CORE SERVICE OFFERINGS
Research and Development
Research and Development assumes a pivotal role in the innovation process. It is an investment in building future capabilities and technology, which is perhaps used to transform into new products, processes, and services.TCR has the competence to effectively set up and manage an in-house laboratory for an organization and provide innovative, professional and superior service. TCR brings a strong process, deep technical expertise and a performance-oriented approach that rests on integrity and reliability.
TECHNICAL CAPABILITIES
Contract Research and Development
TCR’s dedicated engineering and the metallurgical consulting team is the perfect partner for solving manufacturing and product quality problems. TCR's senior consultants with several years’ of experience are available to support and advice on corrosion and materials selection queries. The team also provides advisory service on welding engineering and heat treatment problems. From initial product design to final production, TCR’s in-depth engineering consulting services ensure that clients are producing the best possible product.
TCR also undertakes research projects in the areas of Computer-Aided Designing (CAD) including Engineering Design, Legacy Data Conversion, Detailing Plant & Process Layout, CAM and Computer-Aided Engineering (CAE) including Finite Element Mode.
Areas of research assistance include:
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Determining the Right Material for a Product
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Undertaking Corrosion Engineering, Corrosion Testing and Corrosion Investigations
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Conducting Metallurgical Failure Analysis and Welding Evaluations
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Investigating The Effects on Environmental Conditions
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Preparing Material and Process Specifications for In-House Quality Control
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Comparing Vendor or Competitor Products
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Identifying Equivalents Between Local and Foreign Specifications
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Assisting In Solving Product Quality Problems
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Assisting In Cost-Benefit Analysis Post Failure Analysis
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Reverse Engineering and Rapid Prototyping
R&D @ TCR
Technical Help for Indigenization
In order to generate baseline standard for indigenization, multiple metallurgical studies are undertaken to identify status and properties of imported components by different methods including destructive/non-destructive studies. Technical help is provided to decide on the right manufacturing route or process and to develop quality checks on indigenously created components. TCR’s proprietary approach seeks structural details from the client across several areas to optimize indigenization support:
Working condition of component
Type of loading and stresses
Design and operation condition
Service history of component
Life of an important component
R&D @ TCR
Selection of Materials
Weight loss experiments: Samples of different metals/alloys are exposed to simulated or actual process plant solution in the laboratory, with and without stirring. Coupons of different metals/alloys are exposed to actual plant environment and a systematic approach is formulated, based on the requirement of intended services, literate survey and relevant standards like NACE, ASTM and API. The laboratory study is performed on the exposed sample to categorize the performance and a suitable MOC is recommended. Electrochemical experiments to find out relative corrosion resistance is performed by accelerated testing under laboratory conditions. MOC selection is done with off the shelf database and is combined with the experience of other experts drawn from published literature.
Quality Improvement
TCR undertakes total quality improvements for stringent requirements against international specifications. A thorough survey is undertaken by auditing the existing manufacturing procedure followed by stage-wise investigations of raw material and other components required for product manufacturing. Effects of processing conditions are derived with respect to different properties of the component. Based on the study, recommendations are made for improvements in metallurgical process/raw material. The required quality control checks are suggested to ensure consistency for optimum and continuous production.
TCR deploys a team of expert metallurgists to perform this task. The specially designed report enlists the fundamentals of metallurgical processing variables on final properties of the components and includes recommendations for corrective measures.
CORE SERVICE OFFERINGS
Solutions of Critical Weld Problem
TCR prides itself on having a huge knowledge bank of success stories compiled from over 1800 failure investigations across several industries. The insights gained in the area of failure mechanism has augmented the knowledge of TCR’s technical team and because of this, there is a direct implementation of repair weld solutions.
With its deep technical and market expertise, TCR is a leading player in solving critical weld repair solutions for the aged plant components.With limited material resources and increased value of new products, repair weld solutions can salvage critical components of process plant and ensure massive savings by mitigating production loss. The repair weld technology requires an in-depth understanding of metallurgical degradations, operating conditions, physical metallurgy and welding technology. There is a right solution for every problem that can be determined via strong fundamentals, technical competence, and engineering output.
When a plant with critical machinery component has a breakdown, an immediate problem resolution is necessary. There have been several instances when repair welding is done with little or no understanding of the metallurgical fundamentals and this proves to be disastrous. The management loses trust in its usefulness and technical competency. This philosophy promotes hasty decisions for replacing the components at a premium cost. Instead, a systematic detailed metallurgical investigation would provide the extent and nature of degradation, thereby utilizing the knowledge of metallurgy and a proper welding procedure can be devised. TCR has helped many industries by providing repair solutions on critical pump casing, shaft, nitrided components reformers and many other such issues.
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The TCR’s engineering consulting team, when provided with a detailed history of the problem can reach the client’s site within 24 hours and they start generating data and draw up the way forward for the components to be repaired.
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For successful repair, a mock test is necessary from the same material (or preferably for the aged material of similar grade). In case it is not available, virgin material of similar grade can also be used as an alternative. A mock test will establish the confidence in the welder and welding parameters.
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After successful welding, thorough NDT testing is recommended to ensure that the welding joints remain trouble free for future service.