Metallurgical Testing

Failure Investigation & Root Cause Analysis

Failure analysis is the process of collecting and analyzing data to determine the root cause of failure, often with the goal of determining preventive actions or liability. It is an important discipline in many branches of manufacturing industry, such as the heavy industry, where it is a vital tool used in the development of new products and for the improvement of existing products.

we specialize in failure analysis services crucial for ensuring industrial reliability. From initial examination to comprehensive testing, we uncover root causes of failures, offering insights to enhance product performance.

Our complete Procedure to Perform Failure Analysis:

1. Gather Background Data and Select Samples
2. Conduct Initial Examination of the Failed Part
3. Perform Comprehensive Metallurgical Analysis of Failed Material
4. Thoroughly Examine the Failed Part, including Macroscopic and Microscopic Examination and Analysis. Tests may also include Weld Examination, Case Depth, Decarburization Measurement, Coating/Plating Evaluation, Surface Evaluation, and/or Grain Size Determination.
5. Perform Chemical Analysis to Simulate Environmental and Physical Stress Factors that may have Contributed to the Failure.
6. Analyze Fracture Mechanics to Understand the Mechanism of Failure.
7. Select and Test Alternative Products and/or Procedures Aimed at Improving Performance.
8. Provide On-Site Evaluation, Consulting Services, and Formulate Conclusions. Compile the Report, including Recommendations.
9. Our team of experts utilizes advanced techniques to provide in-depth insights into failure mechanisms. By identifying weaknesses and recommending improvements, we help our clients enhance product performance and prevent costly breakdowns.

Condition Assessment

Ensuring the optimal performance and safety of your boiler system is essential in industrial settings. Petromaster offers comprehensive boiler condition assessment services, including on-site inspections and laboratory analysis. Our experienced team utilizes state-of-the-art NDT techniques to identify potential issues and provide real-time evaluations, minimizing downtime and ensuring compliance with regulatory standards. With precise measurements, metallurgical analysis, and customized reporting, we deliver actionable insights tailored to your needs. Choose Petromaster for expertise, cutting-edge technology, customized solutions, and timely delivery of assessment reports.

Benefits:

1. Enhanced Efficiency: Identify issues in real-time, minimizing downtime and optimizing operational efficiency.
2. Improved Safety: Receive immediate recommendations for maintenance or repairs, enhancing safety and compliance.
3. Tailored Solutions: Benefit from customized reporting and recommendations tailored to your specific needs.

Ready to optimize your boiler system’s performance? Click “Read More” for detailed insights and solutions.

Petromaster has established expertise in the life assessment of components from petrochemical and power plants operating in the creep regime.

The assessment of the remaining life of high-temperature components generally requires creep analysis, which is very sensitive to temperature. In most cases limited data on operating temperatures is available, however, in steam plants, the thickness of the protective internal oxide layer provides a good indicator of thermal history. Using ultrasonic techniques, from the outside of the tubing, we are able to measure wall thickness and the deposit thickness nondestructively and from this infer tube metal temperature.

Petromaster can provide a full Component Life Assessment service Which can include the following:

1. On-site inspection using advanced NDE
2. Metallographic evaluation
3. Review of design drawings
4. Remaining Life Assessment calculations
5. Development of inspection procedures
6. Weld repair
7. Component replacements where appropriate.

Petromaster is pleased to announce its on-site life assessment capabilities including replication, hardness testing, and field metallography. These services are complimentary to our plant integrity and life assessment services as well as other capabilities and utilizes the extensive knowledge and experience of Petromaster’s in-house and international technical experts. Field metallography provides early warnings of the onset of many damages to the process and engineering industries.

USE of in-situ Metallography

1. Failure Investigation & Remaining Life Assessment.
2. Health Assessment of Critical Components.
3. Damage Assessment of fire-affected equipment.
4. Quality checks for heat treatments.
5. Useful for repair welding decisions.

Damages Identified by In-Situ Replica

1. Graphitization, Creep, Thermal Fatigue, Oxidation
2. High Temperature Hydrogen Attach (HTHA)
3. Spheroidization of Carbides
4. Hydrogen Cracking, Stress Corrosion Cracking
5. Sigma Phase Embrittlement, General degradation of Materials.
6. Sensitization, Corrosion & Carburization.

Fitness-for-service (FFS) assessment is a multi-disciplinary approach to determine, as the name suggests, whether equipment is fit for continued service. The equipment or system in question may contain flaws or other damage or may be subjected to more severe operating conditions than anticipated by the original designer. The outcome of a fitness-for-service assessment is a decision to run as is, repair, re-rate, alter, or retire the equipment.

Petromaster assesses the fitness for service of plant under operating conditions which can give advanced warning of in-service failures. This can help plant operators reduce costs by avoiding costly unplanned outages and at the same time minimize excessive maintenance or premature inspection.

Petromaster assesses the fitness for service of plant components and materials under operating conditions, which can confirm that a material or component is safe to use, give advanced warning of in-service failures, and resolve disputes between suppliers and operators.