TCR Engineering- Company Profile

ENGINEERINGTECHNICAL CAPABILITYWelding Procedure ProgramThe welding inspector deployed on-site by TCR is responsible for monitoring andverifying conformity of tasks against all the relevant requirements including codes,specifications and/or standards:- Ascertain the weld performance parameters are - Based on the requirement,procedure(s) employed maintained the inspector may choose- Review weld procedure - Perform visual examination to send test samples to theand welder qualifications upon completion of welding TCR Engineering Services’- Supervise weld profile - Monitor specified pre and material testing laboratorypreparation post weld heat treatment - Verify all necessary visual- Inspect joint fit-u - Monitor the physical inspections are completed- Oversee filler metals and examination including non- and all other necessary non-consumable materials destructive test, hydrostatic destructive examinations are- Ensure correct welding test, mechanical test executed as specifiedBased on the requirements, the inspector may employ equipments to accelerate theprocess:- Inspection mirrors - Physical size measuring ammeter, voltmeter etc.- Torch or other electrical instruments such as welding - Temperature measuringlighting facilities (permitted gauge, rule, vernier etc. instruments (thermometer)/by safety codes eg. 24V - Electrical parameter aids (thermo chalk)system etc.) measuring instruments such asAdvantage TCRAll TCR welding inspectors are certified in accordance with the requirements of oneor more of the following schemes:- Certification Scheme for - American Welding Society - ASME B&PV CodeWeld Inspection Personnel (AWS) - ANSI / AWS D1.1(CSWIP) - British Gas (BGAS ERS)- ASNT Level II VT - Section IX,API Standard 1104 51

TCR Company ProfileF. Civil TestingTCR Engineering provides superior end-to-end solutions for civil testing across allelements and parameters of a building structure. 1 Structural Audit Services 2 Soil Testing Services 3 Concrete Services 4 Concrete Mix Design 5 Bitumen Testing Services 6 Tiles Testing Services 7 Ceramic Testing Services 8 Brick Testing Services 9 Cement Testing Services 10 ToR Steel Testing Services 11 Mortar Testing Services52

ENGINEERING 1 Structural Audit ServicesA structural audit entails evaluating the overall health and performance while ensuringthat the building and its premises are safe and are at no risk. A structural audit isdone by an experienced and licensed structural consultant who analyses and suggestsappropriate repairs and retrofitting measures required for the buildings to performbetter in its service life. TCR Engineering has recently undertaken various structuralaudit services for both residential and commercial buildings including Vikas Complexin Thane West, KC College in Thane and Essential Power Transmission in Andheri.As per clause No.77 of revised Bye-Laws of Cooperative Housing Societies: TheSociety shall cause the ‘Structural Audit’ of the building as follows:For building aging between 15 to 30 years once in 5 yearsFor building aging above 30 years Once in 3 yearsPurpose of Structural Audit- To save human life and that need to be attended of the problems and thebuildings and warn against or repaired with immediate urgency required to attendany potential threats or effect to the samefailures - To comply with statutory - To enhance the life cycle- To understand the requirements of municipal of a building by suggestingcondition and health of a authorities preventive and correctivebuilding and to project the - o proactively assist the measures like repairs andexpected future life residents and the society to retrofitting- TTo find critical areas understand the seriousnessUsers - For damage assessment - For proposing additions, due to earthquake, fire, alterations and/or extensions- For insurance blast, vibration, corrosion in building / structure- For bank mortgage etc.- For valuation 53- For structures that showsdistress

TCR Company ProfileProcessPart A – Visual Inspection Part B – Non Destructive Part C – Repair &- Visual inspections of Evaluation Rehabilitation Consultancyindividual building / - In addition to visual For preparation of detailedstructures from inside inspection, the real report for range of visualand outside and to study strength and quality of a inspection & ND testspresent status of different concrete structure need - For Interpretation of NDstructural members to be checked with non- test results- Study of Architectural / destructive tests. - For Diagnosis & Root causeRCC / Structural drawings ( - A number of non- analysis of the problems /If available ) destructive tests (NDT) observations- Photographic Survey for concrete members are - For preparation of Repair available to determine & Rehabilitation scheme- Capturing multiple details present strength and quality to make structure durable,including: of concrete healthy and to stand for a1. Load transfer system, - To Conduct Non- long life2. Structural framing Destructive tests as required - For preparation of technicalsystem, in detail visual inspection specifications & draft tender3. Structural deficiencies, document for repair and4. Settlement if any, rehabilitation5. Cracks in RCC members, - For preparation of cost6. Cracks in masonry / estimates for the sameplaster - For scrutinizing the tender7. Leakages, documents8. Loads on structure, - For periodic inspection of9. Defects in non-structural workelements etc. - For issuing Structural Stability Certification after- Identification of broad completion of entire jobareas / locations in thestructure requiring furtherdetail investigation and forconducting various Non-Destructive Tests54

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TCR Company Profile2 Soil Testing ServicesSoil is formed by the combination of rock, TESTS CONDUCTED:organic matter and pieces of minerals, air, and CR Engineering provideswater. It is considered to be the skin of the earth’s world class services for soilcrust. The quality of soil varies depending on its testing in the laboratory ascomposition, strength, and type. Poor quality well as on site. Some of theof the soil is one of the critical issues faced by tests conducted routinely are:builders. Before starting any construction onland, it should be ascertained that the land is CBR In situsuitable for the planned infrastructure and the CBR Laboratory, Soaked Singlesoil can bear the load of the proposed building, Pointroads, etc. Problems and errors can be greatly Chloride Contentavoided by conducting a study on soil and site Electrical Resistivitycharacteristics. Linear Shrinkage Modified Procter CompactionThe quality of the soil is judged by analyzing those Testproperties which limit a planned use. Various soil Organic Matter Contentand site factors need to be determined in order Particle Size Distribution byto check the limitations before constructing a Hygrometer, Sieve Analysisbuilding or a structure. Some of these include: and HygrometerSurface texture, Permeability, Water table,Erosion hazard and Depth of soil and bedrock

ENGINEERING3 Concrete Testing ServicesConcrete is a construction material that is TESTS CONDUCTED:composed of cement (commonly Portland TCR Engineering provides a widecement) as well as other cementitious materials range of concrete testing servicessuch as fly ash and slag cement aggregate that are conducted both, in the(generally a coarse aggregate that has gravel, lab and on site. Some of the testslimestone, or granite, plus a fine aggregate include:such as sand), water, and chemical admixtures.There are various methodologies for concrete Chloride Content, Permeabilitytesting to ensure that it maintains adequate and Pondingstrength and durability. If major repairs are Core Compressive Strengthto be executed in the concrete structure, it is Coring: 10cm and 15cm diameteroften useful to check the bond strength of the Cube Compressive Strengthmaterial used in the concrete structure. Depth of Carbonation Drying Shrinkage/ wettingMechanical and physical testing is performed Expansionon hardened concrete to determine values Flexural Strengthsuch as electrical conductance, the compressive Hammer Soundingstrength of a concrete core, cube or cylinder Porosityand classify its durability. Mixing design trials Rebound Hammer Surveyare also carried out to ensure the concrete will Sulphate Contentexhibit values that are within the normal ranges. Ultrasonic Survey Water Absorption and penetration

TCR Company Profile4 Concrete Mix DesignConcrete Mix Design is a method of selecting suitable TESTS CONDUCTEDingredients for concrete and analyzing their relative TCR Engineering offersquantities for the production of concrete. The produced a range of concrete mixconcrete should be made aseconomically as possible design testing services thatwith minimum properties, significant workability, are conducted both in thedurability, and strength. An accurate determination of laboratory as well as onmix proportions by using computer data is usually not site. Some of the routinepossible as the materials used are essentially variable tests are:and their properties are not assessable quantitatively. Abrasion resistanceConcrete Mix is an extremely flexible building material Abrasion valuewhich can be exclusively designed for strength and it Accelerated cube strengthmay range from M10 to M100. A mix selection needs Air content & alkali contentappropriate knowledge of concrete properties as well Bleeding testas experimental data especially for the person who is Block densityconducting the mix design. The objective of preparing Bridge load testa design mix is to achieve good quality concrete in Compressive strengththe most economical way. Good quality concrete is Core cuttingdense, homogeneous and imparts better strength and Permeability testdurability. dense and homogeneous concrete Rapid Chloride Penetration Test (RCPT) 5 Bitumen Testing Services TESTS CONDUCTED A range of bitumen testingBitumen is a mixture of organic liquids that are highly services is available both on-viscous, black, sticky, entirely soluble in carbon disulfide, site and in the laboratory atand composed primarily of highly condensed polycyclic TCR Engineering Services.aromatic hydrocarbons. It is principally obtained as a Some of the tests TCRresidual product in petroleum refineries after higher routinely conducts are:tractions like gas, petrol, kerosene and diesel, etc., areremoved generally by distillation from suitable crude Bitumen Contentoil. Bitumen Penetration Flash PointIndian standard institutions define Bitumen as a black Specific Gravityor dark brown non­-crystalline soil or viscous material Softening Pointhaving adhesive properties derived from petroleum Paraffin Waxcrude either by natural or by refinery processes Loss on Heating Water Content58 Ductility Test Bitumen Emulsion

