Consulting
Failure Analysis Services

MISTRAS Group offers expert failure analysis to identify root causes and prevent future issues. Through various laboratory testing and metallurgical techniques, we provide actionable insights to enhance component reliability and system safety.

Failure analysis is a critical process for understanding why a component or system fails, helping facilities mitigate risks and improve reliability. At MISTRAS, we offer a wide range of failure analysis services, utilizing state-of-the-art tools and a multidisciplinary approach to uncover the root causes of failures in areas the downstream refining, chemical, petrochemical, and other processing industries, along with critical infrastructure like storage tanks and pipelines.

MISTRAS’ goal is to identify contributing factors, recommend actionable solutions, and support our clients in maintaining the highest standards of safety and operational efficiency. MISTRAS’ failure analysis services can be broken down into three primary areas:

• Preliminary Examination
• Laboratory Testing
• Metallurgical Analysis

Each of these areas plays a key role in providing a holistic and detailed evaluation, ensuring that the underlying issues are thoroughly understood and addressed.

Preliminary Examination

The preliminary examination is crucial for establishing the conditions surrounding the failure. By collecting samples and relevant data, MISTRAS helps you identify key operational and design factors that may have influenced the failure. This stage lays the groundwork for further analysis by evaluating whether issues arose during manufacturing, maintenance, or operational processes.

• Preliminary Examination Methods: Collection of samples, design/process data, and operational/maintenance practices and history.
• Review MTRs and Prior Reports: Examination of Material Test Reports (MTR) and previous failure or maintenance reports to identify recurring issues or deviations that might indicate patterns

Laboratory Testing

Laboratory testing focuses on identifying the internal and structural factors contributing to the failure. It involves applying advanced diagnostic techniques to analyze the material and detect any hidden flaws or weaknesses that may not be visible during initial inspection.

• Visual Documentation and NDT: Visual inspections and NDT (e.g., ultrasonic, eddy current) are conducted to detect cracks, corrosion, or sub-surface flaws without damaging the component. MISTRAS offers a wide range of laboratory testing techniques for a plethora of materials and components.
• Microscopy, PMI, and Mechanical Testing: Performing microscopic analysis, Positive Material Identification (PMI) and mechanical testing helps to evaluate material properties, structure, and strength under operational conditions.

Metallurgical Analysis

Metallurgical analysis dives deeper into understanding the material's response to stress and the failure mechanism. This stage combines evidence from the earlier steps to provide a comprehensive understanding of how material characteristics and environmental factors led to the failure.

• Literature Review and Failure Mechanism Determination: Through a review of relevant literature and case studies, MISTRAS engineers help to determine possible failure mechanisms, such as fatigue or stress corrosion.
• Evidence Evaluation: Analysis of test results and collected data to determine how the material and environmental conditions contributed to the failure.
• Conclusions and Recommendations: Finally, conclusions can be drawn on the root cause of the failure, with actionable recommendations provided for material selection, design, and operational improvements to prevent future failures.