MISTRAS Group offers expert failure analysis to identify root causes and prevent future issues. Through forensic, investigative, and metallurgical techniques, we provide actionable insights to enhance component reliability and system safety.
Failure analysis is a critical process for understanding why a component or system fails, helping facilities mitigate risks and improve reliability. At MISTRAS, we offer a wide range of failure analysis services, utilizing state-of-the-art tools and a multidisciplinary approach to uncover the root causes of failures in areas the downstream refining, chemical, petrochemical, and other processing industries, along with critical infrastructure like storage tanks and pipelines.
MISTRAS’ goal is to identify contributing factors, recommend actionable solutions, and support our clients in maintaining the highest standards of safety and operational efficiency. MISTRAS’ failure analysis services can be broken down into three primary areas:
Each of these areas plays a key role in providing a holistic and detailed evaluation, ensuring that the underlying issues are thoroughly understood and addressed.
Forensic failure analysis involves the examination of failed components and the identification of the mechanisms behind their failure. Our experienced engineers at MISTRAS Group leverage a wide range of forensic techniques to determine not just how a failure occurred, but why it happened in the first place, in materials used in piping, storage tanks, pressure vessels, and processing equipment.
In the initial stages of forensic failure analysis, MISTRAS performs a detailed examination of the failed components. This includes a visual examination, considering factors such as wear patterns, surface corrosion, mechanical damage, and fatigue. Often, the failure may exhibit visible signs that provide insight into whether the failure was caused by overloading, environmental exposure, or manufacturing defects. MISTRAS engineers also use traditional and advanced Non-Destructive Testing (NDT) methods like Ultrasonic Testing (UT), Eddy Current Testing (ET), or Radiography (RT) to assess internal damage without compromising the integrity of the component.
Using advanced fracture mechanics tools and techniques, such as Scanning Electron Microscopy (SEM) and X-ray imaging, we can trace the origin of cracks and the patterns of crack propagation down to the microstructural level. Understanding where and how cracks are initiated, and their subsequent path, helps pinpoint weaknesses in the material or design. In particular, it provides critical insights into how similar failures can be prevented in the future. This process is essential for determining whether the failure was due to material defects, environmental stressors, localized corrosion, or other factors specific to the components' operating environment.
A failure investigation goes beyond the physical examination of a component and delves into the broader factors that contributed to the failure. At MISTRAS, we conduct thorough root cause analyses to understand all aspects of the failure, including design, operational, and maintenance considerations. Our investigation also includes reviewing how corrosion and material selection may have contributed to the failure of assets like piping systems or storage tanks.
Root Cause Analysis (RCA) is a methodical approach used to identify the fundamental cause(s) of the failure. Our engineers gather data from all relevant sources, including maintenance records, operational conditions, and previous failure histories. The result is an accurate understanding of the underlying causes, which can be complex and multifaceted. In the case of refinery and critical downstream equipment, this often involves evaluating how poor maintenance practices, extreme operating environments, or improper material selection for corrosion resistance impacted the system's reliability.
Once we have identified the root causes, we evaluate the entire lifecycle of the component, including its design, operational use, and maintenance practices. Poor design, incorrect materials for handling corrosive substances, improper operational procedures, or insufficient maintenance can all contribute to failures.
MISTRAS reviews all these factors to provide a comprehensive analysis. For example, in the case of mechanical systems, failure could stem from misalignment during installation, inadequate lubrication, or overloading during normal operations. In storage tanks and pipelines, failure could also occur due to corrosion caused by improper material choice or environmental conditions. We also review whether the failure could have been avoided through more effective inspection or maintenance procedures.
In many cases, component failure is related to the properties of the materials used, and understanding material behavior is crucial to determining failure causes. MISTRAS provides expert metallurgical analysis to assess the material integrity of failed components, especially when dealing with critical infrastructure like material components, storage tanks, and pipelines. This rigorous metallurgical analysis provides essential data for improving material selection, manufacturing processes, and design choices, ultimately leading to higher reliability and fewer failures in industries like downstream operations.
Our metallurgists use advanced microscopy techniques, such as SEM, metallography, Energy-Dispersive X-ray Spectroscopy (EDS), Electron Backscatter Diffraction (EBSD), and optical microscopy, to perform a detailed examination of the material's microstructure. These techniques reveal critical information about the material's composition, grain boundaries, phase structure, and defects at the microscopic level. By understanding the microstructure, MISTRAS can help determine whether material degradation, such as grain growth, segregation, or corrosion contributed to a component failing.
MISTRAS performs chemical analysis and chemical composition analysis through techniques like EDS analysis, X-ray Fluorescence (XRF), or Optical Emission Spectrometry (OES). These analyses ensure the material composition matches the specified standards and help identify potential material anomalies.
For example, variations in alloy content, impurities, or manufacturing inconsistencies can all impact the material's strength, fatigue resistance, and corrosion resistance. Material verification can also confirm whether a failure occurred due to the use of substandard or incorrect materials, which is especially important for industries relying on materials like stainless steel and other materials.