ENGINEERING6 Tiles Testing ServicesTiles are the construction materials or the Tiles TESTS CONDUCTEDare manufactured pieces of materials like stone, TCR tests tiles on many parametersceramics, glass or metals and are considered and some of them include:construction materials. Their major applicationis for usage in floors, roofs, walls, tabletops and Dimensionother similar objects. Tiles are categorized on Flexural strengththe basis of the applied manufacturing process Surface qualityand are classified as per their water absorption Breaking strengthlevel. Abrasion resistance Compressive strengthTCR Engineering is proficient in evaluating the Impact resistanceperformance of glass tiles, acid resistant tiles, Thermal expansionceramic tiles, stones, marbles, slates, limestone Chemical resistancealong with their their respective installations. Bulk densityTCR provides testing facilities for all types of Staining resistance materialstiles as per various National and InternationalStandards. Standards.7 Ceramic Testing ServicesCeramic materials possess a combination TESTS CONDUCTEDof properties which make them unique and Ceramic material testing done atsuitable for high-performance applications. TCR Engineering includes:Most ceramic materials are metallic oxides likezirconium oxide and aluminum oxide. Metallic Refractories & Allied materialscarbides are one of the most important classes White wares which includes tableof ceramics. wares, tiles, cook wares and sanitary wareTCR Engineering offers a complete range of Structural including bricks, pipestesting services for all the construction materials and tilesincluding the raw materials and final products as Engineering ceramicswell as quality control services according to theNational & International Standards. 59

TCR Company Profile 8 Brick Testing ServicesBricks are categorized as the TESTS CONDUCTEDbuilding blocks of any structural To analyze the quality of bricks, TCRbuilding. Thus, the quality of each performs several tests that include:and every brick has to be top notchto avoid any serious damage to the Apparent Porosity and Densitybuilding. A brick is a single unit made Cold Crushing Strengthfrom clay bearing soil, lime, and Permanent Linear Change (PLC)sand or it may also be made up of Abrasion Resistanceconcrete material. Bricks are named Creep Testdepending uponBricks are named Refractoriness under load (RUL)depending upon their composition Modulus of Rapturesuch as Burnt clay bricks, Concrete Compressive Testbricks, Sand lime bricks, Fly ash, Clay Water Absorption Testbricks and Fire clay brick 9 Cement Testing ServicesCement testing is performed to TESTS CONDUCTEDdetermine if there is alteration/loss TCR Engineering offers testing servicesof material when in its solid state. for cement inclusive of:Methods of testing include subjectingit to a high temperature to determine Chemical analysis Loss On Ignitionloss of material, compressive Compressive strength Physical Analysisstrength, hand fineness among other Fineness Setting Timefactors to ensure that they meet the Heat of Hydration Soundnessrelevant international standards.10 ToR Steel Testing ServicesTOR steel is one of the best grades TESTS CONDUCTEDof steel that is used in reinforced TCR Engineering provides world classconcrete and is a high adherence services for ToR Steel testing in lab as wellsteel. Other types of steel are used as on site. Some of the routine tests are:for less resistant concrete. Thermo­mechanically Treated (TMT) bars are Bend Test Ultimate Tensile Strengtha type of corrosion resistant steel Chemical Analysis 0.2% Proof / Yield stressreinforcing bar used in concrete Elongation Mass per meter runconstruction. Rebend TestSoundness60

ENGINEERING11 Mortar Testing ServicesMortar is a mixture of lime or cement or a TESTS CONDUCTEDcombination of both with water and sand. It is Few of the routine tests conducteda paste used to bind together building blocks at TCR Engineering for mortarlike stones, bricks, etc. It fills the irregular gaps testing include:between the blocks and seals them completely.Mortar is also used to add patterns or colors in In­Situ Metallographythe masonry walls. Cement mortar is composed Reduced wastageof sand and aggregates of water and is used as Accurate content of cementa building compound. Water is used to hydrate Consistent strength and qualitythe cement and hold the mixture together. It also Enhanced health and safety onfinds application in creating smooth surfaces on sitewalls made up of bricks and another masonry. Reduced mixing and labour costsM​ ortar when mixed is a much thicker substancethan concrete and this makes it ideal to act asglue for building materials. It hardens into astone­like mass and distributes the load evenlyover the bonding surfaces providing tight joints.Advantage TCROur in-house structural audit teams have carried out several evaluation engagements.The TCR advantage includes:Decades of Experience: Registered Service Provider: with a full-fledged set upTTCR Engineering has Registered and certified to undertake all types ofexpertise built over two by various municipal structural audit activitiesdecades and has partnered corporations, TCR has been Cost Estimates: Withwith several developers providing services across TCR’s expertise, structuralto undertake testing, Government and private irregularities are identifiedinspection and auditing sectors with ease and this mitigatesservices In-house Capability: TCR is a the cost impact resulting knowledgeable and customer from the deterioration of the oriented service provider building. 61

ENGINEERING

TCR Company ProfileII. NON-DESTRUCTIVE TESTING SERVICESNDT Testing is an essential requirement for all the industrialverticals ranging from manufacturing, automobiles, oil and gas,refining to the power industry, etc. In addition to conventionalNDT Testing services, TCR Engineering provides advanced NDTTesting services like TOFD/PAUT, Videoscopy, Eddy currenttesting, Helium leak testing, Acoustic eye for tube inspection,UCI hardness testing and in-situ metallography.Core Service Offerings high temperature inspectionCONVENTIONAL NDTIn-Situ Metallography Boiler InspectionPositive Material Identification (PMI) Electro-Magnetic AcousticUltrasonic Inspection Transmission (EMAT)Leak Testing Automated Reformer Tube InspectionLiquid Penetrant Examination System (ARTIS)Magnetic Particle Testing Internal Oxide Scale BoilerDye Penetrant MeasurementPaint and Coating ThicknessCertified Weld Inspectors Pipelines and WeldVisual Inspection Services InspectionPortable Hardness ToFD and Phased ArrayRadiography Inspection Long Range Guided Wave Ultrasonic Testing (LRGWUT)ADVANCED NDT Testing Post Weld Heat TreatmentThermographyAlternating Current Field Measurement Storage Tanks and StaticASNT Level III consultancy in India Equippment Inspection Helium Leak TestingTube Inspection Robotic Inspection Of TanksEddy Current TestingAcoustic Eye 63

TCR Company ProfileA. Conventional NDT Services i. In-Situ Metallography ii. Positive Material Identification (PMI) iii. Ultrasonic Inspection iv. Leak Testing v. Liquid Penetrant Examination vi. Magnetic Particle Testing vii. Dye Penetrant viii. Paint and Coating Thickness ix. Certified Weld Inspectors x. Visual Inspection Services xi. Portable Hardness xii. Radiography Inspection64

