materials testing lab, corrosion study, rbi, failure analysis

Materials Testing Lab, Corrosion Study, RBI,

Failure Analysis, Advanced NDT Services, Training and Consulting

TCR Arabia Company Llc.P.O. Box 3422, No. 3 & 4, Besides Al-Kifah Construction Company,

Near Al-Kadi Tent Factory, King Abdulaziz Seaport Road,Dammam, Kingdom of Saudi Arabia

Tel: +966-3-8475784/85 | Fax: +966-3-8475768E-Mail: [email protected] | URL: www.tcr-arabia.com

2www.tcr-arabia.com Proprietary & Confidential © 2010-11

TCR Arabia : QA / QC Partner in KSA• TCR Arabia, founded in 2007, is a Joint Venture

Company between TCR Engineering Services (India) and GAS Arabian Services (Saudi Arabia).– Backed by 37 years experience of NDT, Inspection

& Metallurgical Testing and Failure Analysis services of TCR Engineering of India.

– TCR is a global company with offices in KSA, Kuwait, Qatar, India, Malaysia, South Africa, USA

• Completed major projects for Saudi Aramco, SEC, SWCC, SABIC, SIPCHEM, APPC, PetroRabighand other private companies in Saudi Arabia– Approved and Registered by all major companies

in KSA

– Several appreciation letters received

• Located in Eastern and Western Regions– Dammam and Jeddah

• Laboratory in Dammam only

– Cost-Effective and Fast Mobilization

• Awaiting ISO 17025 accreditation


Solutions for Plant ReliabilityMaterials Testing

Laboratory

Tensile Testing, Bend Testing, Hardness Testing, Impact Testing, Welder Qualification, Chemical Analysis Spectrometer, Inter-granular Corrosion Tests, Salt Spray, Sour Gas Corrosion (HIC/SSC), Metallography, Micro and Macro ExaminationMicrostructure Analysis (SEM/EDAX/XRD)

Contract Research and Development

Heat Treatment Studies2D to 3D ConversionFinite Element ModelingComputer Aided Engineering (CAE)Piping Stress AnalysisAdvise on Materials

Engineering Consulting

Risk Based InspectionFitness For ServiceDamage Mechanism StudyThird Party Inspection

Failure Analysis and Remaining Life

Fatigue FailureCorrosion Related FailureOperations FailureRemaining Life AssessmentBoiler Assessment

Plant Shutdown Management

Manpower SupplyAPI 510 Pressure Vessel Inspectors, API 570 Piping Inspectors, API 653 Tank Inspectors, ASNT Level III Experts, BGas Paint Inspectors, Multi-Skilled NDT Level II Technicians, CSWIP/AWS Certified Welding Inspectors, QA/QC Inspectors and Engineers, NACE Cathodic & Coating Inspectors

Conventional NDT Services

Ultrasonic Flaw ExaminationUltrasonic Thickness SurveyMagnetic Particle TestingLiquid Penetrant TestingRadiography EvaluationFerrite MeasurementPortable Hardness MeasurementPaint and Coating ThicknessHoliday DetectionPositive Material Identification

Advanced NDT Services

Time of Flight Diffraction (ToFD)Phased Array In-situ MetallographyEddy Current TestingCorrosion MappingCorrosion under InsulationHelium Leak TestingThermographyInternal Rotary Tube Inspection Alternating Current Field MeasureLong Range Ultrasonic TestingRobotic Crawler Video Inspection*OTIS - In Service Tank InspectionHD 200 - In Service Tank CleaningClose Interval Potential SurveyDirect Current Voltage Gradient Survey

Heat Treatment Services

Electric Resistance (PWHT)Oil Firing on Pressure VesselsFurnacesInduction Heating

Training

Mechanical Metallurgy LaboratoryMicrostructure CharacterizationMetallurgy for Plant ExecutivesCorrosion Damage MechanismsSour Gas Corrosion TestingFitness for Service AssessmentAPI 571 damage MechanismsImplementing RBI best practicesFailure and Root Cause AnalysisIntroduction to NDT for ExecutivesUltrasonic Testing – Level I and IIMagnetic Particle Test – Level I, IIDye Penetrant Test – Level I and IIEddy Current Testi – Level I and IIRadiography Testing – Level IIVisual Testing – Level IIThermography – Level I

