TCR Arabia - NDT and Material Testing Services in Saudi Arabia
NDT and Material Testing per ASTM API and NACE in Saudi Arabia
Failure Analysis and RCFA
Having core competency in the field of Metallurgy and Corrosion, TCR Arabia undertakes Root Cause failure investigation for variety of industries like Petrochemicals, Refinery, oil exploration, Chemical, Fertilizers, Power and Energy, pharmaceuticals, Transport and automobile, Fabrication and Engineering industries.

TCR Arabia's failure analysis strength is in evaluating high temperature and high pressure failures.

Approach to failure analysis at TCR is unique and unequivocal. We are meticulous in carrying out first hand examination and gathering background information with regard to the problem. We at TCR fully aware about the complexity of the analysis and pit falls of taking short cuts.

The team of experts from different discipline synergize scenerio of failure analysis and assist in arriving at correct solution to the problem. Professional approach adopted at TCR is unique and has evolved over the years of hard work. Experience gained by our immaculate approach to the failure analysis has brought accolades not only within the country but also from the overseas customers.

The Need for Failure Investigation
Often a component or equipment does not perform to its intended use and its recurrence requires to be prevented. A robust common sense based on pragmatic considerations can solve many of the problems. However, when it becomes repetitive, critical and when the consequences of failure result into formidable economical losses, violation of safety and environmental considerations, it requires to be attended with more scientific approach.

Once the root cause of the problem is ascertained, solution is always around the corner. Nevertheless, approach requires to be systematic to trace the root cause, which is more often influenced by parameters like process inputs, raw material, fabrication, heat treatment and several other aspects.

The laws of forensic science equally apply to the metal when they fail. They record evidences of failure at subject location. The language of failure can only be deciphered by an experienced metallurgist after close observation of the failed part on fracture surface under optical and electron microscope.

Planning for Failure Investigation

TCR Arabia works with 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.

Failure Analysis Procedure

Cause of failure is determined using state-of-the-art analytical and mechanical procedures. 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, if needed)

  • If necessary tests may 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)

  • 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)
In the course of the various steps listed above 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.

Metallography strong hold of TCR

Certainly we have a leading edge in preparing the metallography samples and their interpretation. Microstructure of metals and alloys is a resultant of many metallurgical processes right from melting to finish components. Also, it records misuse and the abuse of the component during either processing or service which is always in terms of some defects or degeneration of phases. We have a large data base of metallurgical structures which is quite useful for failure investigation. It has been developed after incessant hard work with commitment.

Presentation of Investigation Report

TCR has developed its own way to report the details of investigations encompassing all the evidences recorded. It explains the background of the problem, visual examination, low magnification examination, NDT results, and Chemical Analysis, Scanning Electron Microscopy and EDS Analysis, Metallography, Corrosion and Mechanical Test results.

All the test results are summarized in the discussion part and at the end the failure scenario is elucidated vis--vis evidences recorded, with the proper analysis. Based on the analysis done, the most probable cause of the problem is identified. Suitable recommendations are also made to prevent reoccurrence of the problem. Indeed it is a valuable document that can act as a reference guide for the future course.

TCR is unique in approach to the investigation

Prima facie, our approach is synergistic and creative based on proper team work between different specialists. We are down to earth practical in providing a pragmatic solution to the problem that provides complete satisfaction to our customers and we in turn gain their confidence. Thus, we build long term relations with them to meet their future demands of problem solving.

It is not exaggerating to say that we doctor failure investigation.

Failure Analysis Projects
Our partner company, TCR Engineering in India has completed more than 800 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.

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

· Inconel-600 Tubes of Salt Chest Heat Exchanger

· Condenser Tube of 500 MW Power Generator

· Bursting Problem for 204Cu Stainless Steel During Manufacturing

· Crown Wheel (Bevel Gear) of a Rotary Trailer

· Aluminum-Magnesium Alloy Sheet Without Required Strength After Welding

· Duplex Tube Used in The Fabrication of Process Plant Reactor

You can also download failure analysis case study examples.
Reactor Failure
Reactor Failure

Stress Corrosion Cracking
Stress Corrosion Cracking

Turbine Blade Failure
Turbine Blade Failure

Corrosion Fatigue
Corrosion Fatigue

Centrifuge
Centrifuge

Underwater Pipeline Failure
Pipeline Failure

Fatigue Failure
Fatigue Failure

Boiler Tube Failure
Boiler Tube Failure

Drilling Equipment Failure
Drilling Equipment Failure

Thick Lip Rupture Failure
Thick Lip Rupture

Gear Failure
Gear Failure

Bearing Failure
Bearing Failure

Intergranular Corrosion Cracking Failure
Intergranular Cracking

Fatigue Striations
Fatigue Striations

Grinding Cracks
Grinding Cracks

localized corrosion
Localized Corrosion

Mass Flow Meter Failure
Mass Flow Meter