Failure Analysis Services

Identify root causes. Prevent recurring failures. Improve safety, reliability, and asset performance.

Engineering-Based Failure Analysis for Industrial Equipment

Failure Analysis is a systematic engineering process used to determine the root cause of why equipment, components, or materials fail during operation. By studying damage patterns, material properties, and operational conditions, engineers identify what went wrong and develop corrective actions to prevent future failures, improve safety, and extend asset life.
Image

What We Investigate

Failures investigated include:
Mechanical & structural failures
Pressure boundary breaches (leaks, ruptures)
Weld cracking & fabrication defects
Piping or pressure vessel wall loss
Fatigue failures from cyclic loading
Material or metallurgical issues
Improper installation or maintenance
High-temperature degradation

What Our Failure Analysis Includes

Image

On-Site Damage Assessment

Visual inspection, measurements, and data collection to document failure conditions immediately.

 

Image

Laboratory Analysis & Testing

    • Metallurgical examination

    • Chemical & material composition (PMI)

    • Hardness testing

    • Microscopy (SEM, optical)

    • Fractography

    • Mechanical testing

     

Image

Operational & Design Review

Analysis of:

  • Stress conditions

  • Pressure & temperature cycles

  • Flow and vibration data

  • Design specifications

  • Past maintenance history

Image

Root Cause Analysis (RCA)

We determine the primary cause and contributing factors behind the failure.

 

 

Image

Engineering Recommendations

Clear actions to:

  • Prevent recurrence

  • Improve reliability

  • Increase safety

  • Optimize maintenance programs

Includes support for repairs, rerating, replacement, and operational adjustments.

Root Causes We Commonly Identify

  • Fatigue cracking from cyclic stress

  • Stress corrosion cracking (SCC)

  • Corrosion under insulation (CUI)

  • Manufacturing and weld defects

  • Incorrect material selection

  • Overpressure or thermal overstress

  • Flow-accelerated corrosion (FAC)

  • Erosion from high fluid velocities

  • Brittle fracture or embrittlement

  • Improper installation practices

Image

Deliverables

Every failure analysis includes a professional engineering report:
Summary of damage & equipment history
Laboratory test results
Root cause conclusion
Repairs & prevention recommendations
Inspection/monitoring intervals
Compliance evaluation (API/ASME)

Benefits of Professional Failure Analysis

PMI/MT/PT/VT inspections are essential for maintaining compliance, preventing failures, and ensuring safe operation of industrial systems.
Prevent recurring failures and costly shutdowns
Improve safety and regulatory compliance
Reduce total maintenance and lifecycle costs
Extend equipment lifespan
Strengthen RBI and Mechanical Integrity programs
Improve engineering and operational practices
Reduce risk of future incidents

Schedule a Failure Analysis

Understand why equipment failed and prevent it from happening again.
Contact Us