CORE SERVICE OFFERINGS
Advanced NDT Services
TCR offers advanced NDT services led by NDT Level 3 experts, with our team operating in full compliance with ASNT CP-189 guidelines to ensure accurate material evaluation and adherence to the highest quality and safety standards.
Phased Array (PaUT)
TCR Engineering specializes in advanced Phased Array Ultrasonic Testing (PAUT) using Olympus OmniScan machines, providing high-resolution inspections for welds, components, pipelines, and pressure vessels. Our certified experts conduct thorough assessments of material integrity with precise defect detection and characterization, ensuring superior safety and reliability.
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In compliance with industry standards, TCR performs PAUT inspections in accordance with ASME Boiler and Pressure Vessel Code, ASME B31.3 for Pressure Piping, and API 650 for Welded Tanks. These inspections are critical for pipelines and pressure vessels, ensuring structural integrity and adherence to the highest safety requirements. Our expertise enables us to deliver accurate, code-compliant results for industries such as oil & gas, power generation, and manufacturing, where operational efficiency and safety are paramount.
Time-of-Flight Diffraction (ToFD)
TCR Engineering specializes in the Time-of-Flight Diffraction (ToFD) technique, an advanced ultrasonic non-destructive testing (NDT) method that relies on the diffraction of ultrasonic energy from the corners and ends of internal structures, primarily defects, within the components being tested. Our expert NDT team provides amplitude-independent, accurate flaw sizing across a wide coverage area, ensuring that even the most subtle defects are detected and evaluated.
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ToFD is particularly valuable for conducting Fitness for Service (FFS) inspections, making it an essential tool in maintaining the integrity of critical assets. This fast and effective method allows for the rapid scanning of extensive weld areas in a limited timeframe, which is crucial for minimizing downtime in industrial operations.
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In addition to providing top-tier ToFD inspections, TCR offers services for creating customized ToFD scan plans and procedures tailored to specific client needs in India. The advantages of ToFD include its ability to deliver precise and reliable defect sizing, comprehensive coverage, and the facilitation of effective decision-making for asset management, all of which are critical for industries such as oil & gas, petrochemical, and power generation.
Long Range Guided Wave Ultrasonic Testing (LRUT)
The Long Range Guided Wave Ultrasonic Technique (LRGUT) is engineered to inspect 100% of a pipe segment from a single location.
This technique involves inducing torsional or longitudinal guided waves into the pipe, allowing them to propagate throughout the entire segment under examination. When these guided waves encounter an anomaly or a feature within the pipe, they convert into laminar waves and reflect back to the original location of the tool. These signals are digitally captured using a laptop, and the time-of-flight for each signal is calculated to determine its distance from the tool. The cross-sectional area is assessed based on amplitude, while the circumferential extent is estimated through focused beams, which are broken down into octants to evaluate the significance of any detected defects.
TCR conducts LRGUT in collaboration with its international partner, which adheres to and exceeds the PHMSA's 18-point requirements for examining casings and crossings. LRGUT is primarily utilized in industries such as oil and gas refining, petrochemicals, storage, offshore operations, and pipeline transportation.
Specifically, these tests play a critical role in External Corrosion Direct Assessment (ECDA) and Internal Corrosion Direct Assessment (ICDA) methodologies, particularly in situations where access to piping systems is challenging, such as:
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Insulated Pipe in Refineries
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Offshore Pipeline Risers
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Cased Road or Railway Crossings
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Loading Lines and Pipework
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Tank Dyke Pipeline Crossings
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Above Ground or Buried Flow Lines
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River or Bridge Pipeline Crossings
Helium Leak Testing
TCR provides vacuum leak testing for all types of vacuum vessels and pressure probe testing for systems operating at or above ambient pressure. Any system requiring leak tightness or suspected of leakage issues can be tested using these helium leak testing methods with high reliability.
