Root Cause Failure Analysis

Overview

The work is accepted across oil and gas, refining, petrochemicals, fertilisers, power, general engineering, defence, aviation, and insurance, and it covers both static and rotating equipment.

The findings are written to stand up where it matters: not only for the plant’s own reliability decisions but for litigation and insurance investigations, which is why the method is evidence-led and the report is defensible. The forensic approach is to read the available physical evidence, run the tests that the case requires, and build the most probable failure scenario from what the evidence supports, then to set it out in plain terms so that engineers, executives, regulators, or counsel can all follow the reasoning.

TCR prides itself on its deep knowledge and has gathered best practices from success stories compiled from over 9,000 failure investigation assignments, which 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.

The Failure Analysis Team’s strength lies in the evaluation of high temperature and high-pressure failures. The Failure Analysis Team at TCR Engineering has experience in the materials space, failure analysis, metallurgical, welding, quality assurance, and forensic engineering fields. The analysis is conducted by engineers holding advanced degrees in metallurgy, mechanical, civil, chemical, and electrical engineering.

TCR Engineering works with clients to draw up a plan for failure analysis to efficiently conduct the investigation. A large amount of time and effort is spent in carefully considering the background of failure and studying the general features before the actual investigation begins. The cause of failure is determined using advanced analytical and mechanical procedures that often includes simulated service testing. Analysis and physical testing, when combined together, locates problems and provides recommendations for effective solutions.

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 considers 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 summarised as under:

Evaluation Sequence for Conducting Failure analysis

• 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) Tests, If necessary may also include Weld Examination, Case Depth, Decarburisation 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 (Including Recommendations)

Failure Investigation Report

The investigation team produces detailed written reports to ensure clients fully understand the implications and can independently examine the conclusions:

• Description of the Failed Component
• Service Condition at the Time of Failure
• Prior Service History
• Manufacturing and Processing History of Component
• Mechanical and Metallurgical Study of Failure
• Metallurgical Evaluation of Quality
• Summary of Failure Causing Mechanism
• Recommendations for Prevention of Similar Failures
• Latest Inspection Solutions

Workflow: visual, NDT, replication, hardness, mechanical and chemical, fractography (SEM and EDS), microstructural analysis, FEA where loading is in question, damage-mechanism attribution, and a written report fit for litigation, insurance, or operator action.

Standards. API RP 571 (damage mechanisms in the refining industry), ASM Handbook Volume 11A, WRC 488, WRC 489, and WRC 490.

Representative engagement. HMEL Bathinda failure-investigation rate contract 9830004894, a three-year retainer covering the full Bathinda refinery and petrochemical complex (June 2025 to June 2028).

Non-Metallic Component Failure Analysis

The practice also covers non-metallic components: polymers, composites, ceramics, rubber, and FRP and GRP systems, which typically degrade through ultraviolet exposure, chemical attack, thermal ageing, or design error. These are investigated through a combination of mechanical testing, spectroscopy, microscopy, and thermal analysis, with the same root-cause discipline applied to the metallic work.

• Materials: polymers, composites, ceramics, rubber, and FRP and GRP systems.
• Typical degradation: ultraviolet exposure, chemical attack, thermal ageing, or design error.
• Methods: mechanical testing, spectroscopy, microscopy and thermal analysis.
• Discipline: the same root-cause method applied to the metallic work.

The failure analysis podcast

• Podcast Episode 5: Root Cause Failure Analysis: How 10,000+ Investigations Prevent Plant Disasters