Micro Lab

MICROLABAn ISO/IEC 17025:2005 Accredited Metallurgical Testing lab.

METALLURGICAL TEST HOUSEFAILURE ANALYSIS | METALLOGRAPHY| IN-SITU METALLOGRAPHY| CORROSION TESTING | MECHANICAL TESTING | CHEMICAL TESTING |

POSITIVE MATERIAL IDENTIFICATION | PWHT| NDT|BOILER, REFORMER ASSESSMENT| PMA

INDIA – CHENNAI COIMBATORE MALAYSIA - KL SELANGUR

MICROLAB

MICROLAB Founded in 2000 by Shri. S.R.Balasubramaniam , a technocrat Masters in Metallurgy from IISc Bangalore, INDIA, trained at USA.

MICROLAB , an ISO/IEC 17025:2005, Accredited metallurgical testing

laboratory with its activities are attested and recognized by NPCIL, NTPC, DGQA, EIL, LLOYDS, DNV, TUV, BV, other National & International Bodies.The scope of testing includes,

Failure Analysis

Metallography

In-Situ Metallography

Corrosion Testing (ASTM,GOST,NACE)

Mechanical Testing

Welder qualification test. (WPS &PQR)

In-situ Hardness Survey , In-situ Ferrite measurement

Chemical Analysis (OES)

ROHS & WEEE Compliance – Euro Norms

Positive Material Identification (PMA)

Positive Material Analyzing including Carbon at site (PMA)

Pre & Post Weld Heat Treatment (PWHT)

Boiler / Reformer Life Assessment (RLA)

Reverse Engineering for critical components



MICROLAB

CHEMICAL ANALYSIS

Microlab has installed optical emission spectrometers (OES) imported from Germany

and Italy for four bases including Nitrogen .

FERROUS BASE

NICKEL BASE

COPPER BASE

ALUMINUM BASE

Microlab `s reference standard bank has more than 250 certified reference

standards, (CRM ) and develops SRM for the regular and customize specifications to

give accurate un-ambiguity test results. Our spectrometer is capable of deducting

more than 28 elements.



Equipment : OES (Optical Emission)Make : OXFORD – GERMANYRange : Fe BASE, Ni BASE, Cu BASE, Al BASE. ( Including Gases)

Equipment : OES (Optical Emission)Make : GNR – ITALYRange : Fe BASE, Ni BASE, Cu BASE, Al BASE. ( Including Gases)

MICROLAB

POSSITIVE MATERIAL IDENTIFICATION & ANALYSIS

Microlab is equipped with 09 XRF based portable spectrometer from NITON,

OXFORD instruments, EDDAX, INNOV-X. All the equipment is backed up

with standard certification sample for cross verification for almost all the grades. These

equipment are capable of measuring Non destructively and

accurately, hence can be used on finished products. XRF equipment are used to

check the incoming raw materials, material mix up sorting, checking on the filler

material etc. The equipment is capable of deducting all alloying elements from No.

14 to 87 on the periodic table. Microlab has completed more than

25000 assignment using XRF equipment.



Equipment : PMI ( Alloy Checker )Make s : INNOV-X USA , X-MET USA, EDAX USA, NITON USA.Range : From No. 14 to No. 87 on Periodic Table

Equipment : PMA ( Alloy Analyzer )Make : ARC-MET USA, GNR -ITALYRange : Fe Base, Al Base Including Carbon.

MICROLAB

POSSITIVE MATERIAL IDENTIFICATION & ANALYSIS

Microlab follows all international test procedures including EIL , Saudi Aramco

, KPCL, IOCL, CPCL, specification for carrying PMI testing .

Microlab is also equipped with ARC MET to check the carbon, Phosphor,

Sulphur in steel at site even at elevated heights. Our technical team is well

trained and can travel to any part of INDIA, SINGAPORE, MALAYSIA,

INDONESIA, THAILAND, DUBAI, QATAR and throughout

EUROPE AND AMERICA, to carry out PMI testing .



MICROLAB

MECHANICAL TESTING

Microlab has installed state-of art testing equipment with traceability to NIST and NPL .

The testing methods followed are as per ASTM, BS,DIN,NACE, IS, GOST

STANDARDS. And also as per customer validated test methods. The test

temperature ranges from RT to 900 degree C for mechanical and

100 degree C to -196 degree C for Impact testing. Microlab has carried

out more than 1500 welder qualification test as per ASME Section IX under

third party witness.



Equipment : UTM – FIE. INDIA Range : 40 Ton , 100 Ton.

