RT Crawler Technique Gets Saudi Aramco's Nod: A Game-Changer for Pipeline Radiography
TCR Arabia's RT Crawler Technique approved by Saudi Aramco. Faster pipeline weld inspection with digitalized film storage across all diameters.
Services · Non-Destructive Testing
Cross-Country and CGD Pipeline Radiography per API 1104
More than 14,000 girth welds across over 2,600 km of cross-country and city-gas pipeline, with radiographic film digitised to Indian Oil and GAIL requirements for the National Gas Grid.
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Overview
TCR Engineering Services Pvt. Ltd., a NABL ISO/IEC 17025:2017 accredited laboratory (NABLT0726MH18640) headquartered in Navi Mumbai, provides cross-country and city gas distribution pipeline radiography per API 1104. The practice covers 14,000+ girth welds across 2,600+ km of mainline, delivered under AERB operation licence 23-IRLOP-893925 in India, Nepal and Saudi Arabia.
Overview
At TCR Engineering, we offer a complete range of pipeline-related services for cross-country and city gas distribution (CGD) pipelines, focusing on inspection, material verification, and asset integrity management.
Our services include Automated Radiographic Testing (ART), Ultrasonic Testing (UT) with advanced methods like Phased Array (PaUT) and Long-Range Ultrasonic Testing (LRUT). We specialise in the digitalisation of RT films as per IOCL and GAIL standards and provide destructive testing for PQR/Welder qualification and material confirmation. Our O&M services utilize advanced technology for pipeline asset integrity management (AIM), including Engineering Critical Analysis (ECA), failure analysis, corrosion assessments, robotic inspections, and leak detection using smart pigs. We also monitor cathodic protection (CP) systems to ensure long-term pipeline integrity.
With a focus on safety, efficiency, and data-driven decision-making, TCR Engineering is your trusted partner for maintaining the health of critical pipeline infrastructure.
Pipeline Weld Inspection
TCR Engineering's Pipeline Inspection for Anomalies services are designed to detect defects and discontinuities in pipelines using advanced radiographic and ultrasonic testing methods. By employing tools like internal crawler robots, external X-ray/gamma radiation, and automated ultrasonic testing, we can inspect pipelines with precision, ensuring their integrity and safe operation.
Our comprehensive approach adheres to relevant industry standards like API 1104, guaranteeing reliable results that help our clients mitigate risks and maintain pipeline health.
Automated Radiographic Testing (ART) of Circumferential Butt Welds from Internal Pipelines Using Crawlers
Automated Radiographic Testing (ART) involves the use of high-resolution imaging technology to inspect circumferential butt welds inside pipelines. We deploy specially designed crawler robots that travel inside the pipeline to scan welds with precision. This method allows for internal inspections where external access may be limited or challenging.
ART is particularly useful for large-diameter pipelines and provides a comprehensive evaluation of weld integrity, enabling the detection of both surface and subsurface defects.
External X-Ray or Gamma Ray Radiation for Detection of Surface and Subsurface Defects in Welds
For pipelines where internal access is restricted, External Radiographic Testing using X-ray or gamma-ray technology is applied. This method enables the detection of both surface and subsurface anomalies in pipeline welds. The process works by emitting radiation through the weld area, capturing images of any defects that may compromise the structural integrity of the pipeline.
This non-invasive testing technique is ideal for pipelines that must remain operational during inspection and complies with API 1104 standards for welding inspections.
Computed Radiography
TCR Engineering has strong expertise in Computed Radiography (CR) as per ASTM E 2033 and ISO 17636-2 which is an advanced form of radiographic inspection that uses imaging plates (IP) instead of traditional X-ray films to capture images of pipeline welds. These plates, coated with phosphor, store the radiographic image when exposed to X-rays or gamma rays.
The stored image is then read by a laser scanner and converted into a digital image, which can be viewed, analysed, and archived electronically. The adoption of Computed Radiography (CR) in the inspection of cross-country pipelines offers numerous advantages over conventional radiography testing, from improved image quality and faster turnaround times to enhanced environmental safety and cost-effectiveness.
UT Shear-Wave Anomaly Evaluation, Phased Array (PAUT) and ToFD for Seam-Weld Assessment
Ultrasonic Testing (UT) is used to detect anomalies like cracks, lack of fusion, and other discontinuities in seam welds. The shear-wave UT technique is particularly effective for identifying these anomalies by introducing ultrasonic waves at an angle to the weld seam.
Phased Array Ultrasonic Testing (PaUT): PaUT provides a more detailed and dynamic evaluation of welds by using multiple ultrasonic beams, which can be steered, focused, and scanned electronically. This allows for greater coverage and sensitivity to defects, making it ideal for inspecting complex geometries.
