fee as anadvance is due when the assignment 101

TCR Company Profileii. Product Sourcing TCR has over the years built significant relationships in the industry, By leveraging its years of expertise, TCR offers end-to-end sourcing solutions. It covers the entire sourcing process, right from finding right suppliers to transferring design specifications. TCR also helps in setting-up the right supply chain, control logistics and ensure that the shipment meets all export guidelines. TCR’s strength lies in its domain expertise in the material testing services that ensures stringent quality control measures across all engagements.ADVANTAGE TCRTRUSTED SOURCING PARTNERTCR continuously forges strong relationships with manufacturers and traders by visitingtheir facilities and confirming “first hand” their capabilities. TCR has the capability tosource, inspect and test ferrous and non-ferrous metals, casting & forging, sheet metal,bar, pipe, stainless steel, nuts, bolts, engineering goods, non-metallic materials such aspolymer, ceramic, glass, machined parts and machine tool components from all parts ofIndia.​TCR has a dedicated team of Engineers, Chemists, Metallurgists and Technicians toparticipate in the material and goods sourcing. It’s Engineers are well versed in interpretingdrawings and assist in the creation of “test” samples. TCR has developed a 5-step sourcingprocess tailored to ensure optimum results for its clients: 1 TCR seeks detailed information Once the client is satisfied with on the product type, drawing, all the parameters including price 2 material specifications, the 3 required quantity and quality, 4 and quality, TCR confirms the order along with target delivery date with the vendor for developing an102 from the client appropriate prototype as a sample for approval TCR goes into the marketplace and contacts metal manufacturers, traders Physical samples are either shipped and producers to determine their or shown in person for approval. production capability, availability, quality, and unit price 5 TCR places the order post client confirmation and verifies all payment TCR shares the product price quote and shipping logistics during the in a FOB price format and directly process negotiates with the manufacturer/ trader to provide the client with a competitive bid

ENGINEERINGiii. Vendor Inspection & Quality AssuranceTCR Engineering provides inspection and quality assurance services to help retailers,trading partners, importers and manufacturers assess product quality and meet theregulatory requirements of their specific industry vertical. TCR’s independent third-party inspection and quality assurance services promote improved product quality and amassive reduction in customer complaints, non-compliance and product recall.The on-site inspection team at TCR is available across all states in India at a competitivepricing model with its man-day framework.ADVANTAGE TCRHELPING CLIENTS WITH THIRD-PARTY INSPECTIONWith over 33 years of experience, TCR Engineering Service has built a team that notonly possess a strong engineering background but also has a track record of performingquality analysis (QA) on all engineering goods sourced from India and validate them asper ASTM, BS, GS, JS, IS and other international standards. The team offers consultingsolutions based on the latest technological advances that incorporates all current nationaland international norms.On successful completion of the final random inspection, a detailed inspection report isshared with the client. TCR Engineering Services Inspection Certificate is issued to themanufacturer/trader to validate the product quality and highlight the positive parameters. A FACTORY AUDIT B RAW MATERIAL INSPECTIONTCR Engineering Services FactoryAudit service verifies the capability TCR conducts on-site visits to the supplier/of a manufacturer to meet the manufacturer’s plant to determine andcontract conditions on all parameters evaluate fabrication techniques, assemblythat include quality, quantity and procedures, quality issues and makes suredelivery terms. These assessments that the production process meets the clientare typically tailor-made as per the specified requirement. The Inspections canclient’s needs and requirements. span from continuous on-site photographyWhen clients avail this service, they and logging, laboratory analysis to securecan rely on TCR and eliminate the storage. Before initiating raw materialneed for their presence either on- inspection service, TCR obtains a detailedsite or at the manufacturer’s plant data sheet for the assignment. Materialor factory Inspection Services are essential to ensure that all the material supplied meets the client/ project defined specifications. 103

TCR Company ProfileC SAMPLE PICK-UP D INITIAL PRODUCTION FOR TESTING CHECKTCR inspectors can select a predetermined The inspection team from TCR Engineeringnumber of samples at the production stage Services, based on the client’s instructionsfrom a factory, seal them, label and send and Purchase Order specifications canthem to its material testing laboratory for perform a visual inspection of products thattesting based on customer requirements. are available at the start of a production cycle.At TCR Engineering Services, the The “Initial Production Check” along with amaterial testing laboratory provides “Final Random Inspection” and other in-lineMechanical Testing, Chemical Analysis, production checks assists in taking correctivePositive Material Identification (PMI), actions at early stages of the production cycle.Non-Destructive Testing, Metallography, The inspection team sends out intermediaryCorrosion Testing, Failure Analysis, Raw reports to the client and keeps them informedMaterial Inspection, Metallurgical Product about the production progress relative to theevaluation, Engineering Research and delivery termsConsulting servicesE IN-PRODUCTION F RANDOM CHECK INSPECTIONThe inspection team performs a visual TCR Engineering Services inspection servicesinspection and random material testing of team performs final random inspectionproducts during the production process. that comprises of a stringent and detailedThis in-production service check mitigates visual inspection of goods before any typethe failure risk at the final random of shipment. It is generally conductedinspection stage. The check can be done on samples selected from the definedas an independant service or for a more sampling procedures and on the premisesstringent approach, it can be combined of the manufacturer. The inspection criteriawith with the “Initial Production Check” includes both quality and quantity, while theand/or “Random Inspection.” marking and packing are based on the client’s specifications and reference samples.G IN-PRODUCTION H LOGISTICS CHECK MANAGEMENTTo ease product delivery, TCR team offers Once the product is ready for shipment, TCRLoading Supervision services including “as verifies all export logistics, including localappropriate” the checking of the container documentation, customs, licensing and tariffcondition, identification of the loaded requirements in the most efficient and cost-packing units with the previously inspected effective way to ensure on-time deliveryconsignment, tallying of the total numberof shipping packing units and sealing ofthe container. Loading Supervision serviceis offered in combination with the FinalRandom Inspection

ENGINEERING

TCR Company Profile INSPECTION PROCESS FOR SOURCING12-STEP AUDIT PROCESS TCR has developed a detailed standardised inspection procedure to optimise efficiency and maximise performance in-line with client requirements. TCR Inspection team seeks specific information from the vendor/ buyer on whose behalf the inspection is to be carried out: 1 i. Name, Address, Telephone & Fax No of Vendor ii. Details of the materials ordered along with specification (IS/BS/ ASTM etc), the quantity, testing requirements and other special needs iii. Sampling plan, if any 2 TCR´s inspection department will then get in touch with the supplier to ascertain the availability of material for inspection. If available, an inspection is fixed within the 24 hourss TCR reviews suppliers internal records, test certificates for different identified stages in the approved quality plan or material procurement 3 for verifying conformance of requirements of the equipment’s/ systems as per Purchase Orders, agreed upon technical specifications/ approved drawings/data sheets, approved Quality Plan and other documents available with the contractor 4 Based on the agreement, TCR carries out stage-based and or final inspection on it own or in conjunction with Customer’s representatives TCR’s inspectors carry out normal visual inspection (capturing detailed size measurements) and mark each and every item (or random sampling, as specified by the client) with a “unique identification number” or TCR Test Certificate Number (if material testing is ordered 5 as well) and a TCR Stamp. Extra stamping would be done on materials randomly drawn for testing as per sampling plan of the buyer. If no specific sampling plan is given by the buyer, it is normal practice at TCR to draw a minimum of 2 samples and one additional sample for a batch of 10. This ensures uniformity in assessment for the whole lot. The TCR inspector will also mark the material from which necessary length of the sample is to be procured106

ENGINEERING6 If the samples are to be cut by the vendor, it must be delivered to TCR´s laboratory making sure that TCR stamp numbering & identification markings are intact on the samples TCR will test the sample at its laboratory and carry out all tests as specified7 by the buyer. The testing can also be performed in stages on request of the vendor if the material fails to meet some of the requirements. The testing can be stalled in such cases when it is established that a sample has failed a certain test All samples drawn from a particular lot must pass all the tests as specified8 by the buyer. If any of the samples fail, the entire lot is rejected. To gain acceptance, the vendor must agree to test each and every bar/plate of the lot with respect to the failed test. Only samples that pass the test will be cleared for dispatch9 All bills for testing & inspection charges are typically raised to the vendor and the buyer may reimburse the same to the vendor for all accepted materials10 All materials dispatched from the vendor to the buyer will carry the TCR stamp and Serial / TC Number, for easy verification by the inspection department of the buyer11 In case of failure, the vendor is advised to offer a new lot and entire procedure is repeated again once the supplier rectifies the deviation as per the proposed corrective actions. In case of minor deviation from standard specification, the vendor may get clearance from the buyer and such clearance is to be directly communicated to TCR by the buyer. Such items can then be cleared for dispatch12 The inspection report is prepared in the prescribed format along with the necessary supporting documents are issued such as Stage Inspection Reports / Test Certificates, etc. confirming the acceptance of the sample and material as per approved technical documentation and quality plans. The same is shared with the client through courier and email 107