Inspection Products

Modsonic – UT Flaw Detectors, Thickness Measurement

Oxford Instrument/Sanco - XRF and OES

MiC – Image Analysis Software and LIMS

TCR – HIC/SSC Lab Equipment and Glassware

Time – Portable Hardness

TCR Arabia has a Strong and Experienced Team of Metallurgists, NACE Corrosion Specialists, RBI Specialists, Shutdown Managers, API 510/570/579 Inspectors, AWS/CSWIP Welding Inspectors, ASNT Level III Manager, ToFD/PA Experts, Heat Treaters, Trainers, PCN Level II and ASNT Level II Technicians in KSA


Flat Organization StructureAbdulrahman K. Al-Dabal

Chairman

V.K. BafnaAbdulrahman K. Al-Dabal

Rohit BafnaFaisal K. Al-DabalParesh HaribhaktiBoard of Directors

Aref K. Al-DabalManaging Director

Syed Ameen HassanCountry Manager

Mechanical Testing Chemical Analysis

Corrosion Metallography

Plant Shutdown Management (India)

Conventional NDT Services

Advanced NDT Services

Heat Treatment Services

TrainingInspection Products

Surendra Singh KamalTech. Head (Metallurgy)

Jaidev Patel (Level III)Tech. Head (NDT)

Percy LakdawalaHuman Resources

Rahul SinghSales

Kamran Ahmed ShariffAdmin

Plant Shutdown Management (USA)

Paresh HaribhaktiChief Metallurgist, R & D

RBI and FFSContract Research and Development

Engineering Consulting

Failure Analysis and Remaining Life

TabreezSp. Projects

Amit BafnaQuality Head

Rohit BafnaMarketing


Noteworthy Works

NDT Works on the Haram Expansion Project in Mecca

ToFD Project in PetroRabigh

NDT Training for Employees of TuV

PWHT Project in Khurais

PMI with Carbon at Saudi Kayan


Major Projects by TCR ArabiaClient Project Description Location

Tekfen Automated UT Using ToFD on 8mm-80mm thick piping as per ASME Code Case 181

PetroRabigh (UOU) Project

Sinopec Automated UT Using ToFD on 9mm-65mm thick piping as per ASME Code Case 181

PetroRabigh Project

Al-Tawleed Energy Post Weld Heat Treatment using Electric Resistance and Induction Resistance

Shoiba Power Plant

Tekfen Positive Material Identification using XRF alloy analyzer and Portable Hardness Measurement

PetroRabigh Project

Tekfen Automated UT Using ToFD on 8mm-80mm thick piping as per ASME Code Case 181

Khurais (KUC) Project

Nasser Al-Hajri Positive Material Identification using Optical Emission Spectrometer for Carbon Detection

Saudi Kayan Project, Jubail

Saipem Positive Material Identification using Optical Emission Spectrometer for Carbon Detection

Khurais (KUC) Project

Encocorp Automated UT Using ToFD on 20mm thick piping as per ASME Code Case 181

KAIA Project, Jeddah

CEPCO/SWCC Remaining Life Assessment / NDT Services of Boiler # 83 at SWCC Jubail

SWCC, Jubail


Materials Testing Lab in Dammam• Tensile Testing

• Bend Testing

• Hardness Testing

• Impact Testing

• Welder Qualification

• Chemical Analysis Spectrometer

• Intergranular Corrosion Tests

• Salt Spray

• Sour Gas Corrosion (HIC/SSC)

• Metallography

• Micro and Macro Examination

• Microstructure Analysis (SEM/EDAX)

Optical Emissions Spectrometer

Inverted Metallurgical Microscope

100KN Tensile Testing

Impact Testing

Proof Rings and High Pressure Autoclaves for NACE Tests

TCR Arabia conducts tests as per ASTM, NACE, API, AWS, ASME or Client-Supplied Specifications


Welder Certifications and WPQR• Coupon Testing as per Weld Procedure Qualification

– Includes visual examination, mechanical testing, metallographic examination and non destructive testing

• In depth weld inspection to include review of the applicable qualification

– Weld procedure specification, welder performance qualification and validity for process materials and consumable items, equipment, set up and other factors, including certificates of calibration and/or conformity governing the work.

