1. What are the first steps in a tube failure investigation?
Secure and document the failure scene. Preserve fracture surfaces from contamination. Collect operational data preceding the failure. Identify and label all components involved. Initiate a formal investigation protocol.
2. How is the origin point of a rupture determined?
Chevron patterns on fracture surfaces point to origin. Oxidation differences indicate sequence of failure. Microscopic examination of crack propagation. Stress analysis of the component. Correlation with operational stress history.
3. What laboratory tests are performed on failed samples?
Metallography for microstructural examination. Hardness testing across affected areas. Chemical analysis to verify material composition. SEM/EDS for fracture surface characterization. Mechanical testing of remaining material properties.
4. How are root causes differentiated from symptoms?
Fishbone diagrams map all contributing factors. Five-why analysis probes underlying causes. Distinguishes between immediate and systemic issues. Considers human, technical and organizational aspects. Focuses on addressable factors.
5. What are the key elements of a failure report?
Chronology of events and discovery. Detailed evidence documentation. Laboratory test results and analysis. Root cause determination. Specific corrective actions. Lessons learned for prevention.
