 |
 What
services are offered by Material Engineering Services? |
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We offer Material Failure Analysis, Condition Monitoring of
high temperature components
during shutdowns, Remaining Life assessment of aged / damaged
components and Fitness
for service assessment of Fire damaged components.
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What
are the facilities available with ITL under Material Engineering
Services? |
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We have both laboratory & portable equipments to cater to
the needs of Material Failure
Analysis, Condition Monitoring of high temperature components,
Remaining Life assessment
of aged / damaged components and Fitness for service assessment
of Fire damaged
components. The laboratory equipments include Advanced Optical
microscope (Reichert
Jung make) with a Leica image analyser, Scanning Electron Microscope
( Jeol make) with
Energy dispersive spectrometer attachment, Bulk Vickers / Brinell
& Micro Vickers hardness
tester, Digital servo hydraulic universal testing machine (Instron
8502 model 25 ton),
Charpy Impact testing machine, Corrosion inhibitor evaluation
facility etc. The portable
equipments include Alloy analyser (Texas nuclear make), Spark
Emission Spectrometer
(WWAS make), Insitu metallography kit with replication unit,
Rebound & indentation type
portable hardness testers, Ultrasonic high temperature thickness
meter, conventional NDT
kits etc.
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What
do you do under Condition monitoring? |
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We undertake the study of microstructural degradation of high
temperature components
on a periodic basis and compare the same with respect to virgin
material. From this we
qualitatively predict the material damage to recommend the suitability
of the components
for further service and predict the further inspection schedule.
Our team of experts &
technicians visit the site during shutdown with prior intimation
of site requisites. A
systematic study of the operating history of the component is
made and vulnerable
locations for the study are identified. Field observations are
also made based on which
interim site reports are submitted for immediate necessary actions
if any. A detailed high
magnification study of the replica film is made after necessary
enhancement processing.
A full-fledged report on the findings with recommendation is
given along with the
photomicrographs as a permanent record.
In addition, we undertake Positive material identification at
site using a portable alloy
analyser. This can check the material mixup if any at the time
of project execution. We
also undertake high temperature thickness survey of running
equipments for evaluation
of adequacy of thickness with respect to operating conditions.
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What
is your Methodology / Approach for Remaining Life Assessment? |
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We adopt varied methodologies for RLA depending on the predominant
damage mechanism
prevailing in the equipment. For RLA of high temperature components
creep damage mechanism based methodology is adopted to level
2 or Pseudo level 3. We generate the rupture property of the
material if samples are provided. Else, we assume the service-exposed
properties of the material generated and kept as data bank.
For equipments under pressure containment service with corrosive
atmospheres, we adopt Engineering Critical Assessment approach
for evaluation of Fitness for purpose as well as RLA in line
with PD 6493 document of TWI. We have developed a software that
addresses the Local stress estimation for any component, finds
out the interactive effects of multiple defects, fitness for
purpose of components under various types & configurations
of crack like defects, predict derated operating conditions
in case of unacceptable defects as well as predict Remaining
life under stress corrosion cracking.
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What
expertise do you have in providing Material related services? |
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We are a group, which has been catering to the needs of seven
of our refineries, vast network
of Marketing installations as well as 7500 KM of pipeline network
within India addressing their
material problems. The group has been actively working for well
over two decades. Over the
period, we have developed wide data base on material behavior
under various operating conditions, many plant failures, material
parameters for various metallurgy, degraded microstructure for
a variety of metallurgy subjected to high temperature from running
components as well as simulated properties of materials through
laboratory aging. We have successfully solved many recurrent
plant failures (around 200 cases so far) with Implementable
recommendations. Through a constant follow-up of these recommendations
we have built-up our confidence levels. We have undertaken RLA
of critical refinery components such as process heater tubes
of CDU, VDU, VBU & Coker, Reactors of Coker, CRU, FCCU etc,
High temperature Pipings / tubing, Boiler components, Pressure
vessels etc. Often multiple degradation are encountered that
warrants critical analysis of life prediction under various
operating conditions. We have developed the expertise of analysing
each type of damage with its impact on the service life and
predict the cumulative / resultant RLA of the component. We
have in built the concept of safety factors incorporated in
our methodologies that take care of operational variations,
operator inaccuracy as well as variations in material properties.
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Whom
you have rendered service in the past? |
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We have rendered our services to all our refineries, vast network
of Marketing installations as well as pipeline network within
India. In addition our clientele includes Bharat Petroleum Corporation,
Mumbai, Chennai Petroleum Corp. Ltd., Chennai, Numaligarh Refineries
Ltd., Numaligarh, India, Engineers India Limited, National Thermal
Power Corporation, India, Oil India Ltd., Gas Authority of India
Ltd., India Kuwait National Petroleum Corporation, Kuwait.
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Do
you serve any other industry other than Refining? |
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The damage mechanisms of process industries are generic and
so is the material selection. Since the basic infrastructure
for the activities already exist with the group, we can extend
our services to Petrochemical, Fertiliser, Pharmaceutical and
Power generating industries.
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What
is your mobilization & response time? |
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We can take-up the site activities for condition monitoring
/ RLA within a fortnight from the date of commercial agreement.
Jobs can be taken up on priority in case shutdown constraints.
Laboratory tests as a part of Failure analysis as well as RLA
can be taken up with proper time schedule that can be mutually
agreed upon depending the type of tests involved.
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Whom
are you associated with? |
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We are associated with reputed national metallurgical laboratories
like National Metallurgical
Laboratory, Jamshedpur, India, Research & Development Center
for Iron & Steel, Ranchi, India, Indian Institute of Technologies,
Eminent Metallurgical & Corrosion consultants within India.
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