ENGINEERINGIV. CONSULTING & ADVISORYTCR’s dedicated engineering and metallurgical consulting team in India is theperfect partner for solving manufacturing and product quality problems. Withseveral years of experience, TCR’s advisory team supports welding engineering,corrosion, material selection queries and heat treatment problems as well. TCR’sin-depth engineering consulting services ensure that clients produce the bestpossible product right from the initial product design to the final production.The cost for engineering advisory and consulting services are billable on an hourlybasis with a minimum of 4 hoursCore Service OfferingsEngineering AdvisoryFailure and Root Cause AnalysisRisk Based InspectionFitness for ServiceRLA and Condition Assessment of BoilersResearch and DevelopmentContract Research and DevelopmentTechnical Help for IndigenizationQuality ImprovementSolutions of Critical Weld ProblemsEngineering Design and Analysis ServicesComputer Aided Designing (CAD)Computer Aided Engineering (CAE)Training, Reverse Engineering and Prototyping 109

TCR Company ProfileA. ENGINEERING ADVISORYTCR’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 offailure and recommend the best solution to prevent recurrence. TCR Engineeringprovides consulting assistance in several areas that include:- Determining the right material for a Develop Non Destructive Testing (NDT)product Plan and TOFD/ Phased Array procedures- Corrosion engineering, corrosion testing - Identify equivalents between Indian andand corrosion investigations foreign specifications- Metallurgical failure analysis and welding - Assist to solve product quality problemsevaluations. - Assist in cost-benefit analysis post failure- Investigate the effect of environmental analysisconditions on a product or material - Expert witness and opinion assistance in- Manage Quality Control Projects case of trade conflicts, materials disputes,- Prepare material and process and litigation issuesspecifications for in-house quality control - Creating a custom Metallurgical Image- Compare vendor or competitive Analysis Softwareproducts - Ensure product compliance with RoHS- Estimate the remaining service life of a and WEEEproduct or machine componentThe consulting practice additionally offers advanced services that include::- Finite Element Analysis and Stress (technology, QA, application- wiseAnalysis requirements of powders)- Advanced materials & processes - Life Cycle Analysis and Engineering Asset- Fractography Management- Surface Engineering - Global Warming-Role of Tribology &- Tribology Surface Engineering- Welding esp. repair welding and cast - Thermal Sprayingiron welding - CAD/CAM Modeling-Atomized Powder Production110

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TCR Company Profilei. Failure & Root Cause AnalysisTCR prides itself for its deep knowledge efficiently conduct the investigation. Aand has garnered best practices from large amount of time and effort is spentsuccess stories compiled from over 1800 in carefully considering the backgroundfailure investigation assignments, which of failure and studying the generalinclude major projects in manufacturing features before the actual investigationand metallurgical failures on ASME boilers, begins. The cause of failure is determinedpressure vessels, gas turbine engine using state-of-the-art analytical andcomponents, oil and gas transmission mechanical procedures that oftenpipelines, food processing equipment, includes simulated service testing.heat exchangers, medical supplies, Analysis and physical testing, whenrefineries, petrochemical plants, aircraft/ combined together, locates problemsaerospace, offshore structures, industrial and provides recommendations formachinery, weldments and ships. effective solutions.The Failure Analysis Team’s strength lies In the course of the various steps nin the evaluation of high temperature the course of the various steps listedand high-pressure failures. The Failure below, preliminary conclusions areAnalysis Team at TCR Engineering has often formulated. If the probableexperience in the materials space, failure fundamental cause of the metallurgicalanalysis, metallurgical, welding, quality failure becomes evident early on in theassurance, and forensic engineering examination, the rest of the investigationfields. The analysis is conducted by focuses on confirming the probableengineers holding advanced degrees in cause and eliminating other possibilities.metallurgy, mechanical, civil, chemical, The metallurgical failure analyst compilesand electrical engineering. the results of preliminary conclusions, carefully considers all aspects ofTCR Engineering works with clients to failure including visual examination ofdraw up a plan for failure analysis to 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:114

ENGINEERINGEvaluation Sequence for conducting Failure analysis- Collection of background Examination, Case - Analysis of fracturedata and selection of Depth, Decarburization mechanicssamples Measurement, Coating/ - Selection and testing- Preliminary examination of Plating Evaluation, Surface of alternative productsthe failed part Evaluation and/or Grain and/or procedures that- Complete metallurgical Size Determination will significantly improveanalysis of failed material - Chemical analysis (bulk, performance- A thorough examination local, surface corrosion - On-site evaluationof the failed part including products, deposits or and consulting servicesMacroscopic and coating and microprobe and Formulation ofMicroscopic examination analysis) conclusions and writingand analysis (electron - Tests to simulate the report (Includingmicroscopy, if needed) environmental and physical recommendations)- If necessary tests stress that may have playedmay also include Weld a role in the failureFailure Investigation ReportThe investigation team produces detailed written reports to ensure clients fullyunderstand the implications and can independently examine the conclusions:- Description of the failed processing history of qualitycomponent component - Summary of failure- Service condition at the - Mechanical and causing mechanismtime of failure metallurgical study of - Recommendations for- Prior service history failure prevention of similar- Manufacturing and - Metallurgical evaluation of failures 113

TCR Company ProfileLatest Inspection SolutionsTCR team has in-house all the necessary tools for conducting a modernfailure analysis. The complete range of equipment at TCR’s network oflaboratories include::Metallurgical Optical Microscope Complete mechanical and chemicalwith Image Analysis system LECO testing equipment500(USA) with 300X facility. Forstudying fracture surface at low Dilatometer: To measure volumemagnification and to decide areas to change while heating and coolingbe studied at still higher magnification Equipments and accessories requiredScanning electron microscope for preparation of metallographicwith EDAX. For the study of high samples including Diamond sawmagnification fractography in critical cutter, Mounting press, Roughsituations. To study surface analysis grinder, Belt polisher, Wheel or discof metal, corrosion product or polisher, Electrolytic etcher polisherlocalized areas and a Microscope with attachments like micro-hardness testing.Stress Analyzer: To detect the levelof stresses in metal Micro Hardness Tester

ENGINEERINGii. Risk Based InspectionThe reliable and proven Risk-Based corporate memory.Inspection (RBI) technology processdeveloped by PP SIMTECH (UK), with The technology is designed to facilitateguidance from API 580/581 and UK successful implementation of RBIHSE, has been accepted globally by technology processes at plant sitesleading international companies as a across oil and petrochemical industries,good engineering practice. PP SIMTECH chemical, fertilizer and power plants.has successfully implemented RBI at BP, The technology causes an increase inDow Chemicals, GPIC, ADNOC-Fertil, plant availability, ensures cost saving,Norsk Hydro, BASF, INEOS. In India, PP allows for a minimum duration ofSIMTECH (UK) has partnered with TCR shutdowns, encourages changes inEngineering Services and this partnership inspection strategies and intervals, andhas resulted in the formation of a new promotes improved safety compliance.joint-venture – TCR PP SIMTECH Pvt.Ltd. The TCR PP SIMTECH has an experienced team of professionals that includerbiAsyst™, a fully auditable and Mechanical Engineers, Metallurgists,transparent software system calculates Corrosion Engineers, NDT Experts, RBIthe risk profile of an item, based on Experts and Project Managers, thatits “active” and “potential” damage provide plants with RBI, Fitness-For-mechanism. The technology ensures that Service (API 579), Material Damagethe resulting inspection interval for the Mechanisms Assessment, Metallurgicalitem is reliably optimized in a safe and Investigation & Failure Analysis andcost-effective manner. Operating limits In-service Inspection. The RBI teamare also defined by the RBI team to prevent study, facilitated by TCR PP SIMTECHan increase in damage rate or initiation of and rbiAsyst™ software, helps all planta new damage mechanism. If business management and operations team toor safety risks are unacceptable, risk- identify and resolve complex technicalmitigating options are also recommended issues associated with static equipmentas a part of the output. TCR’s RBI team including reactors, furnaces, strippers,study improves both, the team’s working distillation columns, heat exchangers,and knowledge sharing at the plant site pressure vessels, reformers, boilers,along with enhancing communication fired heaters with associated items suchacross all departments. Additionally, it as interconnected piping and storagecaptures valuable plant knowledge from tanks.senior engineers in the team, encouragestraining of junior engineers and augments 115