ENGINEERINGi. In-Situ MetallographyTCR Engineering under the NDT service performs In-Situ Metallography to determine in-service degradation of critical components of process and plants operating under hightemperature, high-pressure and corrosive atmospheres. The technique enables real-timecomponent condition monitoring and health assessments. TCR’s metallurgists have strongexperience in the interpretation of microstructures and have more than 15,000 replicamicrostructure interpretations, logged and captured in its proprietary database. Thesedatabases contain extensive information from various plants, captured over the course offour decades of service. The database also includes rare collections of varying microstructuredamage levels from various industries such as power, oil and gas, petrochemical, fertilizersamong others.The In-Situ Metallography team at TCR is highly skilled in the art of replica preparation. TCRhas custom-developed special purpose in-situ polishing devices that assist in metallographicpolishing under difficult locations and allows the field services team to carry out high-qualityreplication even on warm components. The In-Situ metallography is performed for thefollowing areas:- To undertake microstructure - To check the quality of the corrosive atmospheresurvey for critical components microstructure of components - To conduct damageviz., Boilers, Pipelines, for intended service, before Assessment of fire-affectedReactors and Vessels for putting it into use equipment of the plantscondition monitoring/health - To find out in-service - To develop a databank ofassessment degradation of critical critical components of process- To provide suggestions components of the process plant equipment by periodicalabout their welding used plants operating under high monitoring for preventivecomponents of process plants temperature/high pressure/ maintenance and planning for inventory controlTCR also provides microstructure survey for critical components viz., Boilers, Pipelines,Reactors and Vessels for monitoring and health assessments. TCR has developed a databankof critical components of process plant equipment by periodical monitoring for preventivemaintenance and planning for inventory control. With this, TCR can provide suggestions onrepair and welding of used components of process plants.In-situ Metallography and replication is used for microstructural analysis while examininglarge components that cannot be easily moved or destructive sample preparation is difficultor not permissible. The testing allows quick on-site evaluation of a component’s metallurgicaland heat treatment condition and assists investigators while carrying out a remaining lifeassessment study or a failure analysis project. 65

TCR Company ProfileCore capabilities for MetallurgicalReplica InterpretationTCR Engineering Services, India adheres to the guidelines EQUIPMENTSpresented in ASTM E 1351 (Standard Practice for Production At TCR, the 5and Evaluation of Field Metallographic Replicas). Replicas following sets of In-for TCR team analysis are developed with or without gold Situ Metallographysputtering. Using the replication methods, experts at TCR can kits and equipment areverify microstructures of a given component. available: - Insipol 2000 andAt material testing laboratories in Mumbai and Baroda, India, advanced electrolyticTCR has a state-of-the-art Inverted Metallurgical Microscope, flow type polisher andGX51, from Olympus Corporation, Japan. This Inverted etcherMetallurgical Microscope allows expert metallurgists at TCR to Portable rough grinderperform Volume Fraction Measurement by point count method with self-adhesiveas per E-562 used for Duplex Steel and Carbide Morphology papersDistribution as per STAHL-EISEN-PRUFBLATT 1520 (SEP-1520) - Portable fine polishingGerman chart for checking microstructure. (mini grinder) - Portable microscopeTCR Engineering Services has undertaken In-situ Metallography capable up to 400Xprojects at major plants of reputed clients including, Alstom magnificationProjects India Limited, Vadodara (Worked on more than 20 - Replica kit: Used withRLA projects), BARC (Mumbai), Heavy Water Board (Mumbai), specialized plasticBARC, Reliance Industries Limited (Jamnagar and Hazira), based slides for replicaSPIC-SMO, Gujarat Electricity Board, Ahmedabad Electricity preservation (for longerBoard, GSFC Limited, GNFC Limited, IOCL (Vadodara), L & durability and ease ofT, Hindustan Lever Limited (9 Boiler RLA Work), Narmada handling on site)Chematur Petrochemicals Limited, Bharuch and many more.TCR performs Metallurgical Replica Interpretation for NDTCorrosion Control Services (NDT-CCS) in Saudi Arabia as well.KEY INFORMATION FOR REPLICATION INTERPRETATION- Objective of In-situ Metallography - Condition assessment,fire/damage assessment, remaining life assessment, orbaseline data generation- Material of construction with exact specification- Location of replication with sketch- Process parameters and design parameters- Service life of the component at the time of replication- Any history of previous failures at the location of replication66

ENGINEERING

ENGINEERINGii. Positive Material Identification (PMI)The PMI division at TCR Engineering Services The team also conducts positive materialhas an expert engineering and inspection identification test to detect Carbonworkforce to undertake incoming material composition on-site using the ARCinspection and can provide on-site alloy Met 8000, a portable optical emissionverification for quality control and stock spectrometer. The portable opticalcontrol purposes. TCR can analyze both melt emission analyzer is designed to identifyand weld for comprehensive maintenance all the key elements in metals, especiallyassessment. where highest accuracy, analysis of light elements (like C, Al, S, P, Mg, Si) or sortingTCR provides PMI services to a number of of low alloys and aluminum is needed. Formetal producers, foundries, metal fabricators, example, it is ideal for separation of 316scrap yards, scrap traders in the industry, H (>0.04% C) and 316 L (<0.03% C).electric utility companies, fossil and nuclearpower plants, refining and petrochemical Using portable XRF analyzers, TCR offersindustry, construction engineering, and the scrap traders in India all the necessary dataChemical process industry. needed to take fast, informed decisions about material purchases along with theThe range of equipment available at TCR for input and speed required to sort largeundertaking Positive Material Identification quantities of materials, and hence utilize(PMI) is unparalleled in India. TCR’s on- sales opportunities efficiently. Inspectionsite inspection and the testing team have services team of TCR supports the recycleover 12 highly sophisticated Portable Alloy and resell scrap traders in enhancing theirAnalyzer Spectrometers which can in-situ profit margins by measuring preciousnon-destructively and accurately measure the metals in electronics - Pt, Ir, Ru, Rh, Pd. TCRchemical composition of materials. Using these also supports a scrap trader to performspectrometers, TCR’s engineers can provide scrap classification service efficiently.elemental identification and quantitative From titanium alloys to stainless steels todetermination regardless of form, size, and nickel superalloys to red metals to exotics,shape. . No samples need to be cut for PMI. TCR can quickly provide fast, reliableTCR can also deploy the portable optical results that the industry demands.emission spectrometer that can detect C, S,P, Mn and Si. Elements that can be identifiedusing PMI include Ti, V, Cr, Mn, Co, Fe, Cu, Zn,Ni, Se, Nb, and Mo.TCR’s Positive Material Identification service is fast becoming an integral part of the safetymanagement process in petroleum refining, petrochemical, and electric power generationindustries. TCR has provided PMI services to over 700 projects including major oil andpetrochemical installations in India, Hong Kong, China, Singapore, Malaysia, Indonesia,Russia, Dubai, Kuwait, Saudi Arabia and other parts of Middle East in addition to servingNorth America and significant parts of Europe. Some PMI projects were undertaken inconjunction with the third-party inspection of EIL, Lloyds, KTI, TUV, DNV & BARC.68

EQUIPMENTSA wide range of alloys can beanalyzed on site using PMIincluding:1. Carbon and low alloy steels2. Copper Alloys3. Stainless and High Alloy Steels4. Aluminium Alloys5. Nickel Alloys6. AusteniticsDuplex and Super7. Titanium Alloys8. Zirconium AlloysTCR Engineering’s PMIequipment includesPortable X-Ray Florescence(XRF) based Instruments:1. XMet 3000TX (2 Nos.) fromMetorex, Finland2. Niton XLt (2 Nos.) from NitonCorporation, Finland3. XMet 53000TX and 3000Tfrom Metorex, Finland4. Innov-X Alpha Analyzer fromInnov-X Systems, Netherlands5. Metal Master 2000 (3 Nos.)from Metorex, FinlandPortable Optical EmissionSpectrometer (OES) Instrument:1. ARC-MET 8000 MobileLab

TCR Company Profileiii. Ultrasonic InspectionUltrasonic methods of NDT employs the Ultrasonic examinations areuse of beams of sound waves (vibrations) of performed for the detectionshort wavelength and high frequency that is and sizing of internal defects,transmitted from a probe and detected by the flaws or discontinuities in piping,same or other probes. Usually, pulsed beams castings, forgings, weldments orof ultrasound are used and in the simplest other components. Exact sizinginstruments a single, handheld probe is placed techniques have been developedon the specimen surface. to detect and monitor progressive cracking in a variety of equipment.An oscilloscope display with a time base showsthe time it takes for an ultrasonic pulse to travel TCR has in-house capabilityto a reflector (a flaw, the back surface or other to undertake Automated UTfree surfaces) in terms of distance traveled using Time of Flight Diffractionacross the oscilloscope screen. The height of the technique (ToFD) in India as perreflected pulse is related to the flaw size as seen code case 181 for piping, codefrom the transmitter probe. The relationship of case 2235 for pressure vessels andflaw size, distance and reflectivity are complex, API 650 appendix U for storageand a considerable skill is required to interpret tanks.the display.At TCR, complex multi-probe systems are alsoused with mechanical probe movement anddigitization of signals, followed by computerinterpretation.iv. Leak TestingHelium Leak testing in India is performed to detect and locate leaks in pressurecontainment parts and structures. This includes welded, brazed, adhesion-bondedand other assembliesv. Liquid Penetrant ExaminationVarious liquid penetrant examination methods are utilized to detect open or surfacecracks or defects in materials. Red dye or fluorescent penetrants, as well as varioustypes of wet and dry developers, are utilized under this method of examination byTCR70

