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Materials Testing Lab,

Corrosion Study, RBI,


Failure Analysis,
Advanced NDT Services,
Training and Consulting
TCR Arabia Company Llc.
P.O. Box 3422, No. 3 & 4, Besides Al-Kifah Construction Company,
Near Al-Kadi Tent Factory, King Abdulaziz Seaport Road,
Dammam, Kingdom of Saudi Arabia
Tel: +966-3-8475784/85 | Fax: +966-3-8475768
E-Mail: sales@tcr-arabia.com | URL: www.tcr-arabia.com

TCR Arabia : QA / QC Partner in KSA

TCR Arabia, founded in 2007, is a Joint Venture


Company between TCR Engineering Services
(India) and GAS Arabian Services (Saudi Arabia).
Backed by 37 years experience of NDT, Inspection
& Metallurgical Testing and Failure Analysis
services of TCR Engineering of India.
TCR is a global company with offices in KSA,
Kuwait, Qatar, India, Malaysia, South Africa, USA

Completed major projects for Saudi Aramco,


SEC, SWCC, SABIC, SIPCHEM, APPC, PetroRabigh
and other private companies in Saudi Arabia
Approved and Registered by all major companies
in KSA
Several appreciation letters received

Located in Eastern and Western Regions


Dammam and Jeddah
Laboratory in Dammam only

Cost-Effective and Fast Mobilization

Awaiting ISO 17025 accreditation


www.tcr-arabia.com

Proprietary & Confidential 2010-11

Solutions for Plant Reliability


Materials Testing
Laboratory
Tensile Testing, Bend Testing,
Hardness Testing, Impact Testing,
Welder Qualification, Chemical
Analysis Spectrometer, Intergranular Corrosion Tests, Salt
Spray, Sour Gas Corrosion
(HIC/SSC), Metallography, Micro
and Macro Examination
Microstructure Analysis
(SEM/EDAX/XRD)

Contract Research
and Development
Heat Treatment Studies
2D to 3D Conversion
Finite Element Modeling
Computer Aided Engineering (CAE)
Piping Stress Analysis
Advise on Materials

Engineering
Consulting
Risk Based Inspection
Fitness For Service
Damage Mechanism Study
Third Party Inspection

Failure Analysis and


Remaining Life
Fatigue Failure
Corrosion Related Failure
Operations Failure
Remaining Life Assessment
Boiler Assessment

Plant Shutdown
Management
Manpower Supply
API 510 Pressure Vessel Inspectors,
API 570 Piping Inspectors, API 653
Tank Inspectors, ASNT Level III
Experts, BGas Paint Inspectors,
Multi-Skilled NDT Level II
Technicians, CSWIP/AWS Certified
Welding Inspectors, QA/QC
Inspectors and Engineers, NACE
Cathodic & Coating Inspectors

TCR Arabia has a Strong and Experienced Team of Metallurgists, NACE Corrosion Specialists, RBI Specialists, Shutdown Managers, API 510/570/579 Inspectors,
AWS/CSWIP Welding Inspectors, ASNT Level III Manager, ToFD/PA Experts, Heat Treaters, Trainers, PCN Level II and ASNT Level II Technicians in KSA

Conventional NDT
Services
Ultrasonic Flaw Examination
Ultrasonic Thickness Survey
Magnetic Particle Testing
Liquid Penetrant Testing
Radiography Evaluation
Ferrite Measurement
Portable Hardness Measurement
Paint and Coating Thickness
Holiday Detection
Positive Material Identification

Advanced NDT
Services
Time of Flight Diffraction (ToFD)
Phased Array
In-situ Metallography
Eddy Current Testing
Corrosion Mapping
Corrosion under Insulation
Helium Leak Testing
Thermography
Internal Rotary Tube Inspection
Alternating Current Field Measure
Long Range Ultrasonic Testing
Robotic Crawler Video Inspection*
OTIS - In Service Tank Inspection
HD 200 - In Service Tank Cleaning
Close Interval Potential Survey
Direct Current Voltage Gradient
Survey

www.tcr-arabia.com

Heat Treatment
Services
Electric Resistance (PWHT)
Oil Firing on Pressure Vessels
Furnaces
Induction Heating

Training
Mechanical Metallurgy Laboratory
Microstructure Characterization
Metallurgy for Plant Executives
Corrosion Damage Mechanisms
Sour Gas Corrosion Testing
Fitness for Service Assessment
API 571 damage Mechanisms
Implementing RBI best practices
Failure and Root Cause Analysis
Introduction to NDT for Executives
Ultrasonic Testing Level I and II
Magnetic Particle Test Level I, II
Dye Penetrant Test Level I and II
Eddy Current Testi Level I and II
Radiography Testing Level II
Visual Testing Level II
Thermography Level I

