Mod 9 - Failure Analysis

Module from the Materials and Corrosion Curriculum curriculum.

FAILURE ANALYSIS METHODOLOGY · Learning Objectives · 1. Execute systematic failure analysis (gather, examine, analyze, conclude) 2. Use fractography to identify failure mode (ductile, brittle, fatigue) 3. Apply metallurgical analysis (microstructure, hardness, chemistry) 4. Document findings and corrective actions per 8D or RCA methodology · Failure Analysis Process

Step	Activity	Tools / Methods	Deliverable	Common Mistakes	Time Required
1. Secure Evidence	Preserve failed component, photograph, tag	Camera, tags, chain-of-custody	Evidence log	Cleaning the fracture surface, losing parts	Immediate (don't wait)
2. Gather Operating History	Review DCS data, logs, inspection records, MOC	DCS historian, maintenance records, MOC files	Operating timeline	Relying on memory, skipping MOC review	1-2 days
3. Visual Examination	Examine fracture surface, geometry, environment	Low-power microscope, photography, measurements	Photo-documented visual inspection	Cleaning before examination, missing subtle features	1-2 days
4. NDE	Additional inspection of component and adjacent	UT, MT, PT, RT, replication	NDE report with findings	Destructive tests before NDE, skipping adjacent areas	2-5 days
5. Metallurgical Analysis	Cut sections, prep mounts, microstructure	Microscope, SEM, hardness testing, chemistry	Metallography report	Poor section selection, damaged sample prep	1-3 weeks
6. Mechanical Testing	Tensile, impact, fracture toughness if needed	Universal tester, Charpy, fracture mechanics	Test report	Testing from wrong location, test specimen prep	2-4 weeks
7. Root Cause Analysis	5-Why, Fishbone, Fault Tree, 8D	RCA facilitation, team meetings	RCA report with root cause(s)	Stopping at symptom, not finding true root cause	1-3 weeks
8. Corrective Action	Define actions to prevent recurrence	MOC process, engineering review	Action plan with owners, dates, verification	Generic actions ("train operators"), no verification	Ongoing
Source: API RP 585 (Pressure Equipment Integrity), ASTM E2332, FOS Chief Files — Metallurgy folder, TEC-700 memos

Source: Materials_and_Corrosion_Curriculum_v1.xlsx · Sheet: Mod 9 - Failure Analysis

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