ENGINEERINGvi. Magnetic Particle TestingThe Magnetic Particle Inspection method of Ultrasonic examinations areNon-Destructive testing is a used by TCR for performed for the detectionlocating surface and subsurface discontinuities and sizing of internal defects,in ferromagnetic material. Depending on its flaws or discontinuities in piping,operation on the face when the material or castings, forgings, weldments orpart under test is magnetized, discontinuities other components. Exact sizingthat lie in a direction generally transverse to techniques have been developedthe direction of the magnetic field. This causes to detect and monitor progressivea leakage field, and therefore, the presence cracking in a variety of equipment.of the discontinuity is detected by using finelydivided ferromagnetic particles applied over the TCR has in-house capabilitysurface, some of these particles being gathered to undertake Automated UTand held by the leakage field. This magnetically using Time of Flight Diffractionheld collection of particles forms an outline of technique (ToFD) in India as perthe discontinuity and indicates its location, size, code case 181 for piping, codeshape and extent. case 2235 for pressure vessels and API 650 appendix U for storage tanks.vii. Dye PenetrantWith the dye penetrant method, a penetrating TCR can detect cracks as narrowliquid is applied to the surface of the component as 150 nanometers using thisin order to enter the discontinuity or crack. method.Subsequently, after clearing the excess penetrantfrom the surface, the penetrant that exudes oris drawn back out of the crack is observed.Liquid penetrant testing is applied to anynon-porous clean material, metallic or non-metallic, but is unsuitable for dirty or very roughsurfaces. Penetrants can contain a dye to makethe indication visible under white light, or afluorescent material that fluoresces under thesuitable ultra-violet light. Fluorescent penetrantsare usually used when maximum flaw sensitivityis required. 71

TCR Company Profileviii. Paint and Coating ThicknessTCR undertakes inspection of paint and/or TCR’s expert inspectors arecoating, applied to metal surfaces. The paint responsible for the preparationand coating inspection team at TCR is fully of precise, yet comprehensiveequipped and has at its disposal, Wet paint records that include all criticalthickness gauge(s), Dry paint film thickness aspects of:gauge(s), Holiday detector(s), Hygrometerwith Dew Point calculator and Metal surface - Materials control andthermometer. identification - Climatic conditions and SurfaceThe expert paint and coating inspectors conditionat TCR are responsible for monitoring - Details of abrasive(s) andand verifying to ensure that all the work application procedureinspected comprehensively conforms with the - Abrasive/wire brush standardrequirements of the relevant code, specification - Details of coating andand/or standard with respect to the paint/ application procedurecoating procedure, the physical application - Equipment calibrationas well as the physical examination, including - Inspection resultstesting.Senior TCR paint inspectors are qualified BGas(British Gas Corporation) and are NACE certified.The inspectors are responsible for verifying thefollowing requirements:1. The blasting and coating materials ​2. The blasting and coating equipment3. The temperature and humidity4. The surface condition5. The application procedure(s)ix. Certified Weld InspectorsTCR’s team of Certified Welding Inspectors in India (CWI) can pinpoint exactly whichtesting is necessary to qualify a weld, weld procedure, or individual welders. Eachwelding code follows three main categories of Welding Qualification viz. WeldingProcedure Specification (WPS), Welding Procedure Qualification Record (WPQR), andWelder Performance Qualification (WPQ)72

ENGINEERINGx. Visual Inspection ServicesAt TCR, non-destructive visual inspections are performed on-site or at the laboratoryfacility based on the requirements of the client and as per their specifications. Industriesutilizing this service include Fabrication, Construction, Automotive, Power Generationand Transportation. Inspections can be performed at the laboratory facility or onsite.These inspections are performed to meet IS, BS, ASTM, AWS, ASME (American Societyfor Mechanical Engineers) and many other standardsxi. Portable HardnesAs per ASTM E110, the testing is done by TCR for on-site applications as well as forvery large samples. TCR’s portable hardness unit performs the hardness testing byapplying a 5 kg vickers load indenter and electronically converting the values to apreferred scalexii. Radiography InspectionPHYSICAL: TCR’s state-of-the-art laser alignment devices, microprocessor controlledx-ray machines and automatic film processors, ensure high quality, rapid speed, andhence offer the most efficient radiographic services in the industry.DIGITAL USING COMPUTER AIDED RADIOGRAPHIC TESTING (CART): TCR with itscomputer-aided generation of radiographic images, uses linear array detector systemsin place of traditional film. The CART Industrial Inspection System works on the basisof differential densities. When a product passes through the conveyor system, a greyscale X-Ray image of the product is created. Different densities/thicknesses show upin the image as shades of grey. The image is captured from the data and displayedthrough the control panel monitors. It offers several Image enhancement controlsincluding zoom, contrast, brightness, etc. Advanced Software Algorithms clearly andaccurately highlights discontinuities in the image in order to qualify samples as perstandards. 73

TCR Company ProfileB. Advanced NDT Services74

ENGINEERINGi. ThermographyTCR uses these tests to find temperature anomalies present in the equipment during theirTCR uses thermography tests to find temperature anomalies present in the equipmentduring their operation. This is based on remote viewing and is a non-contact method oftesting. As a recent addition to the NDE, helicopters may be used for testing in largeregions. Any hot object that emits heat radiation is captured with an infrared sensor, whichpicks up the radiation to form the image of the hot body. The hot and cold regions on thesurface can be analyzed for the healthy condition of the object. Thermography is useful inapplications such as deposits or blockages in pipelines carrying hot or cold fluids, refractoryor insulation deterioration in furnaces, boilers, heaters, converters etc. It is also utilized withElectric sub-stations for control panels, transformers, switchgear etc. for overloading, looseor damaged contacts, Overheated bearings in rotary equipment, e.g. motors, generators,turbines, etc.ii. Alternating Current Field MeasurementAlternating Current Field Measurement, also known as ACFM is a one-pass method toinspect welds and to locate and size surface breaking cracks. An electromagnetic fieldis induced into the surface being inspected. When the probe is passed over a surfacebreaking crack, the electromagnetic field is disturbed allowing detection of the anomaly.This field is measured using the proprietary software which allows crack depth and lengthmeasurements on a real-time basis. Probes of almost any configuration can be customizedfor nearly any application imaginable.Digital Crack detection method covers:- Sizes Cracks (Length & - No Recoating required Conventional methodsDepth) Applications - No Metal Contact required - High-Temperature- Detects through Coatings, - More Precise than ApplicationsPaint & ScaleTCR performs ACFM in association with its international partner. This technique replacesconventional dye penetrants, magnetic particle testing and ultrasonic testing for sizedefects. Applications of ACFM includes:- Structural Welds on Platforms - Cooling Tower Welds- Structural Welds on Drilling Rigs - Compressor Fin Surfaces and Threads- Pipeline Girth Welds and Supports - Drill Collar Threads- Pressure Vessel System Welds 75

TCR Company Profileiii. ASNT Level III consultancy in IndiaThe American Society for Non-destructive Testing, Inc. (ASNT) TCR’s strengths inis the world’s largest technical society for nondestructive metallurgy combinedtesting (NDT) professionals. ASNT inaugurated its NDT with advanced NDTLevel III program in 1976 with certification offerings in five services is helping globalNDT methods. Over the years, ASNT has certified over 5,000 companies like Shell,individuals from more than 50 countries as ASNT NDT Level Reliance, Saudi Aramco,IIIs and has expanded the certification program to include IOC and BPCL to achieve11 NDT methods. ASNT is the single largest certifying body an increase in plantof Level III personnel today and the ASNT NDT Level III availability resulting incertificate remains the most respected and widely accepted cost saving, minimizingNDT certification globally. shutdown time, change in inspectionTCR Engineering has a strong advanced NDT inspection strategies and intervalsteam that currently maintain ASNT level 3 certifications in and improved safetyEddy Current (ET), Ultrasonic Testing (UT), Magnetic Particle compliance. The TCRTesting (MT), Infrared Thermography (IR), Mass Spectroscopy team is well versed inLeak Testing (MSLT), Radiography (RT), Liquid Penetrant reliable assessment andTesting (PT), Visual and Dimensional Evaluation (VT) methods. calculation of risk profileIn addition to this, the team has the capability to undertake of items in a plant basedprojects on Automated Ultrasonic using the Time of Flight on its “active” andDiffraction technique (ToFD). TCR experts are also certified “potential” Damagein AWS/CSWIP 3.1 and 3.2 CSWIP Painting inspection. Mechanisms ensuring that the resultingAll of TCR’s ASNT Level III certificate holders have the skills inspection interval forand knowledge to establish techniques, to interpret codes, the item is reliablystandards, and specifications, and to prepare or approve optimized in a safe andprocedures/instructions. cost-effective manner.All TCR’s NDT inspectors are qualified to meet therequirements of the American Society for NondestructiveTesting Practice SNT-TC-1A as well as CP-189 guidelines.Each non-destructive examination is performed to therequirements of major Codes, including the ASME Boilerand Pressure Vessel Codes, the ASME/ANSI Codes forPressure Piping, the American Petroleum Institute Codes,American Welding Society Standards and Aviation/Militaryspecifications.76