ENGINEERINGCore Benefits of RBIIt must be recognized that it is the reliability of the RBI technology process, theinclusion of the best practices, the comprehensiveness of the team study method,the engineers involved from the plant site and the quality of the output, is equallyresponsible for delivering the set objectives and desired benefits.- Increased safety and - Effectiveness evaluation - Assessment of proposedequipment reliability of inspection activities process changes that could- Fewer planned shutdowns - Increased consistency of impact degradation rates- Fewer unplanned inspection planning - Documentation of currentshutdowns - Identification of potential plant configuration and- Longer inspection damage mechanisms materials of constructionintervals - Prioritisation of inspection - Improved team working- Reduction in inspection - Identification of key and communicationfrequency and maintenance process parameters between all departmentscosts affecting degradation ratesPlant and Equipment Under TCR’s RBI TechnologyProcess- All types of pressure and other fired heaters, the plant sitevessels including reactors, reformers, utility power - Over ground and buriedfurnaces, strippers, boilers and associated cross country fluid (gas orabsorbers, distillation equipment liquid) distribution Pipelinescolumns, heat exchangers, - Interconnected Piping - All types of Storage Tankscrackers, crude heaters between these items withinTCR’s Continued Support for Plant Sites includes:- RBI technology (API 579, BS 7910) and - Training & Technologyimplementation services Remaining Life assessments Transfer to in-house- Total Asset Integrity - Root Cause Material engineers to effectivelyManagement technology Damage assessments, manage plant integritysupport Metallurgical Investigation- Fitness-For-Service & Failure Analysis116

ADVANTAGE TCRT​ he approach to risk-based inspection is based on developing a strong cooperationbetween the plant personnel and TCR PP SIMTECH experts. The adopted processof guided expert judgment is based on operational experiences and a strongtechnical basis for evaluation of possible degradation mechanisms. TCR believesthat incorporation of these fundamental requirements in the evolution anddevelopment of the RBI technology process has made PP SIMTECH the globalleader in this technology and positively different from the others and the evidencelies in published testimonials from various clients.

TCR Company Profileiii. Fitness for ServiceTCR in conjunction with its international a means for helping the plant operatorUK-based partner, PP SIMTECH, make these decisions on establishedundertakes Fitness For Service (FFS) engineering principles.Assessment based on Level 2 BS 7910standards (broader scope than API Fitness for service assessment is a579). The BS 7910 fracture mechanics multidisciplinaryengineeringanalysisthatmethodology and its application have ensures all process and plant equipmentbeen successfully proven worldwide such as pressure vessels, piping, andin the last 35 years across industries, tanks operate safely and reliably forincluding nuclear pressure vessels to high the desired period of operation andconsequence items in the exploration, until the next turnaround or plannedrefining, petrochemical and construction shutdown occurs in the future. APIindustry. Recommended Practice 579 provides a general procedure for assessing fitnessProcess, plan and equipments are often for service. This assessment procedureA process, plant, and equipment are evaluates the remaining strength of theoften exposed to corrosive environments equipment in its current state, whichand/or elevated temperatures. Under may have degraded from its originalthese conditions, the material used in the condition. Common degradationequipment can degrade or age with time. mechanisms include corrosion, localizedImportant equipment such as pressure corrosion, pitting and crevice corrosion,vessels, piping, and storage tanks become hydrogen attack, embrittlement, fatigue,older, the plant operator must decide if high-temperature creep and mechanicalthey can continue to operate safely and distortion. Methods for evaluating thereliably to avoid injuries to personnel strength and remaining service lifeand public, environmental damage, of equipment containing these typesand unexpected shutdowns. Fitness for of degradation are presented andservice assessment procedures provide reviewed.118

ENGINEERINGCommon Reasons for Assessing The Fitness forService of Equipment Include::- Discovery of a flaw such as - Failure to meet current more severe conditionsa locally thin area (LTA) or design standards than originally expectedcrack - Plans for operating underOutcome of Fitness for Service AssessmentA decision to run, alter, the equipment interval for the equipmentrepair, monitor, or replace - Guidance on inspectionFitness for Service Assessment applies AnalyticalMethods to Evaluate Flaws, Damage and MaterialAging based on:- Stress Analysis may be - Fitness for Service is used to locate, size andperformed using Standard Assessment requires characterize flawsHandbook or Design Code both, knowledge of past The material propertiesFormulas or by means of operating conditions and a include informationFinite Element Analysis forecast of future operating on material damage(FEA). With modern conditions. Interaction with mechanisms and behaviorcomputer technology, operations personnel is in the service environment,the use of FEA is quite required to obtain this data especially on the effects ofcommon. - Non-Destructive corrosion and temperature Examination (NDE): NDE 119

TCR Company Profileiv. RLA and Condition Assessment of BoilersTCR has developed expertise in assessing the current condition of boilers and also theirremaining life. At TCR, both Level–II assessment and Level-III assessment is undertakenfor RLA. Adopting a pragmatic approach, efforts are directed towards collecting data onthe component/equipment history in addition to interviewing external experts familiarwith the operation details. All the details are evaluated vis-à-vis the testing and studiesare conducted at a later stage using either a:CALCULATION BASED APPROACH DESIGN APPROACHCalculation procedures are often Components which operate under creepemployed to determine the expanded regime are generally designed on thelives of components under creep, fatigue basis of yield strength, tensile strengthand creep-fatigue conditions. From plant and fatigue strength with suitablerecords, information about temperature safety factors. Under normal conditions,and cycling history is gathered and by deformation and fracture are not timeuse of standard material properties dependent. As long as the applied stressesand damage rules, the fractional life do not exceed the design stresses, theseexpanded up to a given point in time components should last indefinitely; butcan be estimated. in practice, various factors cause the reduction in life.

ENGINEERINGApproach to Remaining life assessment- Understanding the actual the strength of the material life based on analysis:degradation mechanism and check ruptures Estimates for remaining1. Fatigue - Non-Destructive Testing: life is carried out2. Thermal fatigue To provide a good insight - In addition to this,3. Thermo mechanical into the component periodic inspectionfatigue integrity procedures are spelled out4. Thermal aging - Laboratory Testing: to monitor the health of5. Creep To provide valuable the equipment during the6. Embitterment information about the course of operation.7. Corrosion material soundness - If the results reveal an- Visual examination of - Judgment of fitness of operational mistake,physical properties the equipment: Based on restriction in free- NDT involving In-situ available data movement by thermalMetallography, Ultrasonic - Suggestions on repairing: expansion or any otherTesting, Magnetic Particle If required, repairing of the prevailing damageInspection, DP Test, Ferrite equipment is suggested, mechanism, thenMeasurement. for life extension preventive maintenance- Stress analysis: To know - Judgment of remaining approach is formulatedDefinition of Component LifeHistory-based Performance-based Inspection- basedcriteria criteria criteria30 to 40 years have Severe loss of efficiency Dimensional changeselapsed, statistics of prior indicating component have occurred, leading tofailures indicate impending degradation, large crack distortions and changesfailure, frequency of manifested by leakage, in clearances, inspectionrepair renders continued severe vibration or other shows microscopicoperation uneconomical, malfunction, catastrophic damage, inspection showscalculations indicate life burst crack initiation, inspectionexhaustion shows large crack approaching critical size 121

TCR Company ProfileB. Research and DevelopmentResearch and Development assumes a pivotal role in the innovation process. It isan investment in building future capabilities and technology, which is perhaps usedto transform into new products, processes, and services.TCR has the competenceto effectively set up and manage an in-house laboratory for an organization andprovide innovative, professional and superior service. TCR brings a strong process,deep technical expertise and a performance-oriented approach that rests onintegrity and reliability. 122