Proprietary & Confidential 2010-11

Inspection Products
Modsonic UT Flaw Detectors,
Thickness Measurement
Oxford Instrument/Sanco - XRF
and OES
MiC Image Analysis Software
and LIMS
TCR HIC/SSC Lab Equipment and
Glassware
Time Portable Hardness

Flat Organization Structure


Abdulrahman K. Al-Dabal
Chairman

V.K. Bafna
Abdulrahman K. Al-Dabal
Rohit Bafna
Faisal K. Al-Dabal
Paresh Haribhakti
Board of Directors
Aref K. Al-Dabal
Managing Director

Paresh Haribhakti
Chief Metallurgist, R & D

Amit Bafna
Quality Head

Surendra Singh Kamal


Tech. Head (Metallurgy)

RBI and FFS

Contract Research
and Development

Engineering
Consulting

Failure Analysis and


Remaining Life

Mechanical Testing

Chemical Analysis

Corrosion

Metallography

Conventional NDT
Services

Advanced NDT
Services

Syed Ameen Hassan


Country Manager
Kamran Ahmed
Shariff
Admin
Rahul Singh
Sales

Jaidev Patel (Level III)


Tech. Head (NDT)

Tabreez
Sp. Projects

Heat Treatment
Services

Training

Inspection
Products

Rohit Bafna
Marketing
Percy Lakdawala
Human Resources

www.tcr-arabia.com

Plant Shutdown
Management (India)

Proprietary & Confidential 2010-11

Plant Shutdown
Management (USA)

Noteworthy Works

ToFD Project in PetroRabigh

PWHT Project in Khurais

NDT Works on the Haram Expansion Project in Mecca

NDT Training for Employees of TuV


PMI with Carbon at Saudi Kayan

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Proprietary & Confidential 2010-11

Major Projects by TCR Arabia


Client

Project Description

Location

Tekfen

Automated UT Using ToFD on 8mm-80mm thick


piping as per ASME Code Case 181

PetroRabigh (UOU) Project

Sinopec

Automated UT Using ToFD on 9mm-65mm thick


piping as per ASME Code Case 181

PetroRabigh Project

Al-Tawleed Energy

Post Weld Heat Treatment using Electric Resistance


and Induction Resistance

Shoiba Power Plant

Tekfen

Positive Material Identification using XRF alloy


analyzer and Portable Hardness Measurement

PetroRabigh Project

Tekfen

Automated UT Using ToFD on 8mm-80mm thick


piping as per ASME Code Case 181

Khurais (KUC) Project

Nasser Al-Hajri

Positive Material Identification using Optical


Emission Spectrometer for Carbon Detection

Saudi Kayan Project, Jubail

Saipem

Positive Material Identification using Optical


Emission Spectrometer for Carbon Detection

Khurais (KUC) Project

Encocorp

Automated UT Using ToFD on 20mm thick piping as


per ASME Code Case 181

KAIA Project, Jeddah

CEPCO/SWCC

Remaining Life Assessment / NDT Services of Boiler


# 83 at SWCC Jubail

SWCC, Jubail

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Proprietary & Confidential 2010-11

Materials Testing Lab in Dammam

Tensile Testing
Bend Testing
Hardness Testing
Impact Testing
Welder Qualification
Chemical Analysis Spectrometer
Intergranular Corrosion Tests
Salt Spray
Sour Gas Corrosion (HIC/SSC)
Metallography
Micro and Macro Examination
Microstructure Analysis
(SEM/EDAX)

Proof Rings and High Pressure


Autoclaves for NACE Tests

100KN Tensile Testing


Optical Emissions Spectrometer

Impact Testing
Inverted Metallurgical Microscope

TCR Arabia conducts tests as per ASTM, NACE, API, AWS, ASME or Client-Supplied Specifications

www.tcr-arabia.com

Proprietary & Confidential 2010-11

Welder Certifications and WPQR

Coupon Testing as per Weld Procedure Qualification

In depth weld inspection to include review of the applicable


qualification

Weld procedure specification, welder performance qualification


and validity for process materials and consumable items,
equipment, set up and other factors, including certificates of
calibration and/or conformity governing the work.
Check safety of set up and operation having due regard for self,
welder and other workers in vicinity, particular in respect of
ultraviolet radiation from arc during welding.