ENGINEERINGC. TUBE INSPECTION 1 Eddy Current TestingEddy current testing is a rapid and accurate technique used to detect discontinuities inthe tubing, heat exchangers, condensers, wires, plates, etc. TCR uses electromagneticinduction to detect flaws in conductive materials. Eddy current testing can detect verysmall cracks in or near the surface of the material. The surfaces need minimal preparation,and physically complex geometries can be investigated using this method. Eddy currenttesting is also performed for alloy separation, for the determination of treatmentconditions, for making electrical conductivity and for measuring coating thickness. Thelocation of repair welds, girth welds, and seam welds may also be detected on ground-machined surfaces.TCR has an in-house team of Eddy Current Testing professionals with deep expertise ininspecting a number of tubing in heat exchangers. TCR’s testing devices are portable,contact-less and provide immediate feedback. 2 Acoustic EyeAcoustic Eye’s breakthrough, non-invasive solution for today’s hard-to-inspect tubesenables ultra-fast and accurate inspection of boilers, Fin Fans and other heat exchangers,regardless of tube shape or material (up to 4” inner diameter).Featuring patented Acoustic Pulse Reflectometry (APR) technology, Dolphin G3™ isan advanced, yet easy-to-use tool that overcomes the limitations of many conventionalinspection techniques. With its simple operation, automated analysis and reportgeneration, there is far less dependency on operator expertise. By providing reliableinspection of even the most challenging tube sizes and configurations, TCR with AcousticEye increases inspection cycle efficiency and provides operational cost savings 77

TCR Company ProfileD. high temperature inspectionHigh-temperature hydrogen attack (HTHA) is observed in steels exposed to a temperatureof 200 °C or more. At such high temperature, atomic hydrogen diffuses in steel. Thishydrogen reacts with carbon present in the steel and forms CH4. The methane so formedbubbles and forms voids at the grain boundary.MC + 4H = M + CH4These bubbles exert pressure and also coalesce resulting into fissures. The growth of voidsand fissures weakens the metal, leading to a major crack. This reaction decarburizes thesteel, produces micro cracks/fissures and lowers toughness of steel but not necessarilycause a loss in thickness.​Advantages Limitations- Supports in inspection of large and wide - Deep expertise required in interpretationareas - Very initial micro level degradation- Convenience with accessibility as only (decarburization) cannot be estimatedone side external access is required(opening of equipment or removal ofcatalyst is not required)- Depth of attack can be estimatedHTHA relies on detecting the scattering ofultrasound energyThe technique detects the presence of fissures The procedure for testingon the internal side of the low-alloy steel metal is based on API 941 usingsurface exposed to hydrogen at high temperature different approaches like:by scanning from the outside surface. - Attenuation measurement - Velocity measurementThe extent of damage by HTHA can be - Spectral analysisassessed using the above techniques as well as - Analyzing scattered signalsother internal techniques such as WFMPI (Wet - Testing weld joints and HAZfluorescent magnetic particle inspection), in-situ using high-frequency shearmetallography and hardness testing. Testing from wave ultrasoundboth sides overcomes the limitations encountered - Advanced ultrasonic testingwhile testing only from outside. like Phased array and TOFD78

ENGINEERINGE. Boiler Inspection 79

TCR Company Profilei. Electro-Magnetic Acoustic TransmissionUsing EMAT technique with panametric probes, TCR can measure the high-temperature (up to 325° C) surface thickness. Above this temperature, the thicknessreadings become unstable, unreliable and non-repeatable.The surface for thickness measurement needs to be fairly smooth, free from rust, scaleor any other kind of deposits. To get a clean surface for thickness survey, a metallicfile, wire brush, small chisel and emery paper can be used for cleaning. Hammering isstrictly not advisable for removal of scale/deposits. In case the above method doesnot yield the desired cleaning, then mechanical cleaning by power brush should beused. Under exceptional circumstances, grinding is used as a method for cleaning,with prior permission from the inspection engineer.Thickness can be measured on painted surfaces, provided the surface paint is visiblewithout any blisters. For critical measurement where the corrosion rate calculationsare important from the remaining life point of view, paint removal is done beforedoing thickness survey.Thickness measurement across differentmediums 1 PIPING a grid of size 1.5” x 1.5”, with each For all on-site piping, corrosion loops component marked with chalk before80 are the basis for carrying out thickness thickness scanning survey whereas, for offsite and tank 4. Out of all the locations, few TMLs farm piping, special loops are made are identified for regular scanning. for thickness monitoring: The selected TMLs are identified by 1. Each corrosion loop (for on-site the inspection engineer, based on piping) have a combined isometric the probability of corrosion at these where Thickness Management locations (as compared to other Locations (TML) are serially marked locations in the loop) and accessibility 2. If any base readings are taken considerations. before commissioning, it is done 5. Respective maintenance with random values measured on the departments provide access to components ladders, scaffolding or portable 3. Routine, on stream or shutdown trolleys for thickness scanning. In thickness measurement at these case corrosion is observed in these locations, is done in the form of a TMLs, then other TMLs in the loop scanning. The scanning format is in are included for thickness scanning

ENGINEERING23Hot Tap Locations THICKNESS LOCATION IN TANKSIn case of thickness survey of equipment - In case of storage tanks, the thickness isand piping for hot tap locations, following measured from outside first, followed bysteps are undertaken: shell course from the bottom- The maintenance team marks the locationof the new nozzle as per the exact type and - In all the other shell courses, the thicknessdimensions of the component to be welded is measured along the staircases. Fewon the parent pipe thickness points are taken near the weld- The Inspection engineer verifies the type and few at the center of the shell courseof component to be welded viz. weldolet, platepipe of pipe connection, a nozzle withreinforcement pad, split sleeve nozzle - In case of roof plates, the thickness isetc. The Inspection engineer marks the measured on each plate, with two thicknesscenterline of the proposed weld joint: A points at the center of each plate and onewidth of 1.5” to 2” shall be marked on either thickness point at the corner of each plateside of the proposed weld centerline. Aclose thickness survey is undertaken along - In case of bottom plates, thicknessthe centerline and on either side and the measurement is possible only duringminimum thickness measured is reported in an internal inspection. Under this, thethe hot tap file. thickness is measured on each plate, with two thickness points at the center of eachIf the thickness measurement is comparable plate and one thickness point at the cornerto nominal or previously measured values of each plate.(if available at the same locations or atdifferent locations in the same pipe), then itcould be assumed that there is no corrosionat the location.If the thickness measurement indicatessevere corrosion, and thickness measuredis very close to the minimum allowable forhot tapping, then hot tapping should beavoided at the location, as it will be difficultto pick up a thickness point with minimumthickness through this procedure.Minimum thickness required for hot tappingis 4.8mm. If the pipe is corroded and actualthickness is in the range of 6 – 8mm, thenalternate methods should be used to checkthe pipe thickness and certify the same fitfor the hot tap. 81

TCR Company ProfileRecording of Thickness MeasuredThe thickness is measured and recorded by TCR in a standard format that includes thefollowing details:- Plant etc.- Tag Number of equipment/pipeline - Identification number of the standardor appropriate description (in case block used for calibration of the metertag number does not exist for the before starting the jobcomponent/job) - Nominal thickness of the component- Date of measurement being checked for thickness- Sl. No Meter used for thickness - Name of the technician measuringmeasurement the thickness- Details of the meter used forthickness measurement like frequencyIn case of piping where spot readings have been measured at Thickness ManagementLocations (TML), against each TML number, measured readings are filled in.In case of equipment, a development drawing of the equipment needs to be submittedshowing an approximate location of thickness measurements. The thickness may beentered on the sketch itself. Alternately the TMLs can be marked on the sketch and thecorresponding thickness values for each TML submitted separately.In case of close scanning of a location in equipment or a pipe, the readings can besubmitted as a grid. The grid will have the orientation (N/S/E/W) with possible referencefrom a nearby nozzle, weld etc. The grid identification at the site is required in order tocheck the thickness at the same location and compare the same for corrosion if any. Thegrid size shall be clearly mentioned in the sketch.