ENGINEERING 1 Contract Research and DevelopmentTCR’s dedicated engineering and the metallurgical consulting team is the perfect partnerfor solving manufacturing and product quality problems. TCR’s senior consultants withseveral years’ of experience are available to support and advice on corrosion and materialsselection queries. The team also provides advisory service on welding engineering andheat treatment problems. From initial product design to final production, TCR’s in-depthengineering consulting services ensure that clients are producing the best possible product.T​ CR also undertakes research projects in the areas of Computer-Aided Designing (CAD)including Engineering Design, Legacy Data Conversion, Detailing Plant & Process Layout,CAM and Computer-Aided Engineering (CAE) including Finite Element Mode.Areas of routine research assistance include:Determining the right Investigating the effects on between local and foreignmaterial for a product environmental conditions specificationsUndertaking corrosion Preparing material and Assisting in solving productengineering, corrosion process specifications for in- quality problemstesting and corrosion house quality controlinvestigations Assisting in cost-benefit Comparing vendor or analysis post failure analysisConducting Metallurgical competitor productsfailure analysis and welding Reverse Engineering and Rapidevaluations Identifying equivalents Prototyping 123

TCR Company Profile2 Technical Help for IndigenizationIn order to generate baseline standard for indigenization, multiple metallurgical studiesare undertaken to identify status and properties of imported components by differentmethods including destructive/non-destructive studies. Technical help is provided todecide on the right manufacturing route or process and to develop quality checks onindigenously created components. TCR’s proprietary approach seeks structural detailsfrom the client across several areas to optimize indigenization support:Working condition Type of loading Design and Service history Life of an important operationof component and stresses condition of component component 3 Selection of MaterialsWeight loss experiments: Samples of different metals/alloys are exposed to simulatedor actual process plant solution in the laboratory, with and without stirring. Couponsof different metals/alloys are exposed to actual plant environment and a systematicapproach is formulated, based on the requirement of intended services, literate surveyand relevant standards like NACE, ASTM and API. The laboratory study is performed onthe exposed sample to categorize the performance and a suitable MOC is recommended.Electrochemical experiments to find out relative corrosion resistance is performed byaccelerated testing under laboratory conditions. MOC selection is done with off the shelfdatabase and is combined with the experience of other experts drawn from publishedliterature. 4 Quality ImprovementTCR undertakes total quality improvements for stringent requirements againstinternational specifications. A thorough survey is undertaken by auditing the existingmanufacturing procedure followed by stage-wise investigations of raw material andother components required for product manufacturing. Effects of processing conditionsare derived with respect to different properties of the component. Based on the study,recommendations are made for improvements in metallurgical process/raw material. Therequired quality control checks are suggested to ensure consistency for optimum andcontinuous production.T​ CR deploys a team of expert metallurgists to perform this task. The specially designedreport enlists the fundamentals of metallurgical processing variables on final propertiesof the components and includes recommendations for corrective measures. 124

ENGINEERING5 Solutions of Critical Weld ProblemTCR prides itself on having a huge knowledge bank of success stories compiled fromover 1800 failure investigations across several industries. The insights gained in thearea of failure mechanism has augmented the knowledge of TCR’s technical team andbecause of this, there is a direct implementation of repair weld solutions.With its deep technical and market expertise, TCR is a The TCR’s engineeringleading player in solving critical weld repair solutions consulting team, whenfor the aged plant components.With limited material provided with a detailedresources and increased value of new products, repair history of the problem canweld solutions can salvage critical components of reach the client’s site withinprocess plant and ensure massive savings by mitigating 24 hours and they startproduction loss. The repair weld technology requires an generating data and drawin-depth understanding of metallurgical degradations, up the way forward for theoperating conditions, physical metallurgy and welding components to be repaired.technology. There is a right solution for every problemthat can be determined via strong fundamentals, For successful repair, a mocktechnical competence, and engineering output. test is necessary from the same material (or preferablyWhen a plant with critical machinery component has for the aged material ofa breakdown, an immediate problem resolution is similar grade). In case it is notnecessary. There have been several instances when available, virgin material ofrepair welding is done with little or no understanding similar grade can also be usedof the metallurgical fundamentals and this proves as an alternative. A mock testto be disastrous. The management loses trust will establish the confidencein its usefulness and technical competency. This in the welder and weldingphilosophy promotes hasty decisions for replacing the parameters.components at a premium cost. Instead, a systematicdetailed metallurgical investigation would provide the After successful welding,extent and nature of degradation, thereby utilizing thorough NDT testing isthe knowledge of metallurgy and a proper welding recommended to ensure thatprocedure can be devised. TCR has helped many the welding joints remainindustries by providing repair solutions on critical trouble free for future service.pump casing, shaft, nitrided components reformersand many other such issues. 125

TCR Company ProfileC. Engineering Design & AnalysisServicesTCR Engineering provides design and analysis services such as Computer AidedDesigning (CAD) Engineering Design, Legacy Data Conversion, Detailing Plant &Process Layout, CAM, Computer Aided Engineering (CAE) including Finite ElementModeling, Structural Analysis and Noise, Vibration, Harshness (NVH) analysis, andProject Management Services.The team consists of a pool of highly qualified professionals armed with diversifiedtechnical skill sets. The experts have an optimum mix of experience, enthusiasm,extensive knowledge of design, product development and software domains. 126

ENGINEERINGI COMPUTER AIDED DESIGNING (CAD) DESIGNING LEGACY DATA DETAILING PLANT & Initial concept CONVERSION Part drawings PROCESS LAYOUT 3D Modeling Drafting Conversion Assembly layouts 3D Surfacing from 2D to 3D Manufacturing Structural Concept layout Data extraction MechanicalProduct definition Data validation drawing Hydraulics Parametric models GD & T Pneumatic Process sheets Castings Tool drawings Plastic parts Product drawing Sheet metal parts Part listsII COMPUTER AIDED ENGINEERING (CAE)FINITE ELEMENT STRUCTURAL ANALYSIS NOISE, VIBRATION, MODELING Linear & Non-linear HARSHNESS (NVH) 2D Mesh Static & Dynamic Sound Transmission Hybrid Mesh Contact Stress Hexa Mesh Moldflow Analysis Sound Radiation Tetra Mesh Fatigue Analysis Sound Quality Study Failure Analysis Vibration Impact and Crash Analysis Structure Borne Noise Steady State & Transient Air Borne Noise Thermal Analysis 127

TCR Company ProfileIII TRAINING, REVERSE ENGINEERING AND PROTOTYPINGCORPORATE TRAINING REVERSE ENGINEERING PROTOTYPING CAD Fundamentals CMM Rapid prototyping CAE Fundamentals Micro Profile Tester CNC MachiningSoftware Applications for Roundness Jigs and Fixtures CAD & CAE Roughness tester Profile Projector CAD Modeling & SurfacingMicrostructure Characterizer SoftwareMetallurgical Image Analysis SoftwareTCR Engineering has developed Microstructure Characterizer Software, an imageanalysis tool. Using this software, a Metallurgist or a Material Science engineer cancharacterize different types of micro structural images for grain size, coating thicknessand phases; get images from one or more files; and intensify the image using the filteringand enhancement features.Microstructure Characterizer Software 3.0 (MiC) characterizes micro structuralfeatures using standard methods of material characterization such as ASTM grainsize measurements, coating thickness, linear and angular measurements, comparisonof superimposed grain size reticules, inclusion rating as per IS and ASTM standards,nodularity measurements, powder particle size distribution and so on. It helps generatecustom-made formatted reports of live and stored images and offers results as thecomputer display as well as hard copy multi-color printouts.ADVANTAGE TCRExtensive deployment experience; the software has been deployed at more than 295commercial laboratories and universities till date. Custom modifications to this software canbe done in conjunction with the engineering consulting team at TCR128

