Services · Asset Integrity and Engineering Consulting
Solutions for Critical Weld Problems
Repair the critical component instead of waiting for a replacement.
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In brief
TCR Engineering Services Pvt. Ltd., Navi Mumbai, designs repair weld solutions for aged pressure-boundary components: ASME Section IX-compliant WPS development, repair-methodology design, a post-repair NDT plan and fitness-for-service sentencing, from a metallurgical investigation of the degradation first.
Solutions for Critical Weld Problems
ASME Section IX-compliant WPS development, repair-methodology design, post-repair NDT plan, and FFS-supported sentencing for weld repairs in pressure-boundary service.
TCR draws on a knowledge bank compiled from more than 9,000 failure investigations across several industries. What those investigations show about failure mechanisms goes directly into the repair weld solutions TCR's team designs.
TCR designs repair weld solutions for aged plant components. With limited material resources and new components costly, a repair weld can salvage a critical process-plant component and avoid the production loss of waiting for a replacement. The repair weld technology requires an in-depth understanding of metallurgical degradations, operating conditions, physical metallurgy and welding technology. The right solution follows from metallurgical fundamentals and engineering analysis.
A breakdown of a critical machinery component needs an immediate answer. Repair welding done without the metallurgical fundamentals has repeatedly failed, after which management loses trust in repair and replaces components in haste at a premium cost. A systematic metallurgical investigation instead establishes the extent and nature of the degradation, and a proper welding procedure is devised from it.
TCR has provided repair solutions for critical pump casings, shafts, nitrided components and reformers, among other components.
- Given a detailed history of the problem, TCR’s engineering consulting team can reach the client’s site within 24 hours, start testing and draw up the repair plan for the affected components.
- A successful repair needs a mock test on the same material, preferably aged material of a similar grade; where none is available, virgin material of a similar grade is the alternative. A mock test will establish the confidence in the welder and welding parameters.
- After successful welding, thorough NDT is recommended to ensure that the welded joints remain trouble-free for future service.
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Frequently asked questions
How quickly can TCR reach a site with a weld repair problem?
Given a detailed history of the problem, TCR's engineering consulting team can reach the client's site within 24 hours, start testing and draw up the repair plan.
Why does TCR insist on a mock test before the repair?
A mock test on the same material, preferably aged material of a similar grade, establishes confidence in the welder and the welding parameters; virgin material of a similar grade is the alternative.
Which components has TCR repaired?
Critical pump casings, shafts, nitrided components and reformers, among others.