Time-of-Flight Diffraction (ToFD): ToFD complements PaUT by detecting and sizing defects using the diffraction of ultrasonic waves. It is highly accurate for locating crack tips and providing a quantitative assessment of defect size. The combination of PaUT and ToFD ensures a thorough evaluation of seam welds, with high sensitivity to both small and large anomalies.
Automated Ultrasonic Testing and LRUT / Guided Wave Including A-, B-, and C-Scans
Automated Ultrasonic Testing (AUT) and Long-Range Ultrasonic Testing (LRUT), also known as Guided Wave Testing, are powerful tools for pipeline inspection, particularly in situations where accessing the entire pipeline is impractical. LRUT allows for the inspection of long sections of pipeline from a single access point, making it cost-effective for detecting corrosion, cracks, and other anomalies over large distances.
A/B/C-scans provide detailed cross-sectional images of the pipe’s wall thickness and defect locations, ensuring comprehensive evaluation as per API 1104 standards for pipeline welding.
- A-Scan: Displays the amplitude of received ultrasonic signals, helping identify the depth of defects.
- B-Scan: Provides a side-view image of the pipeline, showing the thickness of the walls and the presence of defects.
- C-Scan: Gives a plan-view image of the pipeline, mapping the location and extent of anomalies across the pipeline's surface.
Weld Assessment of Difficult-to-Access, Small Diameter Pipes (1.5 Inch to 3.5 Inch)
For pipelines with smaller diameters (1.5” to 3.5”), weld inspection becomes more challenging due to space constraints. TCR Engineering employs specialized palm scanners that are designed for these hard-to-reach areas. These handheld scanners use high-frequency ultrasonic waves to inspect welds in small-diameter pipes, ensuring comprehensive coverage even in difficult-to-access locations.
This method allows for the detection of anomalies like incomplete fusion, porosity, and cracking that can compromise the integrity of small-diameter pipelines.
Digitalisation of RT Films
TCR Engineering's Bengaluru-based central operations team, comprised of IT and Google-certified experts, remotely coordinates with sites across India to ensure compliance with stringent film density and resolution standards all conducted in full accordance with ASME Section V - Article 2, and ASTM E 1936.
Key Benefits of NDT Film Digitisation:
- Prevents film degradation while maintaining image quality
- Eliminates physical storage costs for films
- Allows secure storage on custom developed Google Cloud platform
- Enables archiving of inspection RT reports including UT and MPI data
- Utilises Artificial Intelligence (AI) for easy retrieval and comparison of scans
Standards: API 1104 (welding of pipelines and related facilities), ASME B31.4 and B31.8 (liquid and gas pipeline transportation codes), SAEP-1143 (Saudi Aramco radiographic engineering procedure), IBR 1950 with amendments, AERB Safety Manual AERB/RF-IR/SM-1 Rev. 2, with SMPV(U) Rules 2016 and Gas Cylinder Rules 2016 (PESO).
Saudi Aramco Anchor
Saudi Aramco approved Radiographic Standard Procedure TCR.QCP.REV-02 (2023) is conformant with SAEP-1143 (Engineering Procedure for Radiographic Examination, 6 September 2020). Saudi Aramco Engineering Report SAER-13115 dated 8 September 2025 names TCR as the technology provider for the Internal RT Crawler with $4,980,000 documented cost avoidance over five years (approximately 80 percent reduction).
Internal RT Crawler specifications. 16 inch to 52 inch diameter range. 160, 200, and 300 kV X-ray heads at 5 mA. ±5 mm positioning accuracy. Operating temperature range minus 10 to plus 70 degrees Celsius.
AERB Regulatory Stack
| Credential | Document | Validity |
|---|---|---|
| Operation Licence | 23-IRLOP-893925 | Active |
| Source Storage Facility, Mumbai | 22-ASSF-793303 | Valid 28 June 2027 |
| Source Storage Facility, Bhubaneswar | 23-ASSF-927086 (Plot 125/2094, Vishnu Vihar) | Valid 30 August 2027 |
| RSO 1 | Shemi K B, 21-RSO-681725 | Active |
| RSO 2 | Ananta Kishore Parida, 22-RSO-734005 | Active |
| BARC leak certificates | Multiple | 2024 |
Cross-border permission: Nepal Oil Corporation Ref 2080/81 dated 30 July 2023 for the Motihari to Amlekhgunj International Pipeline (MAPL) Phase II via Likhita Infrastructure (the first non-GCC cross-border deployment).