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TCR Company ProfileWHAT WE BELIEVEOUR CORE VALUESTRUST: TCR is guided by its intrinsic Our work is founded on a rigorousvalue of building trust among all its understanding of every client’s businessstakeholders. For over four decades, context, sector dynamics, and theTCR has displayed deep intellectual macroeconomic environment. We havehonesty to tell it like it is, in a direct evolved into a trusted transformationand straightforward manner with partner who is focused on bringing touncompromised accuracy. life solutions that drive progress for our clients.PASSION: Passion drives TCR. We arepassionate about what we do and it is ACCOUNTABILITY: We set high-deeply reflected in all our activities. Our performance standards and areteam of experts demonstrates the same accountable for the quality of workpassion and are committed to making a delivered to our clients and thedifference and ensuring business success results we achieve as individuals, asfor our clients. team members, and as a company. We ensure responsiveness, reliability,INTEGRITY: At TCR Engineering, and repeatability and deliver onIntegrity means being ethically our commitments — to our clients, stakeholders, our partners, on time,unyielding and maintaining absolute every time.honesty. We inspire trust by matching WORDS THAT DEFINES USour actions to our words and take - Responsiveness, Reliability & Repeatability - Uncompromising Quality delivered onresponsibility for our actions. We are time - Tangible Results that drive actioncommitted to conducting business on - Fiercely Unbiased with unwavering ethics - Passionate experts equipped with latesta daily basis with fairness, integrity, and technologyrespect for the regulations and stayingtrue to our values.COLLABORATION: We foster a trusting,open and inclusive environment whereeach interaction is reflective of ourvalues. We believe that respect buildstrust and promotes collaboration. Wetreat our people and places around uswith the greatest degree of care.PERFORMANCE EXCELLENCE: TCREngineering is united by a strong set ofvalues that are focused on client impact.130

ENGINEERINGOUR MISSION: To provide trustedand unbiased solutions for efficientlymanaging plant operations of globalorganizations and build a betterfuture for material testing driven byits highly credible thought leadership.OUR VISION: To be a significanttransnational company by providingon-time repeatable solutions,impeccable quality and actionableresults in material testing, inspection,and consulting servicesWHO WE ARE: Laboratory forMaterial Testing, EngineeringResearch, and Consulting ServicesWHAT WE DO: Testing | Advisory |InspectionWHAT WE OFFER- 44 Years of Legacy- Honest Intellectual Insights based onDeep Subject Matter Expertise- Global Perspective that is Translatedto Teams for Addressing Local Needs- Diverse Local and InternationalClients- Comprehensive Service Offeringunder One RoofCLIENT ADVANTAGE: Reductionin plant shutdown time with on-timequality results

TCR Company ProfileWHAT WE BELIEVETCR Health, Safety And Environmental PolicyTCR is committed to good Health, Safety and Environment (HSE) practices based onsound risk assessments and appropriate training. With its zero tolerance approachtowards HSE compliance, TCR has an exemplary track record since the inception ofthe company with the absence of any major lost-time arising out of health, safety, orenvironmental accidents. With its proactive risk aversion approach, TCR remains as thesafest chain of commercial laboratories in the region.By setting high standards, TCR expects all - Fire Alarm and extinguishers maintenanceits managers to be actively involved with contractrespect to safety and protection of all - H2S Proceduresstakeholders including its clients, visitors - Training Recordsand contractors on company premises - Injury Recordsand the public at large. TCR ensures - Control of flammable substances and acidssafety controls with procedures, recordsand maintenance contracts are in place tocontrol safety including:

ENGINEERINGTCR is committed to conducting its activities as perthe following guidelines:Each TCR location will play their part and to fulfill responsibility to maintain acomply with all applicable their legal obligations safe working environmentSafety, Health and under Health and Safety in which risks arisingEnvironment Regulations Legislation by taking from the TCR’s workingwithin the territory in which reasonable care to avoid practices are identifiedit operates accidents to themselves and controlled. Any willful and others and following violation of safety policyWhile the Directors and company procedures. Full will result in disciplinaryManagement accept their mutual cooperation will action.responsibilities for Health ensure common objectivesand Safety at work, they are achievedexpect all employees to Every employee has theOn-Site Safety ReadinessEach member of the site safety officer TCR will supply all thesite team working on a required safety wearparticular project will be In case a safety-training necessary to provide thebriefed prior to his or her program is in existence on required protection on-site,first visit to site on the client site, staff will have to if the same is not providedsafety hazards associated attend it mandatorily by the clientwith site work. The companyA site visit can be representative carries outorganized by the company periodic site visits andrepresentative to discuss regular safety reviews withthe safety aspects with the site staff 133

TCR Company ProfileTCR Environmental Protection GuidelinesAs a responsible organization, TCR has over the years demonstrated a strongcommitment towards environmental protection. Continuous improvement andsustainability has been the driving force of its environment policy. TCR acknowledgesthat its activities have an impact on the environment; therefore, it encourages all itsemployees to strictly comply with our internal policies by ensuring:Zero disposal of untreated Storage of all oils and Only authorized personnelchemicals or other chemicals including solvents are allowed to fill or drainsubstances down internal and paints in designated bulk storage tanksdrains. It’s mandatory for bounded areasall employees to check with Mandatory reporting oftheir supervisor for the Use of designated area all spillages/leakages andcorrect disposal procedure especially for Refueling site other incidents including transport, compressors etc. breakdown or malfunctionUse of proper waste of any plant, equipmentmanagement system Special training for site controlling discharge intoto ensure all classes of emergency procedure for the environment and otherwaste are disposed of in spillage or leakage for all housekeeping activity ataccordance with current the employees handling risklegal requirements and substances hazardous tolocal rules the environmentBreach of HSE PolicyThe definition of a serious breach of Health, Safety and Environment Policy is verydifficult to categorize objectively in a prescriptive sense and therefore circumstancewill dictate the appropriate disciplinary action. There are of course specific instanceswhere summary dismissal will be applicable:Recklessness in the use of Operating equipment hazardous substancechemicals and radiation under the influence ofsources or any other alcohol or drug abuse Willful negligence to carryhazardous materials out proper maintenance of Falsification of safety buildings, equipment etc.Intentional removal or records or incident reportsdeactivation of any safetydevice Illegal disposal of any134

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TCR Company ProfileTEAM TCRTCR demonstrates a “one team” attitude that is reflected in its leadership in all practices andoffices across TCR. TCR’s strength lies in its people. They have driven individuals who workin teams with cutting-edge technologies set in an environment of transparency to deliverpragmatic action. The teams constantly re-engineer themselves to be more responsive tocustomer needs by identifying challenges and facilitating solutions that promote growthand deliver exceptional results for their clients, their communities and their people. Meetour exceptional talents by reading their profiles below:A Paresh Haribhakti, Chief Failure Analyst and Managing Director, TCR Advanced Engineering Mr. Paresh Haribhakti is the Managing Director of TCR Advanced Engineering Services in Baroda, India (a TCR Engineering Services partner company). With more than 250 failure investigation cases Paresh has an intensive and vast body of work to his credit. He has solved materials engineering problems and performed failure analysis on components from petrochemical plants, oil and gas transmission pipelines, offshore structures, ships, pharmaceutical plants, food processing equipment, gas turbine engine components, and weldments. He investigates the available physical evidence, andperforms the necessary tests to develop the most probable accident scenario. He simplifiescomplex engineering theory into easy to understand and useable concepts. Paresh usessimple analogies and every day examples in laymen terms to explain data and findings toclients, corporate executives, government officials, or attorneys for them to understandengineering concepts.Mr. Haribhakti has specific experience in welding, heat treating and materials technologyfor oil & gas drilling and production applications, including production tubing, casing anddown hole motor failures. Recently, Paresh was lead member of the Failure Investigationteam consulting to Asia’s largest refinery, RIL-Jamnagar, India for damage assessmentwork during a fire incident in their VGO-HT2 Plant. He has provided damage assessmentof Hydrocracker reactors at Baiji refinery Iraq and also helped a customer procure secondhand equipment from Taiwan by a Health assessment approach.136

ENGINEERINGHe is skilled in the use and application developed a well respected chemicalof scanning electron microscopy (SEM) composition mapping method forin support of failure analysis and identification of dilution in weld zone.fracture identification. Mr. Haribhakti He performs color metallographyalso undertakes Optical metallography to increase the capabilities ofand interpretation of microstructures, interpretation of microstructure.Remaining Life Assessment, provides He has also developed customHeat treatment solutions and studies the electrolytic polishing for carbon anddegradation of microstructure under high alloy steel material.temperature high pressure conditions.He has done extensive research in study Mr. Haribhakti is a Founder memberof hydrogen embrittlement of steels and of Metallography Society of India. Hestainless steels. is an active member of the Institute of Engineers, Institute of FoundryResearch oriented creativeness of Mr. Man, Indian Institute of Metals andHaribhakti spearheaded the development Indian Institute of Welding. Mr.of a powerful image analysis software for Haribhakti is a B.E. (Metallurgy) andMetallurgical use - the Microstructure M.E. (Materials Technology) fromCharacterizer Software (MiC). He has also M.S. University, Vadodara. 137