ENGINEERINGThickness Values More Than Previous ReadingsIt is also not unusual to record thickness values more than the previously measuredreadings at the same locations or in the same grid. This is done considering the inherentlimitations of the thickness measurement technique. Some of the factors that contributeto the increase in thickness could be:- Inability to put the probe exactly at the - Corroded surface profile on the insidesame location. Even If the probe is kept surface of the component, from whereonly a couple of millimeters away from the the sound waves are reflected backprevious location, there could be a different - Surface preparation prior to theand probably a higher reading thickness surveyThe inherent accuracy of the thickness meter is +/- 0.1mm. Hence a thickness value thatis 0.2–0.3mm more than the previously measured value is considered to be acceptable.A measured thickness value more than the above-mentioned limits needs to be re-checkedagain especially in a grid scanning exercise. Based on the repeat thickness survey, thereport can be verified and corrected if required. The following steps are undertaken forverification of the readings:1. Checking for instrument calibration using a step wedge and a standard block of thicknessclose to the thickness range being measured2. Checking of the thickness measured with another meter and probe at the same location3. Checking of the surface preparation before taking readings

TCR Company Profileii. Automated Reformer Tube InspectionSystem (ARTIS)TCR has indigenously developed an automated robotic crawler to aid ultrasonicinspection of reformer tubes. It provides a tabular and interactive digital output.The 1st point on every tube is referred at the bottom of the tube, climbing up to14 meters height and provides tube data at every 0.1-meter distance. The ARTiScan simultaneously collect tube data such as ultrasonic dB level of attenuation, thediameter of the tube and bowing angle at every location. An interactive, graphicaluser interface is part of the digital report along with a conventional hardcopyprinted in a tabular format.Few of the key advantages of using ARTiS:The method follows a similar technique attenuation and creep strainof manual ultrasound coupling makingit an industry-wide proven technique of It avoids the need for scaffolding, savesinspection total tube inspection time and helps to achieve reduction in shutdown time of theA macro-level view of the overall tube plantcondition in the reformer is also reported,emphasizing troublesome areas/corner of Automation deploys limited water sourcethe furnace if any for coupling and nearly eliminates the need for overhead water drum arrangement,The outcome of inspection work becomes which overcomes additional issues relatedmore systematic and traceable with point- to drum filling, vacuum water clogging,wise reading on each tube for ultrasound etc.84

ENGINEERINGiii. Internal Oxide Scale Boiler MeasurementThe very high temperatures found inside steam boilers (in excess of 1000 degree fahrenheitor 500 degree centigrade) can cause the formation of a brittle iron oxide called magnetite onthe inside and outside surfaces of steel boiler tubing.Steam side: Water vapor will react with the Iron in the steel to form magnetite and hydrogenaccording to the formula: 3 Fe + 4 H20 = Fe3O4 + 4 H2Fire Side: Flue gases react with the Iron in steel to form Magnetite and Sulfides (ExternalScale). Oxygen diffuses into the steel and Iron diffuses out of the steel to and combines toform magnetiteThe thickness of Oxide helps predict tube life as the internal oxide scale builds above.013“(0.33mm) it impedes the heat transfer between the tube metal and the steam. Transducers:- M2091 Normal Incident Shear 20 MHz (0.006” In. or 0.15 mm Min Internal Oxide): Measuresand displays Oxide and tube thickness at the same time. 85

TCR Company ProfileF. Pipelines and Weld Inspection 86

ENGINEERINGi. Time of Flight Diffraction (ToFD) andPhased ArrayTime-of-flight diffraction (ToFD) technique is an ultrasonic NDT technique, which relieson the diffraction of ultrasonic energies from ‘corners’ and ‘ends’ of internal structures(primarily defects) from the component being tested. Using TOFD, the expert NDT teammembers at TCR provides amplitude-independent accurate flaw sizing on a wide coveragearea. ToFD being an advanced and automated weld examination technique, it assists inFitness For Purpose (FFP) inspections as well.ToFD is a fast and effective method of scanning a wide weld area in a very limited timeperiod. While TOFD is a very powerful and efficient technique, it suffers from limitedcoverage resulting from two dead inspection zones:- The first dead zone: Near the surface, as a result of the lateral wave- The second dead zone: At the back-wall, resulting from the width of the back-wallreflection.By combining the use of TOFD and conventional pulse-echo methods, dead zones inproximity to the front and back surfaces can be improved substantially. TCR Engineeringoffers services of creating ToFD scan plans and procedures in India. This technique hasmany advantages including:Wide coverage area using a pair of Setup is independent of weld configurationtransducers Highly sensitive to all kinds of defects withAccurate flaw sizing; amplitude- no sensitivity to defect orientationindependent, Sizing technique usingtime-of-flight information Amplitude-insensitive, acoustical coupling less criticalOne-line volume inspection, provideshighly efficient scanning 87

TCR Company ProfileToFD is a quick and accurate toolfor flaw sizingPhased Array technology (using a TCG (Base Resource Document recommendsor DAC) and flaw location indicators automated ultrasonic shear wavewith experienced analysts is also testing as a highly effective inspectionrecommended. The team has done a technique for crack detection and sizing).number of noteworthy ToFD projects: The capability of the Automated UT technique/type is evaluated using the- 100% weld inspection of Storage Tanks probability of detection (POD curvesat Kuwait as per API 650 appendix U from round-robins in the past where- Random inspection of pipelines in ToFD showed the best performance)..Rabigh, Saudi Arabia as per ASME CodeCase 181 British Standards Institute’s welding- Pressure Vessel inspection in India as standards policy committee has createdper ASME Code Case 2235-9 BS 7706 as a guide for calibration and setting-up of the Ultrasonic Time ofASME Boiler and Pressure Vessel Flight Diffraction (ToFD) technique forStandard Section VIII Code Case 2235-9 defect detection, location and sizing ofstates that it is acceptable to use the ToFD flaws. Another well-documented guide isfor Ultrasonic examination in accordance the PrEN 583-6.with ASME Section V, Article 4. ASMECode Case 2235-9 mentions replacing RT TECHNOLOGY & EXPERTISEwith UT and has resulted in incorporating The team at TCR with its decades ofToFD into pressure vessel work for both experience have extensive clues to thedetection and sizing of flaws. This now characterization of various types of flawsallows ToFD to be used on all Section using TOFD with the exception of fewVIII pressure vessels. TOFD is perfectly instances where definitive conclusionsacceptable to use as per Code Case 181 are rare. In the case of Phased Arrayand Code Case 179 of ASME B 31.3 for technology, an experienced analyst haspiping products. a greater chance of determining flaw type based on the percentage of soundAPI 579 in its current draft form states transmitted back to the probe.the Recommended Practice for Fitness-for-Service (crack depth, length, angle TCR uses products from Olympus’sand distance to other surfaces) where OmniScan technology, which hasbreaking or embedded cracks are capabilities to indicate to the operatordetermined using UT examination the exact location of a flaw with respecttechniques, either ToFD or angle beam. to the weld centerline and bevel face. An experienced analyst from TCR is ableDraft-API 580 states the Risk Based to characterize fusion flaws based onInspection Recommended Practice location and amplitude response.88