Equipment : UTM – FIE. INDIA Range : Upto 900 Degree C

MICROLAB

MECHANICAL TESTING

Microlab is equipped with in-house machining facilities to turn round the test specimen

within 48 hrs from the log in of the sample . Microlab shoulders the responsibility of

stamp transferring of inspecting authorities from the test sample to test specimen to

maintain the traceability of the testing. The range of testing includes ,

Ultimate Tensile test,Yield strength, % Elongation, RA

0.2% proof stress using electronic extensometer

Bend testing

Welder qualification test

Hardness Testing ( Rockwell,Brinell,Superficial,Micro Hardness)

Proof Load/ Drop Weight Test

Decarburization

Micro Hardness

Impact testing - Izod and Charpy ( U & V notch) ASTM & BS machines

Coating/Plating analysis



Equipment : UTM – FIE. INDIA Range : 40 Ton , 100 Ton.

Equipment : Hardness - VICKERS. Range : 1 kgs to 10 kgs.

MICROLABMICROLAB

METALLOGRAPHY

Microlab `s assets include qualified metallurgist who are well trained in

metallographic preparation and examination to evaluate the characteristics of metals

in any form. Microlab is equipped with the latest image analyzing software. Micro

examination includes ,

weld examination

Case Depth

Decarburization

Micro Hardness

Coating/Plating analysis

Percentage grain growth ,

Inclusion Rating

Particle size

Volume percentage

Porosity

Equipment : Equipment :

MICROLAB

IN-SITU METALLOGRAPHY

Microlab has carried out more than 5000 replica microstructures for various process

plants and refineries under plant working and shut down atmosphere . In demanding

applications of current industrial scenario high quality non-destructive in-situ

metallographic preparation, replication and evaluation is a requirement in many

critical fields such as energy, petrochemical, trasportation etc.

The skill lies on the preparation of the samples and replica. Our metallurgist are trained

to polish even at critical locations. Upto 400x we can magnify the structures using

portable microscope.

Non-Destructive evaluation of microstructures by adopting high quality sample

Preparation with good resolution is needed for evaluating material condition after

various types of service such as creep, fatigue, stress corrosion cracking etc. of critical

components in plants.



MICROLAB

CORROSION TESTING

Microlab covers the corrosion related test to determine the weight loss corrosion, Inter-

granular attack (IGC) as per ASTM, NACE, GOST. The test range includes,

IGC , As per ASTM A 262 ( Practice A to F)

Pitting Corrosion as per ASTM G 48 method A

Crevice Corrosion Test as per ASTM G 48 method B

Chloride stress corrosion Test as per ASTM G 36

Salt spray test as per ASTM B 117



MICROLAB

CORROSION TESTING

Microlab has expanded her branches to test as per NACE standards for specially for

refinery application . Microlab has completed more than 300 heats of samples for

testing . The testing range includes,

HIC Test – NACE TM 0284

SSCC test - NACE TM 0177 at 24 deg C

SSCC test - NACE TM 0177 at 90 deg C

Microlab is equipped with the all the relevant instrument, proof rings, Automatic PID

controllers, 12 channel Yokogowa Recorders. Microlab follows strict quality control and

safety procedures for carrying out the testing. All testing can witnessed under third

party inspection Agencies including LLOYDS, DNV,EIL, BV etc.



MICROLAB

IN-SITU HARDNESS & FERRITE MEASUREMENT

Microlab is equipped with portable hardness testing equipment with the accuracy

of 95 % confidence level. Our Trained Engineers can travel across the globe . The

evaluation for PWHT is carried out by these equipment.

The Fisher – Ferrite measurement equipment plays a vital role at microlab to

carry out ferrite count from 0 – 100 FN and percentage including Stainless steel ,

Duplex, Super Duplex plates, vessels, weld joints etc.



MICROLAB

FAILURE ANALYSIS

Severe Damage in a plant due to boiler explosion

Explosion of hydro processor pressure vessel due to Hydrogen embrittlement

STRESS CONCENTRATION PATTERN AT TIP OF CRACK IS MADE VISIBLE USING LAQUER COATED STEEL TEST SAMPLE UNDER BENDING STRESS & PHOTOGRAPHED IN POLARIZED LIGHT

Cracking & Fracture, H attack

Microlab has crossed more than 1000 failure investigation assignment including

Heavy Engineering, Petro-chemical plants, Marine, Navy, offshore structures ,

Automobile sectors, etc. The team consists of metallurgist , engineers from chemical,

civil, electrical and Instrumentation with decades for theoretical and practical

knowledge.



