Services · Asset Integrity and Engineering Consulting
Knowledge-Based Audit (KBA), TCR's Branded Risk-Based Inspection
1,500+ boiler tube failure investigations, 400+ boiler remaining-life assignments, and CBB Well-Known RLA Organisation approval under the Indian Boiler Regulations sit behind the audit. Chambal Fertilisers ran it across 51 items on the G-1 and Ammonia-I plants.
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Overview
TCR Engineering Services Pvt. Ltd., NABL ISO/IEC 17025:2017 accredited in Navi Mumbai, delivers Knowledge-Based Audit, its branded Risk-Based Inspection per API 580 and API 581. A multi-disciplinary panel reviews design, operating history, inspection findings and damage-mechanism susceptibility across boilers, heat exchangers, pressure vessels, reactors, piping and tanks.
KBA is the company's branded delivery of Risk-Based Inspection per API 580/581. KBA is not boiler-only. It applies to boilers, heat exchangers, pressure vessels, columns, reactors, reformer tubes, piping, and tanks. Boilers anchor the practice; they do not bound it.
Overview
Representative engagement. Chambal Fertilisers G-1 and Ammonia-I plant, risk-based inspection per API 580 and API 581 with AiOM software across 51 items.
- Risk-based inspection: API 580 and API 581, 4th editions, January 2025.
- In-service inspection: API 510, API 570 and API 653.
- Integrity operating windows: API RP 584.
- Industry guidance: the Energy Institute Risk-Based Inspection Best Practice Guide.
- Representative engagement: Chambal Fertilisers G-1 and Ammonia-I plant, risk-based inspection with AiOM software across 51 items.
Standards: API 580 and API 581 (4th editions, January 2025), API 510, API 570, and API 653 (in-service inspection), API RP 584 (integrity operating windows), and the Energy Institute Risk-Based Inspection Best Practice Guide.
The KBA Method
A multi-disciplinary panel reviews equipment design, operating history, prior inspection findings, damage-mechanism susceptibility, and remaining-life curves, and issues a three-stream output:
| Stream | Action |
|---|---|
| Improve | Inspection interval revision, NDT method change, IOW tightening |
| Repair | Plug, weld overlay, sleeve, seal weld, partial replacement |
| Replace | Component replacement scheduled at next opportunity |
The Authority Anchors
- 1,500+ Boiler Tube Failure investigations.
- 400+ Boiler RLA assignments.
- 100,000+ replicated microstructure reference database.
- CBB Well-Known RLA Organisation approval under the Indian Boiler Regulations.
Cross-Vertical Application
| Vertical | KBA Application |
|---|---|
| Power generation | Critical and sub-critical, supercritical and ultra-supercritical, CFBC, AFBC, HRSG, waste heat boilers, package boilers |
| Refining | FCCU, hydroprocessing, hydrocracker, alkylation, sulphur recovery |
| Fertilisers | Ammonia synthesis loop, urea reactor, primary and secondary reformer, granulation, prilling tower |
| Petrochemical | Olefins crackers, polymer reactors, aromatics, methanol, melamine |
| Chemical processing | Caustic-chlorine, agrochemical reactor trains, fine chemicals |
| Steel | Coke oven battery, blast furnace, BOF, continuous caster (refractory and pressure boundary scope) |
| Pipelines | Cross-country mainline, CGD, LNG terminal piping (cross-pillar with AiOM-CCP) |
Knowledge-based inspection on video
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Frequently asked questions
What is a Knowledge-Based Audit?
KBA is TCR's branded delivery of Risk-Based Inspection per API 580 and API 581. A multi-disciplinary panel reviews equipment design, operating history, prior inspection findings, damage-mechanism susceptibility and remaining-life curves, then issues a three-stream output of improve, repair or replace, with revised inspection intervals and integrity operating windows.
Is KBA limited to boilers?
No. Boilers anchor the practice but do not bound it. KBA applies to boilers, heat exchangers, pressure vessels, columns, reactors, reformer tubes, piping and tanks, across power generation, refining, fertilisers, petrochemicals, chemical processing, steel plants and cross-country pipelines including city gas distribution and LNG terminal piping.
Which standards govern KBA?
API 580 and API 581 for risk-based inspection, API 510, API 570 and API 653 for in-service inspection, API RP 584 for integrity operating windows, and the Energy Institute Risk-Based Inspection Best Practice Guide. The boiler scope is backed by CBB Well-Known RLA Organisation approval under the Indian Boiler Regulations.
What evidence base supports the audit?
The practice draws on 1,500+ boiler tube failure investigations, 400+ boiler Remaining Life Assessment assignments and a reference database of more than 100,000 replicated microstructures, so risk judgements are calibrated against documented failure histories rather than generic likelihood tables.