TCR Advanced was engaged to assess the metallurgical integrity of different components and equipments including pipe lines, flanges, Heat Exchangers, Reactors etc to judge the extent of damage by microstructure examination at Reliance Industries Limited Jamnagar at the time of major fire incident of VGO-HT2 plant. Total 1200 microstructures were prepared and evaluated at site to judge GO / NO-GO condition of the refinery components. The dedicated team of TCR Advanced has worked round the clock and completed the marathon assignments in the record 15 days time. The metallurgical experts from TCR Advanced had provided the judgments based on our vast experience of evaluation of different Refinery components and failure investigation related expertise.

We had a bend failure in our hydrogen line in 2006 and we contacted TCR Advanced Engineering Pvt. Ltd., Vadodara to conduct an in-depth root cause failure analysis. The work carried out by the dedicated team of TCR helped Godrej Industries to take necessary corrective actions for the second hand plant of "Hydrogen Generation" procured form England. The entire plant was thoroughly assessed by NDT and metallography with Health Assessment approach by TCR. The components included Reformer section, Pigtails, SS pipelines /Carbon steel/Alloy steel pipe lines Heat exchangers etc. TCR’s assessment approach is scientific by knowledge of anticipated degradation mechanism of different components with organized team work by trained and qualified man power.

Total 8-Boilers of different capacities were evaluated for their remaining life by detailed metallurgical approach. Based on the operational and design/construction of the boiler their damage mechanisms were anticipated. With NDT, In-situ metallograrphy and chemical analysis of Boiler feed water/scales and corrosion products vis-à-vis metallurgical degradations under microstructure were compared. The safer remaining life was evaluated based on microstructure degradations and thickness measurements criteria’s. The recommendations were made to operate these boilers for safe and efficient use. TCR Advanced has very rich data based on different power boilers which are operated from 10Mw to 250 Mw capacity. TCR Advanced is also engaged by different RLA agencies to undertake metallography evaluation which is most critical in Life assessments.

M/s GSFC, Baroda has Fertilizer & Chemical Plants at Fertilizernagar, Baroda. In April-May 2007, TCR Advanced Engineering P Ltd was apprised about loss of weldability in the Tee components located between hot & cold headers of Primary Reformer, of Ammonia-IV plant. It was a dire need to formulate the welding procedure to achieve crack free weld joint, to put back the plant in operations at the earliest.. Considering fundamental inferences from microstructure degradations and reviewing of various reports of analysis / tests and discussions, the most probable reason for loss of weldability is judged with an objective to provide solution to improve the weldability and formulated weld procedure. Prima facie, the probable reason of loss of weldability seems to be associated with carbide coarsening & their agglomeration under the microstructure observations. Also, carbide alignment was noticed under the influence of complex stresses of operation. As per the fundamental understating if the carbide precipitations could be re-dissolved in the matrix by sending important alloying elements like Niobium and Chromium back in to the solution . An elaborate repair welding procedure is suggested in the report that principally accentuates on carrying out "Solution Annealing Heat Treatment". Finally, the effectiveness of solution annealing heat treatment has to be assessed to propitiate proper procedure for repair welding purely on metallurgical considerations which can only mitigate the grave situation as a result of post weld cracking that had put the production at grinding halt.

As a requirement, to be used in a Urea plant the M.S. plate is to be overlaid with stainless steel welding. The base material is SA 516 Gr. 70. The weld over lay is of 6 mm thickness. As per the Snamprogetti specification, the chemical composition on the surface of over lay should be 2 RE69, which is equivalent to 310 MoLN. The essential requirement is that the surface shall be free from deleterious phases like carbides, delta ferrite and sigma phase, whose sensitivity for deterioration in presence of Urea is extremely high.

Total 6 hydro cracker reactors manufactured by Kobe Steel Japan had developed blisters at the SS 347 weld overlay form Inside. The health assessment approach was undertaken with detailed microstructure examinations form OD /ID with different etching technique to find out extent of degradations in terms of sigma phase and carbide precipitations and other degradation due to prolonged use. The reason of blisters were identified and the inputs were provided to repair welding of the Reactors.

The high grade Inconel 600 Reactor were to be imported from Taiwan by GFL. TCR Advanced was deputed to judge the heath of these Reactors and recovery columns by undertaking various NDT Test. The health of these equipments were judged to provide the final decisions on procurements which helped the company to not only get the writhe equipment by find out the safe useful life.

RLA was conducted for package boiler at Unilever Bangladesh Limited,. And asked to replace certain tubes.

TCR-KIL approached TCR advanced for metallurgical assessment of cracks observed on the Ball mill a very critical equipment for a cement mill. A detailed report were subjected with the reasons of carking by undertaking NDT approach of assessments.