MICROLAB

MICROLAB

FAILURE ANALYSIS

Overloading fatigue failure of a shaft – started at key way- zone of stress concentration

Res. Stress measurement by blind hole drilling method

MILLING GUIDE

DIGITAL STRAIN METER

STRAIN GAUGE ID fan shaft

mock up

The root cause and the investigation is determined by deploying state-of-art

analytical, mechanical and metallographic equipment. Microlab `s speciallity is not

only investigating the root cause of the failure but also gives solutions and

recommendations

Considering the wider aspect of failure criteria, causes for actual failure / potential

failure is analyzed carefully also by conducting practical tests. Such potential

causes of failure are prevented by appropriate remedial action unique for each

case.



MICROLABMICROLAB

LIST OF SOME PROJECTS EXECUTED

S.NO PROJECT DETAIL CLIENT

1 CPCL – REFINERY M/s.LARSEN & Toubro Ltd2 CPCL- REFINERY M/s.Punj Lloyds.3 CPCL- REFINERY M/s. Bridge & Roof Ltd4 CPCL- REFINERY M/s. Petron Engg ltd5 CPCL- REFINERY M/s. SPIC JEL Ltd,6 CPCL- REFINERY M/s. BHEL7 CPCL- REFINERY M/S. BHPV

8 KOCHIN REFINERY M/s.Punj Lloyds.9 KOCHIN REFINERY M/s. Bridge & Roof Ltd

10 KOCHIN REFINERY M/s. Petron Engg ltd11 KOCHIN REFINERY M/s. SPIC JEL Ltd,12 KOCHIN REFINERY M/s. BHEL13 KOCHIN REFINERY M/S. BHPV

14 IOCL, panipet M/s. Petron Enginnering15 IOCL, panipet M/s. Larsen & Toubro Ltd

16 RELIANCE PETRO CHEMCIAL M/s. PETRON17 RELIANCE PETRO CHEMICAL M/s. POWER MECH INDIA17 NUCLEAR REACTOR (NPCIL) M/s. Larsen & Toubro Ltd18 NUCLEAR REACTOR (NPCIL) M/s. BHEL

19 HPCL, VIZAG- REFINERY M/s. Petron20 HPCL, VIZAG- REFINERY M/s. TECHNIP21 HPCL, VIZAG- REFINERY M/s Larsen & Toubro Ltd



MICROLABM

MICROLAB

MICROLAB

LIST OF SOME PROJECTS EXECUTED

S.NO PROJECT DETAIL CLIENT

22 IGCAR- NUCLEAR PROJECT M/s.LARSEN & Toubro Ltd23 IGCAR – NUCLEAR PROJECT M/S. NPCIL24 KKNPP – NUCLEAR PROJECT M/s. Larsen & Toubro ltd,25 KKNPP – NUCLEAR PROJECT M/s. BHEL

26 HEAT EXCHANGER M/s. GEA ENERY SYSTEM27 PREASURE VESSELS M/s. PRECISION EQUIPMENT28 BOILERS M/S. BHEL

29 PIPING SYSTEM m/S. TECHNIP30 PIPING SYSTEM M/s. VA TECH 31 PREASURE VESSELS M/s. PRECISION EQUIPMENT

32 REFORMER TUBE INSPECTION M/S. GREEN DOME , AJMAN33 PETRONAAS m/S. FISHER ROSEMOUNT34 AUDCO VALVES M/s. AUDCO 35 FLOWSERVE PUMPS M/s. FLOWSERVE



MICROLAB

MICROLAB

Pre-heating, Thermal Recovery, Intermediate tempering and PWHT

MICROLAB is backed up with state-of–art equipment and with high class technical

experts with Electrical, Mechanical and metallurgical background , who are having

3 decades of theoretical and practical experience in the field of

Petro – Chemical Complex installations and NUCLEAR and

THERMAL POWER PROJECTS. Microlab is on continuous Research and

development on meeting the stringent requirement and equipped with customer-

made equipment to confirm all National and International Standards

on all grades of metals including P91 of different geometry of complex

configuration .

Microlab service is attested by Nuclear power corporation , India for performing PWHT on very stringent acceptable criteria with the different geometry and dimensions and chemical composition as per

PNEAG requirement ( RUSSIAN SPECIFICATION) .

MICROLABMICROLAB



MICROLAB

MICROLABMICROLAB

MICROLAB

Contact Person:

Mr. S.R.BALASUBRAMANIAM . C.E.OHand Phone: 91 44 98400 78954

Mr. K.Suresh Kumar. Head- opearations.Hand Phone: 91 44 98409 52816

INDIA- Head Quarters.

SP 101,2nd main Road,Ambattur Industrial Estate,

Chennai - 600058Ph: 91 44 26242525, Fax: 91 44 26244872

E-mail: [email protected]:www.microlabchennai.com



MICROLAB

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Micro Lab