– Check safety of set up and operation having due regard for self, welder and other workers in vicinity, particular in respect of ultraviolet radiation from arc during welding.

• Complete Services conducted by Experienced AWS/CSWIP Inspector

– Welder Qualification Testing Inspection for performance qualification and certification of welders to ASME, AWS, API code

– Preparation of Weld Procedure Qualification

– Documentation of the Procedure Qualification Record


Failure Analysis and RLA• Over 800 failure investigations completed to date

– Sipchem, Tasnee, APPC, SWCC and others are regular customers of TCR Arabia in KSA

• Remaining Life Assessment (RLA) of Several Boilers completed for SWCC

• Unravel the mysteries surrounding parts and assembly failures

– Fatigue Failure– Corrosion Related Failure– Operations Failure– Remaining Life Assessment

• Strong Experience undertaking wide range of root cause failure analysis projects

– Residue Analysis– Corrosion Analyses/Studies– On-Site Investigations– Material Selection– Manufacturing Processes Evaluation– Welding Studies– Product Design Evaluation– Fractography– Heat Treatment Errors– Product Selection Issues

• Fast Turnaround time with in-depth analysis reporting

• Strong History of Past Work, some examples:

Corrosion Evaluation Of Oil Well Tubing

Mandrel Bypass Of Equalizer Sub.

Coriolis mass flow

meter sensor failure

Riser Pipe Failure


RLA & Condition Assessment of Boilers• Level II and Level III assessments based on calculation and

design approaches, including steps such as:

– Collection of background data and history of Boiler Operation.

– Understanding the actual degradation mechanism

• Fatigue

• Thermal Fatigue

• Thermo Mechanical Fatigue

• Thermal Aging

• Creep

• Embitterment

• Corrosion

– Thorough visual examination by an expert

– Dimensional measurement at critical locations

– Collection of scale and deposits samples and it’s analysis

– Detailed Thickness Survey

– Internal oxide scale measurement at Super Heater Tube and Re-heater Tube

– WFMPI of main weld joints of Header and Steam Drum

– In-Situ metallograpy to determine thermal ageing and creep related problem from a RLA perspective

– In-Situ hardness measurement with portable hardness tester

– Suggestions on Repairing• If required, repairing of the equipment is suggested, for life

extension.

– Calculation and Judgment of Remaining Life based on Analysis

Component Tests Location to be checked

Main Cylindrical Shell

Visual 100% after removal of insulation

Thickness Measurement Random

WFMPI/UTWeld joints, Side holes, mud holes and blow down outlet

Replica & HardnessReplica & hardness shall be on

weld/HAZ & parent

Furnace tubes with

bowling hoops

Visual100% thru the hot gases side

with weld joints

Thickness Measurement RandomWFMPI & UT Weld Joints


weld/HAZ & parent

Smoke Tubes and

Stay Tubes

Visual 100%

WFMPI Tube to Tube Plate weld joints



weld/HAZ & parent

Front & rear tube plates and end

plates of wet back

Visual External Side

WFMPI/UT Circumferential Weld seam



weld/HAZ & parent

Reversal Chamber

VisualWFMPI Weld Joints


weld/HAZ & parent


In-Situ Metallography• Onsite Examination and Evaluation of Plant Equipment

– Equipment and piping operating at elevated temperatures undergo microstructural changes which can reduce original design properties and cause unexpected failures

– Study of Replica under SEM and Optical Microscopes in Laboratory

• Field Metallography can be used as a tool to determine remaining life, fitness for service, and damage assessment from creep mechanisms or fire damage.

