Engineering Consulting Services

At TCR Advanced Engineering, our Engineering Consulting Services are designed to provide comprehensive, evidence-based solutions that address the most complex challenges faced by industries today. With decades of expertise in failure analysis, metallurgical assessment, fitness-for-service evaluations, and design validation, we help organizations safeguard critical assets, reduce risks, and enhance operational efficiency.

Our consulting practice blends world-class laboratory testing, advanced simulation tools, and deep metallurgical knowledge to deliver actionable insights that drive safety, reliability, and cost optimization across industries including oil & gas, petrochemical, fertilizer, power, aerospace, infrastructure, and manufacturing.

Why Choose TCR’s Consulting Services?

• Unbiased Root Cause Investigations – Independent assessments trusted globally.

• Regulatory Alignment – Compliance with ASME, ASTM, API, IBR, ISO, and NACE standards.

• Multidisciplinary Expertise – Metallurgists, corrosion experts, mechanical engineers, and certified inspectors.

• Practical Solutions – Repair methodologies, design modifications, and preventive recommendations.

• Proven Track Record – Over 9,000 investigations and 700+ FFS studies completed worldwide.

Our Consulting Capabilities

1. Failure Analysis

We specialize in Root Cause Analysis (RCA) of failed components—metallic and non-metallic—using Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS), metallography, and fractography.

• Metallic Components: Cracks, corrosion, wear, fatigue, brittle fractures.

• Non-Metallic Components: Polymers, composites, ceramics, FRP/GRP tanks—degradation due to UV, chemical attack, or thermal aging.

Each investigation concludes with corrective action plans to prevent recurrence, improve material selection, and enhance process reliability.

2. Remaining Life Assessment (RLA)

Our RLA services help operators understand the remaining service life of critical equipment:

• Process Plant Components: Heat exchangers, pressure vessels, piping systems.

• Boilers (IBR & ASME): Superheaters, reheaters, water walls, and headers.

• FRP/GRP Tanks: Composite tank and piping systems prone to chemical degradation.

• Life Assessment via Omega Method (ACRT): Creep and fatigue evaluations at high temperatures.

We combine NDT, metallography, creep studies, and operational history to deliver reliable life extension strategies.

3. Fitness-for-Service (FFS) Assessment

Following API 579-1/ASME FFS-1 guidelines, we evaluate whether aged or damaged equipment can safely remain in service.

• Level 1 (Screening): Quick assessments.

• Level 2 (Simplified Engineering): Flaw-specific evaluation.

• Level 3 (Detailed Analysis): Fracture mechanics, stress analysis, FEA.

Applications include pressure vessels, storage tanks, piping systems—supporting repair, continued operation, or replacement decisions.

4. Fire Damage & Accident Assessments

Post-fire investigations evaluate the structural integrity of tanks, piping, and machinery using:

• Temperature exposure mapping

• Hardness testing

• Metallographic examination

• Deformation analysis

We classify damage, recommend repairs/replacements, and support insurance claims and regulatory compliance.

5. Engineering Critical Analysis (ECA) – API 1104

Fracture mechanics-based evaluations of pipeline welds and defects.

• Determines crack acceptability.

• Uses CTOD data, FEA, and stress calculations.

• Prevents unnecessary repairs and supports safe operation.

6. Structural Stability Assessment & Certification

We assess industrial structures, chimneys, stacks, platforms, and equipment supports for:

• Corrosion, settlement, fatigue, overloading.

• On-site inspections, stress-strain analysis, and CAD-based modeling.

We also provide regulatory certification to ensure structural integrity and operational safety.

7. Engineering Design Review

Independent review of designs for:

• Structural soundness

• Code compliance (ASME Section VIII, API 650/620, ASME B31.1/31.3)

• Safety and functionality

We validate drawings, P&IDs, and stress reports to ensure error-free, reliable, and maintainable engineering designs.

8. Risk-Based Inspection (RBI) – API 580/581

We optimize inspection intervals and inspection plans by prioritizing high-risk assets:

• Static and rotating equipment

• Storage tanks

• Piping systems

• Pressure vessels

Our RBI assessments reduce unnecessary inspections while ensuring safety and cost efficiency.

9. Asset Integrity Management (AiOM Tool)

Our proprietary software platform (AiOM) integrates inspection data, risk assessment, corrosion monitoring, and maintenance schedules into a centralized dashboard.

Benefits:

• Real-time tracking of equipment health

• Predictive maintenance planning

• Regulatory compliance

• Reduced downtime & lifecycle cost optimization

10. 3D Laser Scanning & Digital Documentation

• Advanced LiDAR-based facility scanning

• Produces point clouds, CAD models, and as-built documentation

• Ideal for revamp planning, reverse engineering, and brownfield projects

11. Specialized Consulting Add-Ons

• Indigenization & Localization Support: Reverse engineering, vendor audits, and material selection for import substitution.

• Electrochemical Studies: Corrosion rate prediction through EIS, cyclic voltammetry, polarization tests.

• Material Selection & Vendor Audit: Ensuring right materials, reliable supply chains, and compliance with standards.

• Cathodic Protection Design: Advanced CP systems for pipelines, tanks, and marine structures.

  
  

Industries We Serve

• Oil & Gas

• Refinery & Petrochemical

• Fertilizer & Chemical Plants

• Power Generation

• Aerospace & Defence

• Infrastructure & Manufacturing

  
  

Benefits of Our Consulting Services

✅ Reduced unplanned shutdowns

✅ Extended asset life and operational safety

✅ Compliance with global codes and standards

✅ Data-driven maintenance planning

✅ Lower operational costs & improved reliability

Conclusion

TCR Advanced Engineering’s Engineering Consulting Services empower industries with the knowledge, expertise, and technical support needed to operate safely, efficiently, and sustainably. By combining world-class metallurgical insights with advanced diagnostic tools, we help clients make informed decisions that protect assets and maximize long-term value.