Failure Investigation

Failure Investigation - Failure Analysis
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Failure Investigation

assignments have been completed till now, by TCR Advanced Engineering Pvt. Ltd. and its associate company TCR Engineering Services , including 50 major projects in the area of ASME boiler and pressure vessels, gas turbine engine components, refineries and petrochemical plants, Off-shore structures, oil and gas transmission pipelines, food processing equipment, heat exchangers, medical implants and devices, automotive components, industrial machinery, and shipping and transportation sector.
We have a team of experts belonging to various engineering disciplines like Metallurgy and Materials Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, and Electrical Engineering supported by skilled personnel from the Software & IT field.
Our investigation team works with clients to plan the modus operandi of failure analysis before conducting the investigation. A significant amount of time and efforts are spent in carefully understanding the background of failure and studying the general features before the actual investigation begins.
We have a methodical approach to determine the mode and root cause of a failure. For experts of TCR, Failure analysis or problem solving is more than just brain-storming a solution to an identified problem. Successful analysis is achieved through a structured technique, which uncovers the facts of the incident and adheres to a defined process for every step of the analysis.

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

Boiler Tube Failure investigation

Shaft failure investigation

Heater tube failure investigation

Reformer tube failure investigation

Failure investigation of steam turbine

Failure investigation of Gas turbine

Failure investigation of Boiler tube

Failure Analysis Objectives

The first step in managing the actual failure analysis effort is to determine what you expect from the final outcome. During TCR's initial meetings with the client we develop a charter that clearly delineates the terminal objective of the analysis. This is further enhanced through the development of critical success factors that outlines whether the terminal objectives have been obtained. At TCR Advanced, we adopt a disciplined vertical problem solving methodology used to determine levels of root causes of specific failure events.

Failure Analysis Procedure

Cause of failure is determined using state-of-art analytical and mechanical testing procedures and often includes testing under simulated service conditions. A combination of analysis and physical testing defines the problem and helps in providing recommendations for the solution.
Cause of failure is determined using state-of-art analytical and mechanical testing procedures and often includes testing under simulated service conditions. A combination of analysis and physical testing defines the problem and helps in providing recommendations for the solution.Failure Analysis
In the course of the various steps listed below preliminary conclusions are often formulated. If the probable fundamental cause of the metallurgical failure becomes evident early 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 the failure including visual examination of a fracture surface, the inspection of a metallographic specimen, and the history of similar failures. The complete evaluation sequence is summarized as under:
  • Collection of background data and selection of samples
  • Preliminary examination of the failed part
  • Complete metallurgical analysis of failed material
  • A thorough examination of the failed part including Macroscopic and Microscopic examination and analysis (electron microscopy, if needed)
  • If necessary tests may also include Weld Examination, Case Depth, Decarburization Measurement, Coating/Plating Evaluation, Surface Evaluation and/or Grain Size Determination
  • 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 analysis of fracture mechanics.
  • Selection and testing of alternative products and/or procedures that will significantly improve performance
  • On-site evaluation and consulting services and Formulation of conclusions and writing the report

The Failure Analysis Report

The failure analysis report represents the culmination of the analysis effort and the beginning of failure elimination. The goal of any failure analysis by TCR is targeted towards avoidance of 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