Window for writing Client name, Description, BTG job reference and date

Client: Total ABK

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P.O Box:
Abu Dhabi
United Arab Emirates

Attention:
Subject: Failure investigation of boiler tube

EXECUTIVE SUMMARY
Write a brief account of the failure investigation. This can be done by condensing the
introduction and the conclusions. In a nutshell the client or reader should get a glimpse
of entire investigation.

Document Approval
Author
Reviewed by
Authorised by

Designation

Signature

Document History
Rev.

Date

15 October 2007

Author

Changes
Original issue

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Table of Contents

1.0
2.0
3.0
4.0
5.0

Introduction
Results of Investigation
Discussion
Conclusions
Recommendation (optional)
Appendix 1
Photographic Documentation

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1.0 INTRODUCTION
Describe the working of the failed component, background of the failure,
circumstances which lead to the failure.
Questions like What, When, How, Why would give clues. A brief call or an email to
the client could get what one is looking for.
Size of the failed component, material specification, service history, design and
operating conditions (temperature, pressure), process fluid, inspection history etc.,
shall be specified in the introduction. These data can be arranged in a table.
Based on the information provided by the client and the failed sections received the
scope of work shall be described
Photographs of overall and close up views of the failed component in the as
received condition can be below the introduction part.

Notes : Each heading / section should be started in a new page

Arial font size 12 shall be used throughout the report.
Wherever necessary photographs can be inserted alongside the text. Otherwise
they shall be in the Appendix as photographic section.

2.0 RESULTS OF INVESTIGATION

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2.1 Visual examination

Examine the component for the presence of deposits / scales/ corrosion
products and general / uniform corrosion attack, pitting, mechanical damages
such as wear marks, tooling marks, dents etc. The parts should be examined
before cleaning. As you observe the failed part make a habit of jotting some
salient features in the work sheet. For tube failures do not forget to visually
examine the inside surface. For tube failures dimensional measurements
such as wall thickness, diameter and comparing the same with original
should be done. Refer to the attached Guidelines for failure analysis report
writing
2.2 Fracture surface examination
Each mode of fracture has distinct characteristics that can be easily seen with
the naked eye or the use of stereo microscope or sometimes a scanning
electron microscope (SEM). Make a sketch of the fracture surface and mark
the various fracture zones / modes such as brittle, ductile, fatigue, beach
marks, multiple initiation points, as applicable. The sketch should be adjacent
to the fracture surface photograph for comparison.
Refer to the attached Guidelines for failure analysis report writing
2.3 Non Destructive Testing
Dye penetrant and magnetic particle inspections are the often used non
destructive testing methods to identify surface and sub surface defects
respectively. Not all failed components require NDT.
2.4 Chemical analysis
The chemical analysis of the component was determined ( state the
method as appropriate). The results are tabulated as below
Table 1
Elements, wt %
Sample
C
identification

Mn

Si

Cr

Ni

Mo

Specification
requirement
State whether the composition meets the minimum requirements of the
specification / standard
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2.5 Chemical analysis of deposit / scale (inside or outside)

The scale / deposit from the inside / outside surface of the component was
analysed ( state the method) for the presence of detrimental elements /
compounds. The results are tabulated as below :
Table 2
Test

Scale / deposit collected from the inside surface

The scale / deposit consist mostly of iron oxide. Highlight the important
constituent(s) whose presence has significantly caused the initiation /
progression of the failure.
2.5 Mechanical Properties
Mechanical testing is done to verify whether or not the mechanical
properties of the material conform to the standards. If sample size permits
and if the investigation warrants the tensile or Charpy impact tests can be
carried out and the results tabulated as below
Table 3
Specimen ID
xxxxxxx
Specification
Requirement

Y.S(Unit)

T.S(Unit)

%E

%RA

A Vickers hardness test was performed on the macro sections. The results are
tabulated as below:

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Table 4
Sample
No.

Sample
description

Hardness values
HV5 or 10

Average Hardness
HV 5 or 10

Mi
M2

If the hardness values are more in number a graphical representation ( as

shown below) could be more presentable than a table. This would be
more applicable when comparing hardness values of failed and normal
areas or PM, WELD and HAZ areas.

Hardness traverse
350
Maximum
Hardness
variation =
65 HV1

300
250
200
150
0

Distance from outer edge [mm]

Traverse 1 - North to South Traverse 2 - East to West

2.5 Micro Examination

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Identify microsections by M1, M2 etc. and mark them in the sketch /

photograph as shown in Appendix 1. This is very important and we know for
sure where the micro sections were located. Typical magnifications
highlighting the features shall be used. Describe the microstructure with
respect to grain size, spheroidisation, grain boundary precipitates, cavities,
graphitization damage, sensitization, overheating, grain growth etc.,
Annotate the weld , HAZ and PM areas/ cracks ( intergranular /
transgranular/ straight/ branched). Look for decarburization, oxidized scales,
pitting, grain flow and deformation. If necessary, some features may be
examined in SEM and photographs taken at appropriate magnifications.
2.6 Scanning Electron Microscope / EDS examination
The salient features observed in the SEM examination should be described
and in what way the findings reinforce the optical microscopic examination
results. For example if beach marks are seen in fatigue failures in the visual
/ stereomicroscopic examination striations should be evident in SEM.
2.7 Other tests
Any other tests such as salt spray tests, simulated / accelerated corrosion
tests, creep rupture tests / fatigue tests done to support the failure
investigations.

3.0 DISCUSSION
Summarise the findings. Discuss the results of various tests with respect to the
working of the failed component. From the results obtained if the chemical analysis
and mechanical properties meet the specification requirement and after ascertaining
from the design and the working principle of the component that the material is
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suitable for the intended purpose, mention first that the component has not failed
due to any poor quality of material selection. Even if the material has not met the
specification requirements (chemical or mechanical) that deficiency may not be the
only reason for failure. Continue the investigation.
Then based on the visual, fracture analysis, corrosion mechanisms, scale /deposit
analysis, identify the most probable cause(s) of the failure. Understand the working
principle of the component and find out what are the normally expected failure
mechanisms. Try to reconstruct the failure and work backwards and understand how
the component would behave under normal and abnormal working conditions. Go
back to the client supplied information and do deep analysis. Apply theory to
practical and arrive at the most probable failure mechanism. Literature evidences
may be quoted with reference to authenticate the failure cause.
Discuss the implications of the findings and convey a thorough understanding of the
failure mechanism to the client.
4.0 CONCLUSIONS
First conclude, whether the chemical, mechanical properties, microstructures are
acceptable for the intended purpose of the component.
Itemize the findings and expresses the authors opinion on the root cause(s) of
the failure. Before concluding the reason(s) for the failure verify whether all the tests
identified in the scope of work were done and results got. Verify whether any specific
information given by the client was addressed or not. (for example, pin hole leak,
broken with a loud noise, vibrated and failed, system was overloaded, fire damage
etc).
5.0 RECOMENDATION (Optional)

Recommendations shall be made only if concrete evidences are found.

Examples could be as follows:
Non conforming product being utilized.
Product not suitable for the reported working conditions and environment.
Poor quality of joining methods (welding, bolting etc.)
Gross negligence in maintaining the operating conditions. Sometimes all you will
be able to recommend is that periodical inspections be carried out
more often.
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REFERENCES
1.0 ASM Metals Hand Book volume 11
2.0 Other relevant text book or literature evidences

Appendix 1

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Photograph or sketch showing the locations of chemical, tensile, hardness macro, micro
sections.

This is mandatory for all the failure iinvestigations

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