FAILURE ANALYSIS & REPORTING
OPTIONS
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|
Level* |
Investigations |
Purpose |
Cost Range** |
Reporting Options |
|
1 |
Forensic Investigation |
Determine the root cause of a failure based on all
discoverable information and knowledge with a complete laboratory
examination. |
open |
Comprehensive Report |
|
2 |
Field Investigation |
Determine the root cause of a failure based on laboratory and
field investigation. |
$3,000 to $20,000 |
Comprehensive Report |
|
3 |
Field Examination |
Take field measurements for wall loss, deposits, water
samples for chemical analysis, etc. |
$500 - $5,000 |
Summary of Findings |
|
4 |
Failure Investigation / Assessment |
Determine the physical cause of a failure based on a laboratory
investigation and background information provided by our client. Type
of failure identified, origin of crack/corrosion based on available evidence
on sample. |
$1,000 - $6,000 |
A - Comprehensive Report |
|
B - Executive Summary |
|
C - E-mail report |
|
5 |
Metallographic Examination |
Determine the properties, heat treatment, pit morphology,
crack path, grain size, etc. of a material. |
$100 - $1,000 |
Summary of Findings |
|
* All levels of investigation can be upgraded
per clients request. |
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** Needs vary from client to client, therefore all quotes are custom
tailored to clients parameters. |
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TYPICAL FAILURE
INVESTIGATION PROCEDURE |
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SCOPE OF WORK |
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The scope of work may include |
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*Review background information, including specifications,
service history, relevant reports, etc., to understand the operating
conditions before the failure event; |
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*Field investigation of system in which component failed; |
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*Analyze the failed component or representative samples for
the mechanism of corrosion or mechanical damage; |
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*Verify the chemical composition of the failed component,
including any scale, debris or corrosion product; |
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*Verify any loss of wall thickness or other dimensions; |
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*Report findings and express an opinion. |
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ANALYSIS TO BE PERFORMED |
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Examinations and analyses to be
performed on the failed component may include: |
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*Visual examination for general condition assessment; |
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*Photo-documentation; |
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*Examination of the inside and outside component surfaces by
stereo-optical microscopy; |
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*Scanning electron microscope fractography; |
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*Metallurgical examination of selected cross sections for
microstructural characteristics; |
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*Dimensional measurements; |
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*Hardness measurements; |
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*Elemental analysis of deposit or corrosion products
associated with failure; |
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*Chemical analysis of the component to verify compliance to
design specifications. |
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Reporting OPTIONS |
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Four (4) basic reporting formats are available: |
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1) Informal e-mail |
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2)
Summary of Findings |
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3) Executive Summary |
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4) Comprehensive Report |
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|
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1)
Informal e-mail |
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Straight to the point, reporting the
cause and mode of failure. For informal use only, no letterhead, signature or
structure is used. |
| |
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2) Summary of
Findings |
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Presents the findings of the examination, testing, or field work. No
interpretation of the results are given. Good for measurements,
chemical analysis or metallographic examination of material. |
| |
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3)
Executive Summary |
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This report is typically 3
pages long with text and pictures. The report is to the point without
formal headings. This format is suitable for internal use for cases in which
our client only seeks a confirmation of a failure mode that is already
strongly indicated by the background information and circumstances of the
failure. Background is summarized in the 1st paragraph, Findings
presented in several paragraphs with limited photo-documentation and
Conclusions in final paragraph. |
| |
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4) Comprehensive Report |
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This report is typically 6 to 10 pages long with 6 to 10
pictures; the report is rigidly structured with formal headings. This format
is suitable for use with third parties or for cases with potential legal
implications. The report format can also be used when the cause of the
failure is obscure or the failure has severe economic consequences. We
attempt to be thorough in discussion of the failure and the environment
causing the failure. Frequently, literature is reviewed for aspects of the
failure that are unusual. |
|
|
|
TITLE PAGE |
Title, author, etc. |
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SUMMARY |
To-the-point-summary of the failure analysis. |
|
BACKGROUND |
Circumstances of the failure and documentation of the
equipment and processes involved. |
|
SCOPE OF WORK |
see above |
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ANALYSES PERFORMED |
see above |
|
FINDINGS |
Summarizes the evidence discovered in the investigation. |
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DISCUSSION |
Discusses the implications of the findings; attempts to
convey a thorough understanding of the failure mechanism to the reader.
From this understanding, the client should be able to better
address the plant environment and reduce the risk of future failures. |
|
CONCLUSIONS & OPINIONS |
Itemizes the findings and expresses the author’s opinion
on the root cause(s) of the failure. |
|
REFERENCES |
Included if appropriate |
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