Root Cause Failure Analysis

RCFA helps identify why a failure happened, not just what went wrong. It looks at the symptoms, possible causes, and the sequence of events that led to the failure. The test helps determine the actual root cause so the same problem can be prevented in the future. It supports better decisions on repair, improvement, and long-term reliability.

Root Cause Failure Analysis Process

Equipment Specifications

• Visual Examination : Digital camera, magnification up to 30×; record crack, rupture, corrosion, erosion, deposits and deformation
• Dimensional Examination: Vernier caliper: 0.01 mm; micrometer: 0.001–0.01 mm
• Wall Thickness: Ultrasonic Thickness Gauge, resolution preferably ≤0.01 mm; calibrated reference block
• Surface NDT: DPT / MPT as applicable; calibrated equipment

Test Standards

• ASTM E8/E8M – Standard Test Methods for Tensile Testing of Metallic Materials
• ASTM B557 – Standard Test Methods for Tensile Testing Wrought & Cast Aluminum & Magnesium-Alloy Products

Boiler Tube Failure Analysis

Identify why boiler tubes fail and prevent repeat failures.

The investigation examines the failed tube, operating conditions and surrounding components. It identifies causes such as corrosion, overheating, erosion, fatigue or material degradation. The results help address the root cause and improve boiler reliability.

Boiler Tube Failure Analysis

Equipment Specifications

• Visual Examination: Detailed examination of tube surface, cracks, bulging, deformation, corrosion, erosion, deposits and fracture features
• Dimensional Examination: Tube OD, ID and wall-thickness measurements; assessment of localized thinning and deformation
• Metallography: Microstructural examination for overheating, creep damage, grain growth, decarburization, oxidation and material degradation
• Hardness Testing: Rockwell / Vickers / Brinell hardness measurement; evaluation of material degradation and overheating effects

Test Standards

• ASME BPVC Section II – A service section of the ASME Boiler and Pressure Vessel Code that provides material specifications, properties, and testing requirements for construction