TCR has completed more than 500 failure investigation assignments, including 50 major projects on manufacturing or metallurgical failure analysis on ASME boiler and pressure vessels, Aircraft /Aerospace, Gas turbine engine components, Oil and gas transmission pipelines, Food processing equipments, Heat exchangers, Medical supplies, Automotive components, Refineries, Petrochemical plants, Offshore structures, Industrial machinery, Weldments and Ships.
TCR's failure analysis strength is in evaluating high temperature and high pressure failures. The Failure Analysis Team at TCR Engineering has experience in the materials, failure analysis, metallurgical, welding, quality assurance, and forensic engineering fields and is conducted by engineers holding advanced degrees in metallurgy, and mechanical, civil, chemical, and electrical engineering.
TCR Engineering works with our clients to plan the failure analysis before conducting the investigation. A large amount of time and effort is spent carefully considering the background of failure and studying the general features before the actual investigation begins.
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 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 the failure including visual examination of a fracture surface, the inspection of a single metallographic specimen, and the history of similar failures.
Procedure to conduct a Failure Analysis
Cause of failure is determined using state-of-the-art analytical and mechanical procedures and often includes simulated service testing. A combination of analysis and physical testing locates problems and provides recommendations for solutions.
Our initial step to perform failure analysis begins with visually studying the failed part and asking detailed questions regarding associated parts, plant environment and operational procedure.A complete evaluation sequence of the failure investigation steps are summarized as under:
- Collection of background data and selection of samples
- Preliminary examination of the failed part
- Complete metallurgical analysis of failed material
- A through examination of the failed part including Macroscopic and Microscopic examination and analysis (electron microscopy may be necessary)
- If necessary tests 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
- Selection and testing of alternative products and/or procedures that will significantly improve performance
- Analysis of fracture mechanics.
- On-site evaluation and consulting services
- Analysis of all the evidence. Formulation of conclusions and writing the report (Including recommendations).
Brief Case Study
View some case study examples of our noteworthy failure investigation projects:
Primary Super Heater R-4 Zone Tube of a 140 Mw Boiler
Radiant Coil of a Cracker Furnace H-130 Refinery
8th Stage Blade of a Steam Turbine
Sac Plant Piping Going to V-801
Integral Pinion Shaft of a Cement Mill
You can also download failure analysis case study examples
Failure Investigation Report
The completed failure analysis report includes the following sections:
a) Description of the failed component
b) Service condition at the time of failure
c) Prior service history
d) Manufacturing and processing history of component
e) Mechanical and metallurgical study of failure
f) Metallurgical evaluation of quality
g) Summary of failure causing mechanism
h) Recommendations for prevention of similar failures
Metallography and Failure Analysis Facility
TCR has all tools required for conducting a modern failure analysis, such as:
· Metallurgical Optical Microscope with Image Analysis system LECO 500(USA) with 300X facility. For study fracture surface at low magnification and to decide areas to be studied at still higher magnification.
· Scanning electron microscope with EDAX. For study of high magnification fractography in critical situations. To study surface analysis of metal, corrosion product or localized areas.
· Stress Analyzer: To detect level of stresses in metal.
· Complete Mechanical and Chemical Testing Equipment at our laboratory.
· Dilatometer: To measure volume change while heating and cooling.
· Equipments 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.
· Micro Hardness Tester
Failure Analysis Team
The Failure Analysis Team is jointly headed by Mr. Virendra Bafna
(MD, TCR Engineering) and Mr. Paresh Haribhakti (MD, TCR Advanced Engineering). The TCR Advisory Board
is often consulted on failure analysis projects.
Mr. Paresh Haribhakti is a B.E. (Metallurgy) M.E. (Materials Technology) from M.S. University, Vadodara. Mr. Haribhakti has done basic research in study of hydrogen embrittlement of steels and stainless steels. Mr. Haribhakti previously worked as trouble shooting metallurgist for India's largest fertilizers and petrochemicals complex, GSFC Ltd., Vadodara for nearly 10 years. His areas of interest are microstructure degradation of components exposed to high temperature and high pressure. He has working experience of more than 250 failure investigation cases of power plants, fertilizers, chemicals and petrochemicals industries. He has solved materials engineering problems and performed failure analysis on components from petrochemical plants, oil and gas transmission pipelines, offshore structures, ships, pharmaceutical plants, food processing equipment, gas turbine engine components, and weldments. Mr. Haribhakti investigates the available physical evidence, and performs the necessary tests to develop the most probable accident scenario. He simplifies complex engineering theory into easy to understand and useable concepts. He uses simple analogies, every day examples, and laymen terms to explain data and findings so clients, corporate executives, government officials, or attorneys may easily understand engineering concepts.