Engineers India Limited (EIL) PMC Approval Pack, 12-Year Footprint
EIL approval covers BPCL Kochi NHDS/SRR Health Check IREP (2012), OPaL Petrochemical Complex Dahej (2013), PNCPL/NRL Bhubaneswar lab approval (2023), multiple EIL-approved Procedure Qualification Records spanning 16 inch to 24 inch diameter on GAIL MNJPL, NRL Brahmaputra River Crossing, ADPL HDD Odisha Rivers, and KGPL, plus EIL Approval renewals 2024 to 2025.
Other Owner / Consultant Approvals
- Adani-Total / Dhamra LNG Terminal: Letter Ref 2340-RLNG-DLTPL-NRP-L-0005 dated 20 October 2021 (EPCC NRP Projects, PMC Wood).
- BHEL NTPC Talcher TTPP-III: BHEL email dated 20 December 2025 approving TCR for the 2 x 660 MW NTPC Talcher Project via Power Mech Projects.
- CGD operator approvals: Bhagyanagar Gas Limited (HPCL-GAIL JV) BGRL Spread-2 Maharashtra via Tractebel ENGIE PMC (June 2021) and Karnataka via Tolani Projects (2022); Green Gas Limited Lucknow GA (December 2022); Torrent Gas Karaikal Puducherry (June 2023).
IOCL PQR Pack
IOCL Procedure Qualification Records covering 12 inch through 36 inch diameters, the foundation of cross-country pipeline mainline radiography.
Track Record
- 14,000+ pipeline girth welds radiographed across 2600+ kilometres of cross-country mainline.
- 9,266 weld joints digitally scanned and cloud-archived on a single project (EnProCon TJTC Kolar).
- 20+ named cross-country pipeline projects with 15+ master contractors.
- Three PWHT engagements delivered alongside RT.
Pipeline radiography on video
TCR publishes its own work on YouTube. One film is below, recorded on the bench and in the field. Each one loads only when you press play: nothing is requested from Google before that.
Related insights
10 of the 65 published insights tagged to Non-Destructive Testing bear directly on Pipeline Radiography. The 6 most relevant are below.
Computed Radiography for Cross-Country Pipelines
TCR Engineering, with its expertise in Computed Radiography (CR), is committed to providing reliable and high-quality NDT services
General Approach for ECA of Girth Welds in Pipelines: A Practical Guide for Large-Diameter Gas Lines
Engineering Critical Analysis of girth welds transforms weld acceptance from guesswork into science-backed decisions for pipeline integrity
TCR Arabia completes Radiography Level II for TUV Rheinland
Trained a group of 6 students from TUV Rheinland
Pipeline Integrity Assessment Services India: Your Complete Guide to Asset Protection
Pipeline integrity assessment services India with 50+ years expertise. TCR Engineering prevents failures through advanced NDT and AI technology.
Preserving Pipelines, Protecting Investments: TCR's Cathodic Protection Solutions
Safeguard pipelines with TCR's expert cathodic protection solutions, ensuring durability and cost efficiency in oil & gas.
Read all 65 Non-Destructive Testing insights →All insights →
Documents
Download the reference documents for this page. Every file is hosted on this domain and is also listed in the site document library.
Frequently asked questions
Which standards govern TCR's pipeline radiography?
Weld acceptance follows API 1104 for pipelines and related facilities, with ASME B31.4 and B31.8 as the transportation codes. Saudi Aramco work runs to SAEP-1143 under approved procedure TCR.QCP.REV-02. Computed radiography follows ASTM E2033 and ISO 17636-2, and film digitisation follows ASME Section V Article 2 and ASTM E1936.
Can welds be radiographed from inside the pipeline?
Yes. Internal RT crawlers travel inside the line and radiograph circumferential butt welds where external access is limited, covering diameters from 16 inch to 52 inch. Saudi Aramco Engineering Report SAER-13115 dated 8 September 2025 names TCR as the technology provider for the Internal RT Crawler.
What is TCR's cross-country pipeline track record?
TCR has radiographed 14,000+ pipeline girth welds across 2,600+ km of cross-country mainline, with IOCL procedure qualification records covering 12 inch to 36 inch diameters. Cross-border work includes the Motihari to Amlekhgunj International Pipeline into Nepal, executed under Nepal Oil Corporation permission via Likhita Infrastructure.
Does TCR digitise old RT films?
Yes. RT films are digitised to IOCL and GAIL requirements in full accordance with ASME Section V Article 2 and ASTM E1936, then archived on a secure cloud platform with AI-assisted retrieval. On a single project, 9,266 weld joints were digitally scanned and cloud-archived.
Is TCR licensed to handle radiography sources?
Yes. TCR holds AERB operation licence 23-IRLOP-893925 with licensed source storage facilities in Mumbai (22-ASSF-793303, valid to 28 June 2027) and Bhubaneswar (23-ASSF-927086, valid to 30 August 2027), certified Radiological Safety Officers, and BARC leak certificates for its sources across India.