1. What are the first steps when a tube failure occurs?
Secure the area for safety. Document failure location and appearance. Preserve evidence before cleanup. Collect operational data prior to failure. Initiate formal investigation process.
2. How is failure origin location determined?
Chevron patterns point to rupture origin. Oxidation differences indicate sequence. Microscopic examination of fracture surfaces. Stress analysis of the component. Correlation with operational stresses.
3. What laboratory tests are performed on failed samples?
Chemical analysis verifies material composition. Hardness testing detects property changes. Microscopy reveals microstructural features. SEM/EDS identifies fracture mechanisms. Mechanical tests compare to specifications.
4. How are root causes differentiated from symptoms?
Fishbone diagrams map contributing factors. Five-why analysis digs deeper. Distinguishes between immediate and underlying causes. Considers human, technical and organizational aspects. Focuses on preventable factors.
5. What are the essential elements of a failure report?
Clear chronology of events. Detailed evidence documentation. Laboratory test results. Root cause analysis. Specific corrective actions. Lessons learned for prevention.