TCR Company Profile B Ganesh Sonawane, Head of Quality Assurance An extremely sound broad-based technical understanding of the laboratory sector has made Mr. Ganesh Sonawane a key contributor in creating TCR Engineering Services into a quality oriented state-of-the-art laboratory. With strong understanding of QA principals (NABL and ISO/IEC 17025) and excellent inter-personal skills, Mr. Sonawane has provided the edge to complete projects on time, within budget and with quality. His patience, business ethics and conduct has ensured that TCR’s QA standards are never compromised. Mr. Sonawane is trained as qualified internal auditor for carrying out audits by DNV. He has expert knowledge in Analytical Chemistry, materials identification of organics and inorganic materials. He has extensive experience in problem solving and method development for non-routine testing and possesses superb knowledge of classical and instrumental method of analysis. As a quality assurance manager, Mr. Sonawane ensures that the TCR laboratory stays compliant and accredited to all applicable standards including NABL, BIS and ISO 17025. He develops and maintains the Scope of Accreditation including conducting internal quality audits on calibration processes and correct test procedures. He also assists in conducting a technical audit on the technicians performing all material testing services. Mr. Sonawane facilitates as a point of contact and escort for customer and regulatory audits. Mr. Sonawane has advanced knowledge of chemical sciences, especially analytical techniques and instruments with good decision making skills. He ensures accurate results reporting from all analytical instruments including the Optical Emission Spectrometer (OES), Inductively Coupled Plasma (ICP) Spectrometer, Automatic Combustion based Carbon and Sulfur determination, and Glow Discharge spectrometer. Mr. Sonawane also performs Material Certification including Unknown Material Identification and Trace Element Analysis on Powdered Metal, Chips/Shavings and Solder Alloys (Tin/Lead), Coating Weight and Identification, Quantitative & Semi-Quantitative Analyses including Density of Powdered Metals. He also supervises the conduct of Restriction of (certain) Hazardous Substances (RoHS) testing using the Portable XRF and ICP spectrometers. Mr. Sonawane’s analytical exposure also includes wet chemical analysis of copper ore, cobalt ore copper carbonate, cobalt carbonate , calcium carbonate , sodium carbonate, sulphuric acid, copper cathode, leach slurry and liquor from Ball mill 138

ENGINEERINGsamples. He has conducted personally analysis of raw material like copper concentrate, Rockphosphate, Ferric sulphate, sodium sulphide, River Sand, quartz chips , Lime stone, Quicklime, Hydrated lime ,Baryte etc by wet chemical analysis. He has also undertaken analysisof moisture , volatile matter, silica, ash content and fixed carbon content of coke and coalsamples as well as complete analysis of Sulphuric acid for various parameters.Mr. Sonawane is well versed in performing fire assaying of copper concentrate and barytesamples for precious metal content, analysis of copper matte ,copper slag, oxidation andreduction samples of copper metal, copper cathode, copper anode and blister samples ofcopper by wet and instrumental method, analysis of converter dust ,gas cooler dust and ESPdust for various impurity level by wet chemical and instrumental method of analysis as well asanalysis of soft water ,Raw water, cooling tower water, DM water, copper electrode samplesfor various parameters.Mr. Sonawane has a Bachelor of Science in Chemistry from Pune University. C S. S. Shanbhag, Chief Metallurgist Mr. Shanbhag is a chief Metallurgist with over 26 years of experience. He serves as a technical expert on the most complex metallurgical testing projects. Mr. Shanbhag is “Hands-on” in the laboratory and performs material testing, analysis and results interpretation of numerous samples analyzed through the laboratory including mechanical, chemical, metallography and corrosion. He is part of the investigative team that performs failure and root cause analysis of failed components. He performs and assists in routine metallurgy, including micro preparation, etching, phase counting, grain size measurement, micro structural assessment etc. He administers the mechanical testlaboratory when team members are conducting tests such as Tensile, Charpy Impact, SourGas corrosion testing including HIC and SSCC, and Microstructure Analysis.He interfaces with the machining department to ensure that samples are prepared as perthe ASTM, NACE, BS, IS or client-specified standards. Mr. Shanbhag reviews, recommendsand implements new and enhanced testing equipment or protocols. He has the uniqueability to research and analyze information of considerable difficulty and draw validconclusions. He has a strong understanding of QA principals (NABL and ISO/IEC 17025)and good inter-personal skill. 139

TCR Company ProfileMr. Shanbhag is skilled in mentoring, supervising, evaluating, training and motivatingemployees. He provides guidance and counsel to fellow team members and is capable ofcross-training department personnel to perform job functions in various testing areas.Interface with customers and vendors in technical issues related to materials and specialprocesses. Assist the customer relations team and help resolve issues in a timely andeffective manner. Contributes to the improvement of metallurgical testing department byadvising on new test equipments and latest innovative procedures.Mr. Shanbhag has a Bachelor of Engineering in Metallurgy. D Mukesh Kumar, Sr. Metallurgist(B.Tech & M.Tech(IIT) in Metallurgy) Mr. Mukesh has extensive knowledge of failure investigations on metallic components related to chemical/refinery plants and to general engineering. Experience ranges from cast iron, engineering steels, aluminum, copper alloys, stainless steels, and nickel base alloys to titanium. This includes all aspects of metallurgical investigations of offshore, marine, refinery and automotive components such as; turbine blades, compressors, gearboxes, motors, pumps, rotors, shafts, valves, pipe work, fasteners, boilers, pressure vessels, plain bearings, rolling bearings, gears, pistons, spark plugs, crankshafts, camshafts, engine valves and associated valve components. Mr. Mukesh is well experienced in the Microstructure Characterizer Software, which has been developed internally at TCR, for grain size measurement, volume fraction, nodularity assessment, case depth measurement. Mr. Mukesh has deep rooted understanding in metallurgy including micro preparation, etching techniques, phase counting, and microstructure assessment etc. 140

ENGINEERING E Avinash Tambewagh, Head of Advance Testing Avinash leads the Advance Testing vertical and has nearly 20yearsofexperienceinCorrosionTesting,In-SituMetallography,Consultancy, Failure Analysis. He has extensive knowledgein carrying out corrosion testing, metallurgical activities,mechanical testing and fractography). Avinash is adept infailure analysis of industrial materials, evaluation of materialcharacteristics for production & quality assurance, materialsselection for specific end-applications. He has extensiveknowledge in heat treatment of Industrial Ferrous Materials,Micro-structural Design for Steel / Alloy development.Avinash has completed B.E (Metallurgy) from Govt. Collegeof Engineering Pune. F Ms. Gauree S. Deole, B.E. MechanicalMs. Gauree has experience working with ‘rotating equipmentdesigns (especially pumps and mechanical seals)’ in oil andgas industry. Analysing technical documents, understandinggeneral arrangement drawings and reaching to a validconclusion is one of her unique characteristics. Along withthis industrial experience in designing field, she is good withmaterial testing knowledge. She looks after all the thirdparty inspections that take place at our laboratory, handlestheir technical queries efficiently and interprets/analyses thetesting results. She also assists her seniors with machiningdepartment to make sure whether the machining of materialtakes place as per standards. G Rohit K. Waghmare, B.E. MechanicalMr. Rohit has knowledge in the field of Fatigue, Fracturemechanics & Fracture Toughness. He has an experiencein the field of Production as well as in the material testinglaboratory. A sweetmouth person who knows how to get workdone from workers. He has hands on practice in the fatiguetesting which includes the components like springs , seatbelts , Reinforcement Couplers etc. he is from productionbackground which includes the Production,Erection,Commissioning and Inspection of FRP BLOWERS, HDPETANKS, COOLING TOWERS , FRP CHIMNEY SYSTEM.