Complete Services conducted by Experienced AWS/CSWIP


Inspector

www.tcr-arabia.com

Includes visual examination, mechanical testing, metallographic


examination and non destructive testing

Welder Qualification Testing Inspection for performance


qualification and certification of welders to ASME, AWS, API code
Preparation of Weld Procedure Qualification
Documentation of the Procedure Qualification Record

Proprietary & Confidential 2010-11

Failure Analysis and RLA

Over 800 failure investigations completed to date

Remaining Life Assessment (RLA) of Several Boilers


completed for SWCC

Unravel the mysteries surrounding parts and assembly


failures

Fatigue Failure
Corrosion Related Failure
Operations Failure
Remaining Life Assessment

Corrosion Evaluation Of Oil Well Tubing

Strong Experience undertaking wide range of root


cause failure analysis projects

Strong History of Past Work, some examples:

Sipchem, Tasnee, APPC, SWCC and others are regular


customers of TCR Arabia in KSA

Residue Analysis
Corrosion Analyses/Studies
On-Site Investigations
Material Selection
Manufacturing Processes Evaluation
Welding Studies
Product Design Evaluation
Fractography
Heat Treatment Errors
Product Selection Issues

Mandrel Bypass Of Equalizer Sub.

Fast Turnaround time with in-depth analysis reporting


Coriolis mass flow
meter sensor failure

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Proprietary & Confidential 2010-11

Riser Pipe Failure

RLA & Condition Assessment of Boilers

Level II and Level III assessments based on calculation and


design approaches, including steps such as:
Collection of background data and history of Boiler
Operation.
Understanding the actual degradation mechanism
Fatigue
Thermal Fatigue
Thermo Mechanical Fatigue
Thermal Aging
Creep
Embitterment
Corrosion
Thorough visual examination by an expert
Dimensional measurement at critical locations
Collection of scale and deposits samples and its analysis
Detailed Thickness Survey
Internal oxide scale measurement at Super Heater Tube
and Re-heater Tube
WFMPI of main weld joints of Header and Steam Drum
In-Situ metallograpy to determine thermal ageing and
creep related problem from a RLA perspective
In-Situ hardness measurement with portable hardness
tester
Suggestions on Repairing

If required, repairing of the equipment is suggested, for life


extension.

Component

Main Cylindrical
Shell

Furnace tubes
with
bowling hoops

Smoke Tubes
and
Stay Tubes

Front & rear tube


plates and end
plates of wet back

Reversal
Chamber

Tests

Location to be checked

Visual

100% after removal of insulation

Thickness Measurement

Random

WFMPI/UT

Weld joints, Side holes, mud


holes and blow down outlet

Replica & Hardness

Replica & hardness shall be on


weld/HAZ & parent

Visual

100% thru the hot gases side


with weld joints

Thickness Measurement
WFMPI & UT

Random
Weld Joints

Replica & Hardness

Replica & hardness shall be on


weld/HAZ & parent

Visual

100%

WFMPI

Tube to Tube Plate weld joints

Thickness Measurement

Random

Replica & Hardness

Replica & hardness shall be on


weld/HAZ & parent

Visual

External Side

WFMPI/UT

Circumferential Weld seam

Thickness Measurement

Random

Replica & Hardness

Replica & hardness shall be on


weld/HAZ & parent

Visual
WFMPI
Replica & Hardness

Weld Joints
Replica & hardness shall be on
weld/HAZ & parent

Calculation and Judgment of Remaining Life based on


Analysis
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Proprietary & Confidential 2010-11

10

In-Situ Metallography
Onsite Examination and Evaluation of Plant Equipment
Equipment and piping operating at elevated temperatures
undergo microstructural changes which can reduce
original design properties and cause unexpected failures
Study of Replica under SEM and Optical Microscopes in
Laboratory

Field Metallography can be used as a tool to determine


remaining life, fitness for service, and damage
assessment from creep mechanisms or fire damage.
Useful in determining the cause for cracking, degree of
overheating, verification of alloy type or other damage
mechanisms manifested by microstructural changes
Applications in Heater Tubes, Boiler tubes, Superheater
tubes, Steam Piping & Tanks

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304SS Tube Creep Voids

Proprietary & Confidential 2010-11

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Risk Based Inspection (RBI)