ENGINEERINGii. Long Range Guided Wave UltrasonicTesting (LRGWUT)The Long Range Guided Wave Ultrasonic Technique (LRGUT) is designed to inspect 100%of a pipe segment from one single location.Torsional or longitudinal guided waves are induced into the pipe body and propagatedalong the entire pipe segment under inspection. When these guided waves identify ananomaly or a pipe feature, they convert into laminar waves and reflect back to the tools’original location. Using a laptop, these signals are digitally captured. The time-of-flight foreach signature is calculated to determine its distance from the tool. The cross-sectionalarea is calculated by amplitude followed by estimating the circumferential extent by thefocused beams (broken down into octants) to determine the significance of the defect.TCR performs LRGWUT in association with its international partner. This partner meetsand exceeds the PHMSA 18 points to examine casings and crossings. LRGWUT’s primaryapplication is in the Oil and Gas Refining, Petrochemical, Storage, Offshore and PipelineTransportation industries among others. More specifically, the tests are used as part ofECDA and ICDA methodologies where access to piping systems are difficult such as:- Insulated Pipe in Refineries - Tank Dyke Pipeline Crossings- Offshore Pipeline Risers - Above Ground or Buried Flow Lines- Cased Road or Railway Crossings - River or Bridge Pipeline Crossings- Loading Lines and associated Pipework 89

TCR Company Profileiii. Post Weld Heat Treatment (PWHT)TCR Engineering Services offers a Stress Relieving: For steel fabrication,diverse range of Heat Treatment Services the most common procedure used isincluding pre-heating, post-heating; Stress Relieving where machining and/stress relieving (SR), intermediate SR, or welding induces stress in parts. Thenormalizing, solution annealing, water bigger and more complex the part,quenching, tempering, step cooling higher is the amount of stress. Stressand drying of the refractory material. Relieving is done by uniformly heatingThe experienced technicians at TCR are the fabricated equipment, a vessel orcapable of performing heat treatment a part of the vessel to a sufficientlyon weld joints, piping, regenerators, high temperature, but below the lowerstripper columns, pressure vessels, transformation temperature range. It isboiler headers, modules, deck pipelines then subjected to a thermal retardationand structure, boiler heater tubes, for a sufficient time depending uponand DOTHERM testing. The team is the material thickness and then finallyalso capable of carrying out Post-weld cooled uniformly.heat treatment of carbon steel pipingwelds (pipe-work, headers, flange TCR has specialized fully-automaticjoints, valves and branches) by means programmable equipments capableof the electrical resistance method, in of controlling Heating rate, Holdingthe form of ceramic heater pads. It can time and cooling rate as well asdesign, fabricate, calibrate and run a carrying out a wide range of heatcustomized electrical furnace for clients. treatment processes like post-weld heat treatment of PQR test couponsPost Weld Heat Treatment Services and various components. TCR has at its(PWHT) is performed after welding/ disposal, well-equipped tools includingmachining, to improve the chemical electrical furnace with 220 and 80and mechanical properties of weldment Volts panel, latest 12 point recorder/ machined surfaces. TCR offers post- with digital display, coil and pad-typeweld heat treatment by using electricity heating element, oil firing systemsas the source of heating for stress and extremely skilled technicians. Therelieving of weld joints. All TCR’s heat Heat treatment equipment is suppliedtreatment services are designed to with a chart recorder to record up tominimize downtime, improve structural 8 thermocouples simultaneously tointegrity and enhance effective plant meet the critical requirements of heatlife. Additionally, depending on the treatment.mobility of the required equipment,many of TCR’s heating processes canbe applied on-site or at client’s facility.90

ENGINEERINGOil Firing on Pressure VesselsTCR Engineering has a talented crew that uses diesel fuel as the source of heatingfor stress relieving of pressure vessels with the sole objective of reinforcing process,component integrity, and high quality. The heat treatment specialists from TCR haveall the necessary experience and equipment to develop a custom configuration as perspecific processes. Our heating processes include low-Range, Mid-Range & High-RangeTemperature Heating.The heat treatment operation is affected by pressure of 700mm W.G, will connect eachthe firing of the furnace, using one or more The burner. burner is fitted with a (25/20)gas/oil high-velocity burners with a nominal stainless steel outlet nozzle designed torating of 1,500.000 Kcals/HR (6,000,000 clear the furnace wall adjacent to theBtu/HR) per burner. Each burner is armored intended opening(s) and in such a way asflexible hosing to Combustion Air Fan (s), to eliminate the possibility of any directwith a maximum output of 2800/Nm³ per impingement on components.hour via a 150mm diameter outlet, at aTCR’s high-velocity burners enable excellent temperature distribution and uniformity at alltimes because of the intense scrubbing action. They are also able to construct temporaryfurnaces at client sites where internal firing is not a practical or cost-effective option.

TCR Company ProfileG. STORAGE TANKS & STATIC EQUIPMENT INSPE 1 Helium Leak TestingThe Helium Leak Testing unit at TCR a dedicated sniffing unit, based on autilizes a proven mechanical vacuum pump well-proven leak-testing concept andtechnology designed specifically for heavy is available for outboard leak testingusage under harsh industrial environments. applications as well.The helium stability of the rotary vanepump guarantees excellent stability of the TCR’s services include vacuum leakhelium signal. The low rotational speed of testing for any type of vacuum vessel asthe M.D.P. (Molecular Drag Pump) at 27,000 well as system and pressure probe testingRPM keeps this unit completely insulated for systems that normally operate at oragainst accidental air inrushes. Further, above ambient pressure. Virtually anyit allows the leak detector to be moved system that has a requirement for leakwhile in operation. The high compression tightness or that is suspected of causingratio of the M.D.P. facilitates the gross leak a problem due to leakage can be testedtest at a high pressure (7.5 Torr / 10mbar) by one of these methods of helium leakwhich speeds up the leak test process testing with a high degree of reliability.of outgassing parts. The internal layoutof the unit allows easy access to all the Additionally, the unit offers evolvedcomponents. TCR’s Helium Leak Testing features to assist the operator with dailyinstrument has a roughing capacity of 10 test operation:m³/h (7 CFM) with usable helium sensitivity - Auto-calibration, with built-inin the 10-11 atm.cc/s range. The unit has temperature compensated calibrated leak (dedicated to the sniffing mode) TCR has performed several leak tests - Automatic signal correction on-site for industries that include -Vocal synthesizer nuclear carriers, polymer plants, oil - Helium background suppression refineries, gas and steam turbine with “floating” zero to keep the signal power plants in Kuwait, Kingdom from going negative and to increase of Saudi Arabia and India. TCR’s sensitivity technicians are highly mobile and - Audio alarm with variable pitch (up to perform helium leak testing on heat 90 dBA) exchangers, steam turbines and condensers, distillation towers, buried pipelines and many other systems and components.92

ENGINEERINGECTION2 Robotic Inspection Of TanksThis technique uses an automatic robotic crawler to enter One of the salient featuresinto the tank for collecting data such as thickness, ultrasonic of this technique is thesoundness etc. The process allows visual inspection by a elimination of the highvideo camera while the tank is in service. The robotic crawler cost of taking down yoursystematically scans the tank bottom with an array of eight tanks. The testing can beultrasonic transducers and relays high volume of UT data completed as per API 653for analysis. The in-tank service follows a digital inspection inspection in days insteadgrid and collects more than 200,000 UT scans (based on the of weeks or months. Itaverage scan pattern in a 100 ft. dia. Tank) for computer reduces environmentalanalysis. The robot pushes sludge aside as it travels, making hazards and is a safecleaning and waste disposal unnecessary in many cases. One process due to minimumof the salient features of this technique is the elimination of contact with the tank.the high cost of taking down your tanks. The testing can becompleted as per API 653 inspection in a few days as opposedto weeks or months. It reduces environmental hazards and isa safe process due to minimum contact with the tank.