TCR Company Profile H Shemi Baskaran, ASNT Level III NDT InspectorMr. Baskaran has 18 years of experience in QA /QC inspection in oil and Gas industry,Petrochemical and refineries and is qualified as a ASNT LEVEL III RT, MT and PT. He isexperienced in static equipment inspection and Third Party Inspection of materials likeplates, pipes, forgings, casting at a vendor’s location. He also has hands on experiencein NDT (RT, MT, PT) and Radiographic testing and film interpretation. I Amit Bafna, Middle-East Operations Manager at TCR KuwaitMr. Amit Bafna has over 5 years of strong NDT and QA/QC project managementexperience. He has the ability to read technical documentation, motivate team membersand do resource allocation. He co-ordinates with team members to ensure that allclient or vendor provided drawings and specifications, technical surveys and majorequipment reviews are in compliance with corporate and international standards.Mr. Amit Bafna has a degree in Science as well as an ASNT Level II certification incompliance with CP-189. He is trained in Canada on the use of Automated UT usingTime of Flight Diffraction. He is well versed in writing NDT test procedures includingconducting hands-on tests in UT, DP, MP, PT, Ferrite Measurement, Hardness Survey,Positive Material Identification and In-situ Metallography. Coupled with strongleadership skills, Mr. Bafna both metors and supervises fellow team members.Mr. Bafna has the cost and technical responsibility for execution of specific contract(s),including devising the planning, directing, and coordinating of project activities toensure that project objectives are accomplished within the prescribed time and fundingparameters. As a Operations Manager for Middle East, Mr. Bafna leads his team members and provides quality assurance, quality control and quality monitoring functions to ensure that all purchased commodities comply with corporate and customer technical standards. His job also includes Performing / Coordinating Quality Control activities on company purchased materials and monitoring activities on contractor issued purchase orders, assessing capabilities of potential vendors as well as performing proactive inspections through increasing surveys, organizing strategy meetings with the client’s Project Management Teams and contractors including coordinating pre-shipment inspections. Experience in managing complex business relationships, both internal and external, where conflicting priorities of team members must be managed with customer satisfaction as a primary goal. Mr. Bafna has a strong understanding of the company operations to properly support and represent TCR in a mature and professional manner. He has developed oral and written communication skills to meet variety142

ENGINEERINGof communication needs (performance reviews, presentations, employee training anddevelopment, and leadership).Mr. Bafna has strong interpersonal skills that foster open upward and downwardcommunication built on mutual respect. Ability to remain calm when faced with mountingpressure related to deadlines and multiple priorities. He has the flexibility, and maturity torepresent the company at a broad range of events in the community, with customers, andwithin the company. J Rohit Bafna, Director Global SalesRohit is currently Director Global Sales basedin TCR World in Washington DC, USA. Underhis leadership the US office has grown fromits incubation stage to one which is nowprofitable. Prestigious clients that have trustedTCR to carry out material testing and qualityassurance services secured by Rohit includeCaterpillar, Enerflex, Hyundai, Aventech, ElliotCompany, Elliott Company, Constar, Xalloy,Sys-Concept and the US Army.Mr. Bafna has the cost and technical responsibility for execution of specific contract(s),including devising the planning, directing, and coordinating of project activities to ensurethat project objectives are accomplished within the prescribed time and funding parameters.Where subcontracts are required, Mr. Bafna manages the development of specifications,statements of work, evaluation criteria, and requests for proposal. Mr. Bafna works with thematerial testing laboratory and engineering consulting divisions to analyze proposals withrespect to cost/risk/quality, lead source selections and negotiation teams, and monitorssubcontract costs, schedules, and technical performance.Mr. Bafna has over 8 years of Sales and Marketing in the Material Testing and QualityAssurance business. Rohit has undergone extensive training on Ultrasonic Testing usingTime of Flight Diffraction (TOFD) at Olympus in Quebec, Canada.Mr. Bafna has a Bachelors degree in Computer Sciences from DeVry Institute of Technology,Los Angeles, California and overall over 15 years of sales experience. 143

TCR Company Profile K Suresh Acharya, Country Head Mr. Acharya has over 28 years of experience managing many projects including the ability to manage multiple priorities while retaining high professional and ethical standards with overseas clients. He maintains close interaction with third-party suppliers, external laboratories, customers and company staff / technicians as well. As Country Head, he receives and analyses scope and specifications for works and services to be contracted, clarifies work aspects andverifies technical evaluation criteria. He also proposes contract type, prepares tenderdocument and finalizes them with Finance and Management input.Mr. Acharya has managed a variety of projects and contracts from routine testing jobsto specialized projects in oil and natural gas companiesMr. Acharya work closely with established clientele to maintain good standing andpursue additional opportunities. He maintains a keen entrepreneurial interest andparticipation in business growth and pursuit of new opportunities and offerings. Atmany occasions, Mr. Acharya suggests and pursues new technical offerings and is atall times aware of potential new clients and pursues relationships as appropriate. Hedevelops business practices that encourage team building and participation by otherswithin the organization.Mr. Acharya’s role also includes responsibility for technical performance, schedule,budget, coordination of proposal responses, and decision making in businessdevelopment globally. He leads a multi-disciplinary filed services team within TCRand provides leadership, vision and direction. Mr. Acharya’s expertise and guidanceenables TCR recruiters to accurately assess potential job seeking candidates’ abilitiesand interests.Mr. Acharya has a Bachelor of Commerce degree from Mumbai University. He hascompleted Post Graduation Diploma in Computer Programming and System Analysisfrom Mumbai University.144

ENGINEERING L Gopul PatelIs a post graduate from Sardar Patel University. He has an extensive knowledge ofvacuum Technology and has worked as Scientific officer at Department of Science andtechnology sponsored Research centre. He has hands on experience of operation andcalibration of various sophisticated analytical instruments such as Transmission ElectronMicroscope, Scanning Electron Microscope with EDS, X Ray Diffraction, ICP OES,spectrometers, Thermal Analyzers such as DSC, TGA. He has experience of variousadvanced methods of material characterization and has worked extensively in the fieldof microscopy.He has been trained for Operation of Electron microscope at PHILLIPS, The Netherlands.In fact he has handled India’s First Environmental Scanning Electron Microscope withEDAX analyser for more than five years.He is responsible for the establishing & implementing Management system at TCRAdvanced and its functionality. He is actively involved in establishing new testingfacilities at lab as well as on site. He has played an instrumental role in establishingcustom designed web based sample management system for handling sample flow inthe laboratory. M Ketan Upadhyay, Reliability EngineeringMr Ketan Upadhyaya is a B.E. (Metallurgy) from M.S. University of Vadodara andhas experience of 22 years in the field of NDE, Acoustic emission techniques,Vibration measurement and signature analysis, Failure Investigations, Microstructureinterpretation, Scanning electron microscopy and digital imaging system. He hasworked as a metallurgist at India’s largest fertilizers and petrochemicals complex, GSFCLtd., His Job profile includes fabrication inspection, providing welding proceduresfor maintenance and relevant heat treatments, troubleshooting against organic andinorganic corrosion and microbial induced corrosion. He is a qualified level II for AcousticEmission testing (IISC Bangalore), Vibration Analyst VT-II (Entec IRD) and UltrasonicFlaw Detection (EEC Mumbai) techniques. He is actively involved in Plant reliabilityEngineering and risk based inspection projects for different components such as heaterpiping, reactors and static equipment of petrochemical and refinery industries. Heis well familiar with API/ASME/ASTM/JIS codes and ASM literature. His associationwith TCR Advanced Engineering strengthens the Remaining Life Assessment, FailureInvestigations and Advanced Non Destructive Examination projects. 145

ENGINEERING N Sohel Vaidya Team Leader Advanced NDT DivisionMr. Sohel is an ASNT II Engineer in Ultrasonic testing, Interpretation of Radiographs,Liquid Penetrant Testing, MPT(Magnetic Particle Testing). As an Inspector he performs daily Inspection of pipingfabrication, Inspection of daily fitup, weld visual inspection and preparation ofdocuments, Monitoring welder performance and weld repair status on weekly basis,Preparing QA/QC reports, Prepare the pre-punch list prior to hydro test, Documentationof Welding, NDT reportsPreparation of reports for client submittal, Welding material control, Welder control,Welding and welding repairs, Responsible to complete necessary documents for allwitnessed items, Co-ordinating with construction supervisor / engineer, Reporting forpoor workmanship and violation and Co-ordination with NDT crew and third partyagencies.He has over 10 years of strong project management experience. He has the ability toread technical documentation, motivate team members and do resource allocation.Sohel co-ordinates with team members to ensure that all client or vendor provideddrawings and specifications, technical surveys and major equipment reviews are incompliance with corporate and international standards. O Anil Joshi ASNT Level II in MSLT (Leak Detection)Mr. Joshi is an ASNT Level II in Leak Detection. He is well experienced in working withthe Alcatel ASM 140 and Varian Helium Leak Detection Machines. He has over 30 yearsof experience in Helium Leak Detection. He is capable of working in the two methodswhich are applied for leak testing and localization of leaks, the “Vacuum method” andthe “Overpressure method”. He has detected leaks in-situ to prevent unplanned andexpensive shut downs.Mr. Joshi has tested components for Nuclear Power Corporation ( NPC), Heavy WaterBoard ( HWB), Bhabha Atomic Research Centre( BARC), Roll Metallizers manufacturedby Gallelio, Italy, Applied Vacuum, Germany as well as Vacuum Furnaces. He has visitedVarian, Palo Alto (USA), Torino (Italy), Zug (Switzerland) for training and inspection ofVacuum Coating Units.146