TCR Arabia and PP Simtech (UK) offer RBI as per API 580

Proprietary & Confidential 2010-11

Possible

Somewhat Unlikely

Internal corrosion (general, grooving, pitting, crevice, under deposit,


galvanic, biological), External corrosion (general, localized, CUI), Erosion &
Erosion Corrosion, Stress Corrosion Cracking (Cl, NH3, caustic, CO/CO2,
amine, methanol), High Temperature Creep, Fatigue (thermal, mechanical,
pressure, vibration), H2S induced corrosion or cracking, Metal Dusting, H2
damage / cracking

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Minor
Low

Exceeds RBI 'best-practice' guide for API 580 and UK HSE


Technology supported by rbiAsyst software system
Multi-discipline teams record the RBI team studies & updates

Risk matrix created and studied for each item of a plant

Significant

Unlikely

Unplanned outages/ extended T/As can have severe financial impact


Incidents affect reputation and have safety consequences

RBI methodology and tool by TCR Arabia-PPS has been proved


successful against rigorous audits by UK HSE

Severe

Profit Linked to Reliability

Major

Very Unlikely

Enable Plant Personnel's make informed business decisions regarding


inspection and maintenance spending

Extremely Unlikely

CONSEQUENCE

PROBABILITY

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Conventional NDT Services

Ultrasonic Flaw Examination


Ultrasonic Thickness Measurement
Magnetic Particle Testing
Liquid Penetrant Testing
Radiography Evaluation
Ferrite Measurement
Portable Hardness Measurement
Paint and Coating Thickness
Holiday Detection
Positive Material Identification

Portable Optical Emissions


Spectrometer for PMI with
onsite Carbon Detection

XMet 3000TX

Niton XLT

Ultrasonic Flaw Detection


Modsonic Einstein II-DGS

XMet 3000
Fisher Ferrite Meter

Coating Thickness Gauge

EPOCH LT
Portable Hardness

www.tcr-arabia.com

Proprietary & Confidential 2010-11

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Advanced NDT Services

Time of Flight Diffraction (ToFD)


Phased Array
In-Situ Metallography
Eddy Current Testing
Electro-Magnetic Acoustic Transmission (EMAT)
Corrosion Mapping
Corrosion Survey under Insulation
Helium Leak Testing
Thermography
Internal Rotary Tube Inspection (IRIS)*
Alternating Current Field Measurement (ACFM)*
Long Range Ultrasonic Testing (LRUT)*
Robotic Crawler Video Inspection*
OTIS - In Service Robotic Tank Inspection*
HD 200 - In Service Robotic Tank Cleaning*
Close Interval Potential Survey (CIPS)*
Direct Current Voltage Gradient Survey (DCVG)*

OmniScan MX from Olympus NDT for ToFD and PA

Alcatel ASM 142 - Helium Leak Detection

Heat Exchanger Tubing Tested with Eddy


Current and IRIS

www.tcr-arabia.com

Proprietary & Confidential 2010-11

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ToFD and Phased Array

TCR Arabia has 5 Saudi Aramco qualified crews

Completed Major projects in PetroRabigh, Khurais, Sinopec and


Kuwait Oil Company

Strong Experience in Rapid Scanning of Welds in Piping, Storage Tanks


and Pressure Vessels with well defined procedures

This technique has many advantages

Wide coverage area using a pair of transducers


Accurate flaw sizing; amplitude-independent, Sizing
technique using time-of-flight information
One-line volume inspection, provides very fast scanning
Setup independent of weld configuration
Very sensitive to all kinds of defects. No sensitivity to defect
orientation
Amplitude-insensitive, acoustical coupling less critical

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Proprietary & Confidential 2010-11

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In-Service Storage Tank Inspection

Robotic Crawler Video Inspection for ASNT Tanks

Quik-Look for inspection of underside of AST fixed roof and roof support
columns without removing the tank from service
Compact, portable video camera inspection service

OTIS - In Service Robotic Tank Inspection & In Service Robotic Tank Cleaning

Systematically scans the tank bottom with an array of eight ultrasonic


transducers, and relays high-volume UT data for analysis. The robot pushed
sludge aside as it travels making cleaning and waste disposal unnecessary.

Determine the amount and distribution of material in the tank


Determine tank conditions such as corrosion and scaling.