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The Helium Leak Testing unit at TCR employs advanced mechanical vacuum pump technology specifically designed for heavy-duty use in challenging industrial environments. The rotary vane pump’s helium stability ensures exceptional consistency of the helium signal, while the Molecular Drag Pump (M.D.P.), operating at a low rotational speed of 27,000 RPM, provides full insulation against accidental air influxes. This design also allows for the leak detector to be relocated during operation. The high compression ratio of the M.D.P. enables efficient gross leak testing at elevated pressures (7.5 Torr / 10 mbar), significantly accelerating the leak testing process for outgassing components. The internal configuration of the unit allows for easy access to all components, enhancing usability. TCR’s Helium Leak Testing instrument boasts a roughing capacity of 10 m³/h (7 CFM) with usable helium sensitivity in the 10^-11 atm.cc/s range. Additionally, it features a dedicated sniffing unit based on a reliable leak-testing concept, suitable for outboard leak testing applications.
TCR has conducted numerous leak tests on-site across various industries, including nuclear carriers, polymer plants, oil refineries, and gas and steam turbine power plants in Kuwait, the Kingdom of Saudi Arabia, and India.
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Our technicians are highly mobile and perform helium leak testing on a wide range of systems and components, including heat exchangers, steam turbines, condensers, distillation towers, and buried pipelines.
Thermography
TCR employs thermography testing to detect temperature anomalies in equipment during operation using remote, non-contact methods. This technique, now also performed via helicopters for large areas, captures heat radiation from hot objects using infrared sensors to create thermal images. By analyzing the hot and cold regions, the condition of the equipment can be assessed.
Thermography is valuable in detecting blockages or deposits in pipelines carrying hot or cold fluids, as well as insulation or refractory damage in furnaces, boilers, and heaters. It is also widely used for monitoring electrical substations, transformers, control panels, and rotary equipment like motors, generators, and turbines for signs of overloading, overheating, and faulty contacts.
Alternating Current Field Measurement (ACFM)
Alternating Current Field Measurement, also known as ACFM is a one-pass method to inspect welds and to locate and size surface breaking cracks. An electromagnetic field is induced into the surface being inspected. When the probe is passed over a surface breaking crack, the electromagnetic field is disturbed allowing detection of the anomaly. This field is measured using the proprietary software which allows crack depth and length measurements on a real-time basis. Probes of almost any configuration can be customized for nearly any application imaginable.
Digital Crack detection method covers:
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Sizes Cracks (Length & Depth) Applications
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Detects through Coatings, Paint & Scale
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No Recoating required
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No Metal Contact required
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More Precise than Conventional methods
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High-Temperature Applications
TCR performs ACFM in association with its international partner. This technique replaces conventional dye penetrants, magnetic particle testing and ultrasonic testing for size defects. Applications of ACFM includes:
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Structural Welds on Platforms
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Structural Welds on Drilling Rigs
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Cooling Tower Welds
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Compressor Fin Surfaces and Threads
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Drill Collar Threads
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Pipeline Girth Welds and Supports
Pressure Vessel System Welds
ASNT Level III Consultancy in India
TCR Engineering boasts a highly skilled advanced NDT inspection team, with ASNT Level 3 certifications in Eddy Current (ET), Ultrasonic Testing (UT), Magnetic Particle Testing (MT), Infrared Thermography (IR), Mass Spectroscopy Leak Testing (MSLT), Radiography (RT), Liquid Penetrant Testing (PT), and Visual and Dimensional Evaluation (VT). The team is also equipped to execute projects using Automated Ultrasonic Testing with Time of Flight Diffraction (ToFD) techniques, and its experts are certified in AWS/CSWIP 3.1 and 3.2 as well as CSWIP Painting inspection.
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TCR’s ASNT Level III professionals possess the expertise to develop techniques, interpret codes, standards, and specifications, and prepare or approve procedures and instructions. All NDT inspectors at TCR are qualified under the American Society for Nondestructive Testing Practice SNT-TC-1A and adhere to CP-189 guidelines. Each non-destructive examination is conducted in accordance with major codes such as the ASME Boiler and Pressure Vessel Codes, ASME/ANSI Pressure Piping Codes, American Petroleum Institute Codes, American Welding Society Standards, and Aviation/Military specifications.
TCR’s combined strengths in metallurgy and advanced NDT services have enabled global leaders like Reliance, Saudi Aramco, QAFCO, IOCL, GAIL, and BPCL to increase plant availability, reduce costs, minimize shutdown times, and improve safety compliance. The TCR team excels in assessing and calculating the risk profiles of plant equipment based on "active" and "potential" damage mechanisms, ensuring that inspection intervals are reliably optimized in a safe and cost-effective manner.