TCR Company ProfileTCR ADVISORY BOARDTCR has assembled a strong team of external experts who will provide technicalleadership to the company. TCR draws on this experience to provide the bestsolutions for their clients The highly talented team of experts includes:1 Dr. G. E. Prasad, Retd. Head Materials Characterization Section BARC, Ex Hon. Secretary of Indian Nuclear Society Dr. G.E. Prasad is a well known personality in the field of Metallurgical Investigations and Failure Analysis. He has been associated with Dept. of Atomic Energy till he retired in 2001. Dr. Prasad has also represented India in a 3 member team who was involved in Kanishka (Air India Jet) blast case. He has numerous investigations of failure in Heavy Water Project, DAE and governmental institutions around the country. Dr. Prasad has been a General Secretary of such renowned societies as Indian Institute of Metals (Mumbai Chapter), Material Research Society (Mumbai Branch) and Indian Nuclear Society (Mumbai). He is the ex. honorary secretary of the Indian Nuclear Society. Mr. C.V. Srinivasan, UNDP Corrosion Specialist2 Mr. Srinivasan is the Technical Director, Nishi Engineers Pvt Ltd Chennai with over 42 years of professional experience. He has published 38 papers on Corrosion, Metallurgy, Welding, N.D.T in various International and National Conferences on Corrosion, metallurgy, Welding, Non-Destructive Testing, Vibration + Journals from 1965 onwards including UNDP conferences. His expertise includes conducting Third Party & Statutory Inspection / Certification of LPG/Butane/Pentane / Ammonia/ VCM/ Chlorine / Nitrogen/ Oxygen Static Storage Vessels (Bullets / Spheres), Petroleum / Methanol/ Diesel/ HSD/ LSD/ Kerosene etc Storage vessels, Used Pressure Vessels / Used Lifting Machines / Lifting Tools, Cranes, Hoists etc. He is an expert in conducting Risk Analysis and Safety Audit for Chemical, Fertilizer, Petro-chemical, Refinery, Steel Industries and also provides consultancy in Corrosion, Metallurgical Studies (including Failure Analysis) for Plant equipment / piping etc failures. He assists in guiding on Non- Destructive Inspection, In-situ Metallography of special equipment / piping during project stage or after some years usage as well as providing Vibration Engineering Consultancy for high speed turbo-compressor rotating machinery / high speed pumps, blowers, fans etc on a need basis. 147

ENGINEERING Mr. K. Ravindran, NDT Level III 3 Mr. Ravindran has the unique distinction of holding the ASNT NDT Level III certification in 11 subjects including RT, UT , MT , PT, VT, ET, LT, IR ,AE, VR and NR. He also carried the AWS CWI certifications. He has an overall experience of 25 years in inspection field of castings, forgings, pressure vessels (Designing, fabrication inspection) and pipe lines inspection. He is familiar in Destructive and Nondestructive inspection technique, as applicable to Welds, castings, forgings etc as well as inspection of raw materials with relevant specifications. He is thoroughly familiar with all the relevant applicable Codes and Standards for Nondestructive Testing and well versed in the documentation procedures. He is a post Graduate in physics, Post Graduate Diploma in Radiation Protection by Bombay University BARC (INDIA). He has over ten years experience in conducting training courses and classes all most in all methods of NDT, welding technology and casting and foundry technology. Dr. Rajendrakumar 4 Dr. Rajendrakumar is a renowned metallurgist of our country. He is a doctorate from world famous University of Shefild, UK. Dr. Rajendrakumar was the Director of National Metallurgical Laboratory, Jamshedpur and a former Director of Regional Research Laboratory, Bhopal. Dr. Rajendrakumar has more than 150 publications in national and international journals of repute. He has been a committee member of IBR for failure investigation. He has written three books on metallurgy. Dr. P. B. Joshi 5 Dr. P B Joshi is a professor in Department of Metallurgical and Materials Engineering, Faculty of Technology and Engineering, Maharaja Sayajirao University, Vadodara. He is a Ph. D. in Material Engineering. Dr Joshi is having more than 25 years of teaching experience in the field of metallurgy. He has more than 50 research publications in International journals & National journals, and authored a book titled “Materials for Electrical and Electronic Contacts”. Dr. K. Baba Pai 6 Dr. Baba Pai is the Head of the department of Metallurgical & Materials Engineering Faculty of Technology & Engineering, M. S. University. He is Ph D from IIT Mumbai. He is having more than 29 years of experience in Educational field. He began his career as lecturer in 1989 and became professor in the Metallurgical and Materials Engineering department148

TCR Company Profile since past 18 years. Under his able guidance more than 4 Students were awarded PhD. Presently three students are perusing PhD Under his guidance. He has more that 90 national and international publications in reputed journals. Dr. Pai is actively involved in providing Testing and industrial consultancy assignments for many industries of Gujarat. Mr. Jagdish Baad, Consultant7 Mr. Jagdish Baad is Bachelor of Technology in Metallurgical Engineering with First Class honors from IIT, Mumbai. He is having experience of 25 years in forge shop, steel, cast iron, S.G. Iron and Non-ferrous foundries. He has worked reached to Sr. Management position starting from the Engineer level. He has handled Turn key projects related to Foundry Mechanization, Quality Assurance and Product management of critical castings for turbine, material handling and wear resistance applications. Some of them are first of its kind. For last 12 years running an independent consultancy, related to TQM-Product Management of Castings & Forgings and metallurgical related turnkey projects. Well versed in kaizen, Edward Debono /Osborn techniques in creativity management. Energy audits related to metallurgical processes. He is Life member of various institutions such as Institute of Indian Foundrymen , Indian Institute of Metals ,Indian Society of Non- destructive Testing, Indian Institute of Welding Metallography Society of India, Alumni Association of IIT Mumbai. Mr. Prakash Bhrambhatt, Consultant8 Mr. Prakash Brahmbhatt is Ex – GM inspection dept of M/s IPCL Erstwhile RIL. His area of responsibilities during his association with RIL includes inspection & maintenance from health assessment & reliability/integrity angle for LDPE, PPCP, PBR-I, PBR-II, PP-IV, LAB, EG plants. Since last 32 years he is working in the field of fabrication, maintenance welding, inspection, testing, up keeping, metallurgy/material science, corrosion, health assessment, reliability & integrity monitoring of piping & static equipment in the petrochemical process plants. Familiar with all different type API/ ASME/ASTM/ASM etc. codes & standards in respect of inspection ,NDT, welding & material of construction used in such plants in above areas/ fields. He was appointed as an faculty on inspection & testing, metallurgy, welding in process plants in training center of IPCL/RIL-VMD. He was also a competent person for pressure vessel testing for GFA compliance. Dr. Mukesh Pandya, Consultant9 Dr. Mukesh Pandya is Ex-DGM (Research) from Gujarat State fertilizer Company (GSFC) Limited, India’s premier fertilizer company. He is having a Ph.D in corrosion from Gujarat University. He has more than 25 years 149

TCR Company Profile of experience in corrosion evaluation, materials selection, failure investigation and online corrosion monitoring in chemical, petrochemical and fertilizer industries. He possesses in-depth knowledge on various forms of corrosion. His is having vast experience in conducting laboratory and field experiments on corrosion measurements as per national and international standards. He has been a member of National Association of Corrosion Engineers (NACE) USA, for 8 years. He has provided consultancy services to many industries in India and also successfully carried out international collaborative projects with M/s Avesta, Sweeden, M/s Krupp VDM Germany and M/s Cormon UK. 150