ENGINEERING

TCR Company ProfileIII. Third party Audit & QualityInspectionTCR is a trusted provider for independent Third-Party Technical Inspection andquality assurance services that include Factory Audits, OEM Development, RawMaterial Inspection, Initial Production Check, In-Production Check, RandomInspection and Loading Supervision directly on-site at the supplier’s location inIndiaTCR’s ISO 17025 certified material testing laboratory delivers best-in-class servicesconsistently to customers around the world. Their deep industry expertise ensuresits performance and service quality are exemplary and they meet all requirements;compliance, regulatory or client specific. TCR helps in augmenting integrity andefficiency of equipment with safe working conditions for its employees. It’s materialtesting laboratory provides full chemical, mechanical, non-destructive testing,metallographic, positive material identification, corrosion testing and componenttesting services, including portable spectrometers, and digital photography. TCRalso has access to scanning electron microscope and EDAX attachments.. 95

TCR Company Profilei. Plant Shutdown ManagementTCR has the capability to rapidly source, engage and deploy talented NDT manpoweracross Petrochemical and Power industry in India. In the last few decades, TCR haseasily deployed several engineering and NDT teams at various onshore and offshorelocations within the Gulf/Middle-East area including Kuwait, Bahrain, Oman andSaudi Arabia.TCR works with industry-specific organizations, research and development facilities,and clients to develop new inspection equipment, applications, and procedures.With its superior Project Management Solutions, TCR meets all client’s projectrequirements at every stage of the business process either through the lifespan ofa project or at different stages, while making sure that operating costs are in-linewith the budget. TCR uses the latest technologies that help minimize downtime andensure each of its clients get the most comprehensive information possible on thestate of their equipment.Manpower Deployment and On-site PlacementsTCR Engineering supports plant shutdown projects with a diverse range of NDT skill-setsthat include:- API 510 Pressure Vessel Engineers - Chemists, Material TestingInspectors - Piping Engineers Lab Technicians- API 570 Piping Inspectors - Painting/Coating - Heat Treatment (PWHT)- API 653 Tank Inspectors Inspection Professionals Technicians- API 579 Fitness for Service - Corrosion Engineers - NACE Cathodic & Coating- Metallurgists including - IRATA (Rope Access) Inspectorsexperts in RBI (API Technicians - NDT Level III in multiple580/581), Failure analysis, - Multi-Skilled NDT Level II subjects (with WeldingRLA Technicians (ASNT/ PCN) Inspector Qualification)- ASNT Level III Experts - CSWIP/AWS Certified - NDT Level II in UT with Auto- BGas Paint Inspectors Welding Inspectors UT, Phased Array and TOFD- Mechanical Engineers - QA/QC Inspectors and Experience- Civil Engineers Engineers / Saudi Aramco - NDT Level II with extensive- Instrumentation Design Approved inspectors experience on pressure vessels96

ENGINEERINGand Multi-Skilled Usage - HSE Managers /Officers - Ultrasonic Inspection- ASNT MSLT Level II with - AutoCAD Operators/ (UT), Magnetic ParticleLeak Testing experience Designers Inspection (MPI),- ASNT Level II in Eddy - PDS/PDMS Designers RadiographyCurrent (ET) - Safety Officers/Engineers - CSWIP Plant Inspector- ASNT UT Level II with TKY - Process Design Engineers Level I (PL 11, PL 12)experience - ASNT RT Level II and RTFI - Positive Material- Plant Process Engineers - QA/QC Inspectors Identification Operators- Project Managers with Static and Rotating - Ferrite Assessment- Construction Managers Equipment Experience - Rope Access Technicians- Procurements Managers - Electrical InspectorsTCR inspectors are conversant with ASME/ANSI Codes and Standards across:- ASME SECTION VIII, DIV. Recommended Practices for Certified WeldersI and II Boiler and Pressure Welding - AWS D1.2, 1.3, 1.4, 1.5Vessel Code, Design and - AWS D10.8 Chromium- Structural Welding Code-Fabrication of Pressure Molybdenum Steel Piping Aluminum, Sheet Steel,Vessels and Tubing, Recommended Reinforcing Steel, Bridge- ASME/ANSI B16.5 Pipe Practices for Welding Welding CodeFlanges and Flanged - AWS D10.10 Local Heating - AWS D9.1 StructuralFittings of Welds in Piping and Tubing, Welding Code - Sheet Metal- ASME/ANSI B16.9 Butt Recommended Practices - AWS D10.6 Titanium PipingWelded Fittings - AWS D10.11 Root pass and Tubing, Gas Tungsten- ASME/ANSI B16.11 Welding of Pipe Without Arc, Recommended PracticesScrewed and Socket Backing, Recommended for WeldingWelded Fittings Practices - AWS D11.2 Welding Iron- ASME/ANSI B31.3 Process - AWS D10.12 Welding Castings, GuidePiping Low Carbon Steel Pipe, - AWS D14.5 Pressure- AWS D1.1/D1.1M Recommended practices and and Press Components,Structural Welding Code - Procedures Specification for WeldingSteel - AWS D14.5 Pressure - SSPC VOL I&II Steel- AWS D10.4 Austenitic and Press Components, Structures Painting CouncilChromium-Nickel Stainless Specification for Welding StandardSteel Piping and Tubing, - AWS QC7 Standard for AWS 97

TCR Company ProfileADVANTAGE TCRAn extension of your human resource teamTCR aims to become an extension of its client’s human resource department. TCR has servmaintaining a search network and providing resources tailored to individual requirements. In aall solicited and unsolicited resumes for providing a comprehensive progress report.TCR’s on-site inspection team and associated manpower along with its state-of-the-art equipmassignments. Alternatively, TCR can collaborate to work with other 3rd Party Inspection AgenINDUSTRY EXPERTISE Competent ProfessionalsTCR has extensive experience TCR’s highly trained NDE professionals go throuacross all major industries. training and are qualified to meet or exceed all iIts’ highly trained teams requirements. In addition to this, TCR provides eprovide clients with deep in-house training and ensures that all its NDT proindustry knowledge, best are always updated with all relevant industry codpractices and expert regulations.perspectives for problemresolutions. TCR has an ongoing commitment to continually b inspection solutions to their clients that will helpTCR aims to assist companies informed decisions and minimize costs and therewith breakthrough business their integrity management programs.insights and set newstandards of excellence for TCR helps augment the integrity and efficiency othem in their industries. and assure safe working conditions for all its em Latest Inspection Solutions TCR’s highly qualified teams have significant experience in various projects, both in India Middle East across various disciplines of NDT including Radiography, Ultrasonic, Welding Metallography & Positive Material Identification. Inspectors have worked on design, fabrication, construction, inspection and erection of P Vessels, Heat Exchangers, Towers, Stacks, Tanks, Plant Pressure Piping, Offshore oil well other advanced projects.98

ved as valuable source for understanding client’s environment, developing andaddition to its own search networks, TCR assists the hiring authority in screeningments and tools can be commissioned to work on contract as well as for on-sitencyugh rigorous Large pool of Talent industry extensive TCR offers a large, experienced and highly qualified ofessionals pool of professionals that can be deployed at any des and location in the shortest of time frames. bring new With over 100 professional NDT technicians, the sheer p them make size and expertise makes TCR the obvious choice for eby enhance meeting inspection requirements across all its clients of equipment TCR provides best integrity management solutionsmployees. across industries. TCR’s talent solution caters to both daily inspection activities as well as large turnaround a and the projects. g, MPI, In-situ T​ CR inspectors can undertake visual inspection, ferrite Pressure assessment, PMI operations, etc and are conversant ls and several with ASME/ANSI, AWS, API, BS, ASTM and NACE Codes and Standards. Number of our inspectors are currently deployed with Saudi Aramco SAP as well: - ASNT Level III personnel have a minimum of 7-15 years of experience - ASNT Level II personnel have 5-10 years of experience - Senior experience team members with over 25 years of experience - Junior NDT inspectors have 2-5 years of experience 99

TCR Company ProfileTERMS OF MANPOWER DEPLOYMENTTCR STREAMLINES THETRANSITION PROCESS TOENSURE MINIMUM DISRUPTIONIf a client needs highly qualified contractors for long-term, short-termprojects and T/A’s or independent contractors, TCR provides the same onper project basis at a flat fee. Payment Terms a minimum notice of 3 weeks to mobilize the right inspector for the - Operating Shift: Work on a standard task. 8-10 hour shift - Billing: Rates for the assignments Contingency Fees are quoted on a per day basis - Overtime Charges: Proportional Contingency searches are based to the daily manpower on 25% of the candidate’s first charges,calculated on an hourly basis years ‘anticipated annual salary’. - Invoice Schedule: Invoices are However, this can vary depending raised on a monthly basis and the on the geographical location, the payment must be made within 15 industry, the specific talent that is days of submission being recruited and the number of - Mobilisation charges: Needs to positions being filled. Candidates be paid in advance to mobilize in a contingency search are usually resources, it will be set off against identified through an existing future invoices database or from public job boards. - T&E Expenses: Client is responsible The search process is usually less and has to bear all the T&E charges structured than a retained search. including food, accommodation, This approach focusses less on local travel, and round trip air ticket an exact “fit” but more about from Mumbai, India to the offshore short listing potentially qualified location or inspection site candidates for the client to make - Additional Charges: Material Testing their own final assessment. (Destructive), if required will be extra SAFETY & HEALTHCARE VISA MOBILIZATION All safety equipment, if required must The client is required to provide visa be supplied by the client’s on-site/ and valid work permit. TCR will need100