– Useful in determining the cause for cracking, degree of overheating, verification of alloy type or other damage mechanisms manifested by microstructural changes

– Applications in Heater Tubes, Boiler tubes, Superheatertubes, Steam Piping & Tanks

304SS Tube Creep Voids


Risk Based Inspection (RBI)• TCR Arabia and PP Simtech (UK) offer RBI as per API 580

– Enable Plant Personnel's make informed business decisions regarding inspection and maintenance spending

• Profit Linked to Reliability

– Unplanned outages/ extended T/A’s can have severe financial impact

– Incidents affect reputation and have safety consequences

• RBI methodology and tool by TCR Arabia-PPS has been proved successful against rigorous audits by UK HSE

– Exceeds RBI 'best-practice' guide for API 580 and UK HSE

– Technology supported by rbiAsyst™ software system

– Multi-discipline teams record the RBI team studies & updates

• Risk matrix created and studied for each item of a plant

– Internal corrosion (general, grooving, pitting, crevice, under deposit, galvanic, biological), External corrosion (general, localized, CUI), Erosion & Erosion Corrosion, Stress Corrosion Cracking (Cl, NH3, caustic, CO/CO2, amine, methanol), High Temperature Creep, Fatigue (thermal, mechanical, pressure, vibration), H2S induced corrosion or cracking, Metal Dusting, H2 damage / cracking

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Conventional NDT Services• Ultrasonic Flaw Examination

• Ultrasonic Thickness Measurement

• Magnetic Particle Testing

• Liquid Penetrant Testing

• Radiography Evaluation

• Ferrite Measurement

• Portable Hardness Measurement

• Paint and Coating Thickness

• Holiday Detection

• Positive Material Identification

XMet 3000

XMet 3000TX

Niton XLT

EPOCH LT

Modsonic Einstein II-DGSUltrasonic Flaw Detection

Portable Optical Emissions Spectrometer for PMI with

onsite Carbon Detection

Coating Thickness GaugeFisher Ferrite MeterPortable Hardness


Advanced NDT Services• Time of Flight Diffraction (ToFD)• Phased Array • In-Situ Metallography• Eddy Current Testing• Electro-Magnetic Acoustic Transmission (EMAT)• Corrosion Mapping• Corrosion Survey under Insulation• Helium Leak Testing• Thermography• Internal Rotary Tube Inspection (IRIS)*• Alternating Current Field Measurement (ACFM)*• Long Range Ultrasonic Testing (LRUT)*• Robotic Crawler Video Inspection*• OTIS - In Service Robotic Tank Inspection*• HD 200 - In Service Robotic Tank Cleaning*• Close Interval Potential Survey (CIPS)*• Direct Current Voltage Gradient Survey (DCVG)*

OmniScan MX from Olympus NDT for ToFD and PA

Alcatel ASM 142 - Helium Leak Detection

Heat Exchanger Tubing Tested with Eddy Current and IRIS


ToFD and Phased Array• TCR Arabia has 5 Saudi Aramco qualified crews

– Completed Major projects in PetroRabigh, Khurais, Sinopec and Kuwait Oil Company

• Strong Experience in Rapid Scanning of Welds in Piping, Storage Tanks and Pressure Vessels with well defined procedures

• This technique has many advantages– Wide coverage area using a pair of transducers

– Accurate flaw sizing; amplitude-independent, Sizing technique using time-of-flight information

– One-line volume inspection, provides very fast scanning

– Setup independent of weld configuration

– Very sensitive to all kinds of defects. No sensitivity to defect orientation

– Amplitude-insensitive, acoustical coupling less critical


In-Service Storage Tank Inspection• Robotic Crawler Video Inspection for ASNT Tanks

– Quik-Look™ for inspection of underside of AST fixed roof and roof support columns without removing the tank from service

– Compact, portable video camera inspection service • Determine the amount and distribution of material in the tank • Determine tank conditions such as corrosion and scaling.

• OTIS - In Service Robotic Tank Inspection & In Service Robotic Tank Cleaning– Systematically scans the tank bottom with an array of eight ultrasonic

transducers, and relays high-volume UT data for analysis. The robot pushed sludge aside as it travels making cleaning and waste disposal unnecessary.

