8/7/2019 Failure Analysis Methodology Thepetrostreet
1/16
FailureAnalysis
Methodology
All rights reserved to thepetrostreet.com
8/7/2019 Failure Analysis Methodology Thepetrostreet
2/16
preliminarycauseoffailureandaftertakinga
,
takeninordertoavoidrecurrenceinfuture
allrightsreservedtothePetroStreet team
8/7/2019 Failure Analysis Methodology Thepetrostreet
3/16
HistorydatacollectionSamplescollection
Preliminaryexamination(VT)NDT
Mechanical Testin
FailureAnalysis
MacroscopicExaminationMicroscopicExamination
MetallographicExaminationeterm nat ono a ure ec an sm
ChemicalanalysesSpecialTests(simulations)
Conclusions/Reporting
allrightsreservedtothePetroStreet team
8/7/2019 Failure Analysis Methodology Thepetrostreet
4/16
ToDoItems: Goals:All
the
files
and
records
related
to
the
failedpartbemadeavailableonyour
workingtable
Collection
of
all
of
the
following:Specificationsheetofthecomponent
Manufacturingdesigndata
So tcopieso scanne reports,emai
notifications,correspondencewith
vendors
/
manufacturerPhoto ra hsofallthe revious
Inserviceinspectionrecor s
Failuresoccurinthepast
Latest
modification
made,
if
anyLastfailuremode ifavailable
inspectionsshallbelookedinto Reportsofpastfailureanalysis,ifany
Photographicrecords
allrightsreservedtothePetroStreet team
8/7/2019 Failure Analysis Methodology Thepetrostreet
5/16
ToDoItems: Goals:ReachthesiteatyourearliestLookforthefailedpartsandpieces
Surveyofthewholeareaalongwithother
FailedpartandpiecestobecollectedPhotographsshallbetakenimmediately
Lookforotherevidences
skilledinspectors
Discussionswiththeoperatingstaff
Listencarefullytotheeyewitnesses,if
Operatingconditionsatthatspecifictime
Interviewtheeyewitnesses
Listentoeverybodypresentatthesite
allrightsreservedtothePetroStreet team
8/7/2019 Failure Analysis Methodology Thepetrostreet
6/16
Goals:ToDoItems:Generalassessmentofbasicdesignandworkmanshipbemade
Apparentsurfacedefectswhichcanbe
Thoroughvisualexaminationwithoutanycleaning
Photographyofthefracturedpartand
seenwithnakedeyemustbelogged
Theoriginalshapejustafterfracturebe
savedforreference
surfaces
Groupdiscussionswithinspectors
partsandsurfaces
Makeareportofpreliminaryexamination
allrightsreservedtothePetroStreet team
8/7/2019 Failure Analysis Methodology Thepetrostreet
7/16
Goals:ToDoItems:Cracks,flaws,discontinuities,metalthicknesslossandothersurfaceorbelow
surfacedefectsmustbepickedupusing
ApplicableNDTtobemade:DyePenetrant Testing
MagneticParticleTesting
applicableNDTtechniques
FormationofallappliedNDTreports
includingalltheobservations/
UltrasonicTesting
Radiography
EddyCurrentInspection
allrightsreservedtothePetroStreet team
8/7/2019 Failure Analysis Methodology Thepetrostreet
8/16
Goals:ToDoItems:Evaluateifdesiredmechanicalattributespresentinthefailedpart
Ifnotthenevaluatewhatwaswrong
Mechanicalattributesofthefailedparttobeconsidered
Whythatmaterialwasselected?
amongthefollowing?
Materialselection
Processconditions
Principalmechanicalpropertiesofthe
failedpart
SelectionofMechanicalTestingtobe.
Hardness
Tensile
Impact
Fatigue
allrightsreservedtothePetroStreet team
8/7/2019 Failure Analysis Methodology Thepetrostreet
9/16
Goals:ToDoItems:DeterminethedirectionofcrackgrowthPresenceofChevronmarks
Determinetheoriginoffracture
Surfaceexaminationsatmagnificationsranges1to100x
Examinationwithunaidedeyeorhard
lens
Lowpoweropticalmicroscopemaybe
used
Originofthefractureontheleft
allrightsreservedtothePetroStreet team
8/7/2019 Failure Analysis Methodology Thepetrostreet
10/16
Goals:ToDoItems:Determinationofdimpledfracture,cleavagefacets,brittleintergranular
fracture,hydrogenembrittlement,fatigue
Transmissionelectronmicroscopestobeusedformagnification upto1500x
Scanningelectronmicroscopefor
failureetc.magnificationintherangeof10000xto
60000x
ResultofScanningelectron
Microscope(SEM)
allrightsreservedtothePetroStreet team
8/7/2019 Failure Analysis Methodology Thepetrostreet
11/16
Goals:ToDoItems:Determinewhetherthematerialhastherequiredstructure
Lookforthefollowing:
SelectionofthemetallographicsectionsPreparationofthemetallographic
sections
Inclusions
Microstructural segregation
Decarburization
Polishingandetching
Improperheattreatment
Intergranular corrosion
allrightsreservedtothePetroStreet team
8/7/2019 Failure Analysis Methodology Thepetrostreet
12/16
Goals:ToDoItems:Determineamongthefollowing:DuctileFracture
Transgranular BrittleFracture
CollectionofallpreviousinformationTranslatingalltheinformationtodetect
fracturetype
Intergranular BrittleFracture
FatigueFracture
StressCorrosionCracking
HydrogenEmbrittlement
Creep&StressRupturefailure
allrightsreservedtothePetroStreet team
8/7/2019 Failure Analysis Methodology Thepetrostreet
13/16
Goals:ToDoItems:Determine:Presenceofrequiredalloying
Exactmatchwithrequiredmaterial
AnalysisofbulksurfaceAnalysisofdeposits
Spottests
Extentofanydeviation
allrightsreservedtothePetroStreet team
8/7/2019 Failure Analysis Methodology Thepetrostreet
14/16
Goals:ToDoItems:RecurrenceoffailuretobeseenConcludeyourinvestigationwiththeaid
ofsimulation
SimulationmaybemadeifpossibleConditionsatthetimeoffailuretobe
replicated
Seeklaboratoryassistance
Makeavideo,ifpossible
allrightsreservedtothePetroStreet team
8/7/2019 Failure Analysis Methodology Thepetrostreet
15/16
Goals:ToDoItems:StatereasonsoffailureProviderecommendationstoavoid
recurrence
WritedownthemethodologyadoptedWorkperformedandresultsfound
Assembleallthepicturesandvideos
Makeacompletepresentationinvolving
laboratoryreports
allrightsreservedtothePetroStreet team
8/7/2019 Failure Analysis Methodology Thepetrostreet
16/16
Formoredetails&information,pleasecontactus.
thePetroStreet Team