Crawler Video Inspection

Eliminate the high cost of taking down your tanks


Complete an API 653 inspection in days instead of weeks or months
Avoid disruptions in normal service and keep revenue consistent
Perform repairs only as needed
Minimize impact to your costs and operations
Reduce environmental and safety risks without opening the tank or due to manned
entry

The tank inspection report provides a complete, 10-year API 653 report on
the condition of your tank. The report will include:

Top-side and bottom-side corrosion locations


Floor-plate thickness and pitting
Videotape of roof underside and vapor space structures
Fiberglass coating measurement

www.tcr-arabia.com

Robotic Tank Inspection

Proprietary & Confidential 2010-11

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Plant Shutdown Management


Personnel available with strong experience
Design, fabrication, construction, inspection and
erection of Pressure Vessels, Heat Exchangers,
Towers, Stacks, Tanks, Plant Pressure Piping,
Offshore oil wells and many advanced projects

TCR Arabia can quickly mobilize


experienced manpower

Experienced Reliability Experts


Metallurgists and Engineers
API 510 Pressure Vessel Inspectors
API 570 Piping Inspectors
API 653 Tank Inspectors
ASNT Level III Experts
BGas Paint Inspectors
Multi-Skilled NDT Level II Technicians
CSWIP/AWS Certified Welding Inspectors
QA/QC Inspectors and Engineers
NACE Cathodic & Coating Inspectors

www.tcr-arabia.com

Proprietary & Confidential 2010-11

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Engineering Design & Analysis Services

Piping Stress Analysis on Ceasar II


Computer Aided Designing (CAD/CAM)
2D to 3D Conversions, Solid Modeling, Surfacing for
automotive, machinery and construction industries, Legacy
Data Conversion for Material Handling Equipments

Computer Aided Engineering (CAE) including Finite


Element Modeling
FE stress analysis undertaken of
cylinder block, cylinder head, connecting rod
crankshaft & crankcase, shock absorber structure including outer
tube, spring seat, knuckle etc

Structural Analysis
Noise, Vibration, Harshness (NVH) analysis
Leading Software used
CATIA, Pro/ENGINEER, UniGraphics, I-DEAS, Inventor,
SolidWorks, DELCAM, Ansys, LS Dyna, HyperMesh, NX
Nastran, Moldflow

www.tcr-arabia.com

Proprietary & Confidential 2010-11

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Heat Treatment Services


TCR Arabia conducts Post Weld Heat Treatment (PWHT) using 70 Kva
Electric Resistance Machines
Completed major PWHT jobs in Khurais and Saudi Kayan Project

TCR Arabia PWHT Crew at Work

www.tcr-arabia.com

Proprietary & Confidential 2010-11

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Technical Training Courses

Mechanical Metallurgy Laboratory Level I and II


Microstructure Characterization
Metallurgy for Plant Executives and NDT Inspectors

Understanding Corrosion Damage Mechanisms


Sour Gas Corrosion Testing Level I and II

Fitness for Service Assessment Training


Understanding API 571 damage Mechanisms
Implementing RBI best practices in Plants

Failure and Root Cause Analysis : Guide

Introduction to NDT for Plant Executives


Ultrasonic Testing Level I and II
Magnetic Particle Testing Level I and II
Dye Penetrant Testing Level I and II
Eddy Current Testing Level I and II
Radiography Testing Level II
Visual Testing Level II
Thermography Level I

Gas Tungsten Arc Welding for Qualified Welder


Shield Metal Arc Welding for Qualified Welder

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Proprietary & Confidential 2010-11

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Inspection Products
TCR Arabia markets and represents the following products in KSA

www.tcr-arabia.com

Proprietary & Confidential 2010-11

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Summary

We listen closely and document each customer


interaction
Deep understanding of project needs and
adherence to timelines
Well documented internal work procedures that
meets client/inspection agency approvals

Customer
Drive
Developing
People

Strong commitment to local community

Building

Commercial
Edge

trust

Active participant in Saudi Chapter of ASNT


Sponsors of Abdullah Al-Dabal Indoor Football
Tournament

Health,
Safety &
Environment
mindset

Highly Competitive Pricing and Fast Mobilization

Ability to Ramp Up team resources very quickly

through
Handson
Execution
Openness
and
Honesty

Strong foundation to arrange for visas and other


formalities

www.tcr-arabia.com

Proprietary & Confidential 2010-11

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Questions?
Contact:
Syed Ameen Hassan, Country Manager
syed@tcr-arabia.com | +966-50-4997683

TCR Arabia Company Llc.


P.O. Box 3422, No. 3 & 4, Besides Al-Kifah Construction Company,
Near Al-Kadi Tent Factory, King Abdulaziz Seaport Road,
Dammam, Kingdom of Saudi Arabia
Tel: +966-3-8475784/85 | Fax: +966-3-8475768
E-Mail: sales@tcr-arabia.com | URL: www.tcr-arabia.com