• Eliminate the high cost of taking down your tanks• Complete an API 653 inspection in days instead of weeks or months• Avoid disruptions in normal service and keep revenue consistent• Perform repairs only as needed• Minimize impact to your costs and operations• Reduce environmental and safety risks without opening the tank or due to manned

entry

• The tank inspection report provides a complete, 10-year API 653 report on the condition of your tank. The report will include:– Top-side and bottom-side corrosion locations– Floor-plate thickness and pitting– Videotape of roof underside and vapor space structures– Fiberglass coating measurement

Crawler Video Inspection

Robotic Tank Inspection


Plant Shutdown Management• Personnel available with strong experience

– Design, fabrication, construction, inspection and erection of Pressure Vessels, Heat Exchangers, Towers, Stacks, Tanks, Plant Pressure Piping, Offshore oil wells and many advanced projects

• TCR Arabia can quickly mobilize experienced manpower – Experienced Reliability Experts

– Metallurgists and Engineers

– API 510 Pressure Vessel Inspectors

– API 570 Piping Inspectors

– API 653 Tank Inspectors

– ASNT Level III Experts

– BGas Paint Inspectors

– Multi-Skilled NDT Level II Technicians

– CSWIP/AWS Certified Welding Inspectors

– QA/QC Inspectors and Engineers

– NACE Cathodic & Coating Inspectors


Engineering Design & Analysis Services• Piping Stress Analysis on Ceasar II

• Computer Aided Designing (CAD/CAM)

– 2D to 3D Conversions, Solid Modeling, Surfacing for automotive, machinery and construction industries, Legacy Data Conversion for Material Handling Equipments

• Computer Aided Engineering (CAE) including Finite Element Modeling

– FE stress analysis undertaken of

• cylinder block, cylinder head, connecting rod

• crankshaft & crankcase, shock absorber structure including outer tube, spring seat, knuckle etc

• Structural Analysis

• Noise, Vibration, Harshness (NVH) analysis

• Leading Software used

– CATIA, Pro/ENGINEER, UniGraphics, I-DEAS, Inventor, SolidWorks, DELCAM, Ansys, LS Dyna, HyperMesh, NX Nastran, Moldflow


Heat Treatment Services• TCR Arabia conducts Post Weld Heat Treatment (PWHT) using 70 Kva

Electric Resistance Machines

– Completed major PWHT jobs in Khurais and Saudi Kayan Project

TCR Arabia PWHT Crew at Work


Technical Training Courses• Mechanical Metallurgy Laboratory – Level I and II• Microstructure Characterization• Metallurgy for Plant Executives and NDT Inspectors

• Understanding Corrosion Damage Mechanisms• Sour Gas Corrosion Testing – Level I and II

• Fitness for Service Assessment Training• Understanding API 571 damage Mechanisms• Implementing RBI best practices in Plants

• Failure and Root Cause Analysis : Guide

• Introduction to NDT for Plant Executives• Ultrasonic Testing – Level I and II• Magnetic Particle Testing – Level I and II• Dye Penetrant Testing – Level I and II• Eddy Current Testing – Level I and II• Radiography Testing – Level II• Visual Testing – Level II• Thermography – Level I

• Gas Tungsten Arc Welding for Qualified Welder• Shield Metal Arc Welding for Qualified Welder


Inspection Products• TCR Arabia markets and represents the following products in KSA


Summary• We listen closely and document each customer

interaction– Deep understanding of project needs and

adherence to timelines

– Well documented internal work procedures that meets client/inspection agency approvals

• Strong commitment to local community– Active participant in Saudi Chapter of ASNT

– Sponsors of Abdullah Al-Dabal Indoor Football Tournament

• Highly Competitive Pricing and Fast Mobilization

• Ability to Ramp Up team resources very quickly– Strong foundation to arrange for visa’s and other

formalities

Building

trust

through

CommercialEdge

DevelopingPeople

Openness

andHonesty

Hands–onExecution

CustomerDrive

Health,Safety &

Environment

mindset

Building

trust

through

CommercialEdge

DevelopingPeople

Openness

andHonesty

Hands–onExecution

CustomerDrive

Health,Safety &

Environment

mindset

Questions?

Contact:Syed Ameen Hassan, Country Manager

[email protected] | +966-50-4997683

TCR Arabia Company Llc.P.O. Box 3422, No. 3 & 4, Besides Al-Kifah Construction Company,

Near Al-Kadi Tent Factory, King Abdulaziz Seaport Road,Dammam, Kingdom of Saudi Arabia

Tel: +966-3-8475784/85 | Fax: +966-3-8475768E-Mail: [email protected] | URL: www.tcr-arabia.com

materials testing lab, corrosion study, rbi, failure analysis

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