Failure Investigation

Failure and Root Cause Analysis

TCR prides itself for its deep sectoral knowledge and has compiled best practices from over 1800

failure investigation

assignments. These success stories include major projects in manufacturing and metallurgical failures on ASME boilers, pressure vessels, gas turbine engine components, oil and gas transmission pipelines, food processing equipment, heat exchangers, medical supplies, refineries, petrochemical plants, aircraft/aerospace, offshore structures, industrial machinery, weldments and ships.

Failure Analysis

team’s strength lies in the evaluation of high temperature and high-pressure failures. The team at TCR Advanced Engineering has extensive experience in the materials space, failure analysis, metallurgical, welding, quality assurance, and forensic engineering fields. The analysis is conducted by experts in metallurgy, mechanical, civil, chemical, and electrical engineering.

TCR Advanced Engineering works with clients to plan for failure analysis and efficiently conducts the investigation. Considerable time and effort are dedicated to understanding the background of failure and studying the general features before the real investigation begins. The cause of failure is determined using both, analytical and mechanical procedures that often includes simulated service testing. The exhaustive analysis along with physical testing detects problems for TCR to provide recommendations and solutions.

During the course of the investigation, preliminary conclusions are formulated. If the probable fundamental cause of the metallurgical failure becomes evident early on in the examination, the rest of the investigation focuses on confirming the probable cause and eliminating other possibilities. The metallurgical failure analyst compiles the results of preliminary conclusions, carefully considering all aspects of failure including visual examination of a fracture surface, the inspection of a single metallographic specimen and the history of similar failures. The complete evaluation sequence to conduct a Failure Analysis is summarized below:

TCR Advanced Engineering Pvt. Ltd. and its associate company TCR Engineering Services have done different failure investigation. Some of them are listed below :

Boiler Tube Failure investigation

Shaft failure investigation

Heater tube failure investigation

Heat Exchanger Inspection

Reformer tube failure investigation

Failure investigation of steam turbine

Failure investigation of Gas turbine

Failure investigation of Boiler tube

Evaluation Sequence for
Conducting Failure analysis

The complete

Failure Analysis Procedure

is summarized as under :

  1. Collection of Background Data and Selection of Samples
  2. Preliminary Examination of the Failed Part
  3. Complete Metallurgical Analysis of Failed Material
  4. A Thorough Examination of the Failed Part including Macroscopic and Microscopic Examination and Analysis (Electron Microscopy, If Needed) Tests, If necessary may also include Weld Examination, Case Depth, Decarburization Measurement, Coating/Plating Evaluation, Surface Evaluation and/or Grain Size Determination
  5. Chemical Analysis (Bulk, Local, Surface Corrosion Products, Deposits or Coating and Microprobe Analysis) Tests to Simulate Environmental and Physical Stress That May Have Played A Role In The Failure
  6. Analysis Of Fracture Mechanics
  7. Selection and Testing of Alternative Products and/or Procedures That Will Significantly Improve Performance
  8. On-Site Evaluation and Consulting Services and Formulation Of Conclusions and Writing the Report (Including Recommendations)

Failure Investigation Report

The failure analysis report represents the culmination of the analysis effort and the beginning of failure elimination. The goal of any failure analysis is targeted towards avoiding any recurrence of similar failure by providing appropriate recommendations. The completed failure analysis report includes the following sections:

  1. Description of the Failed Component
  2. Service Condition at the Time of Failure
  3. Prior Service History
  4. Manufacturing and Processing History of Component
  5. Mechanical and Metallurgical Study of Failure
  6. Metallurgical Evaluation of Quality
  7. Event summary of Failure Causing Mechanism
  8. Recommendations for Prevention of Similar Failures
  9. Latest Inspection Solutions

Latest Inspection Solutions

TCR has the necessary expertise and tools to conduct modern failure analysis. TCR’s complete range of equipment at its network of laboratories include:

  1. Metallurgical Optical Microscope with Image Analysis system: For studying fracture surface at low magnification and to decide areas to be studied at still higher magnification
  2. Scanning Electron Microscope With EDAX: For the Study Of High Magnification Fractography in critical situations. To Study Surface Analysis Of Metal, Corrosion Product Or Localized Areas
  3. Stress Analyzer: To Detect the Level of Stresses in Metal
  4. Complete Mechanical and Chemical Testing Equipment
  5. Dilatometer: To Measure Volume Change while Heating and Cooling
  6. Equipment and Accessories Required for Preparation Of Metallographic Samples including Diamond Saw Cutter, Mounting Press, Rough Grinder, Belt Polisher, Wheel Or Disc Polisher, Electrolytic Etcher Polisher and a Microscope with Attachments like Micro-Hardness Testing
  7. Micro Hardness Tester