Asset Integrity Management

Failure Analysis & Root Cause Analysis (RCA)

Metallurgical + process forensics + structured RCA — closing the recurrence loop for capital-equipment failures

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Technical overview

Failure Analysis & Root
Cause Analysis (RCA)

Failure analysis (FA) and Root Cause Analysis (RCA) of equipment failures combine metallurgical examination (SEM-EDX, optical microscopy, fractography, hardness mapping, chemical composition), fluid / corrosion forensics (ICP, IC, GC-MS, deposit characterisation), and structured causal analysis methodologies (TapRooT, Apollo RCA, ARCA / SOLR, 5-Whys, Cause Map, Ishikawa, TRIPOD) to identify why a vessel ruptured, a tube failed, a compressor crashed, or a pipeline leaked. The discipline distinguishes itself from blame-focused incident review through systematic evidence preservation, multi-layer causal exploration (immediate, intermediate, root, latent), and recommendation development that addresses programmatic gaps not just the specific failure. CSB-investigated events (Tesoro Anacortes HTHA, Williams Olefins de-ethaniser overfill, Husky Superior HF release) demonstrate the cost of inadequate FA / RCA — repeat events at sister facilities and across industries. Modern practice integrates ASM Failure Analysis Handbook techniques, API RP 571 damage-mechanism reference, IChemE Loss Prevention Bulletin learnings, and increasingly digital-evidence chain-of-custody for litigation defence.

Failure Analysis & Root Cause Analysis (RCA) — Overview
Engineering process

Failure Analysis & Root Cause Analysis (RCA) workflow

Incident Scoping & Evidence Preservation

Scope investigation per CCPS Guidelines for Investigating Process Safety Incidents; preserve physical evidence (failed component, residue, debris pattern) per IEC 62740 chain-of-custody; secure DCS / historian data and witness statements.

Failure Mode Identification

Identify candidate failure modes per ASM Handbook / API 689 — overload, fatigue, corrosion, wear, brittle / ductile fracture, creep, environmental cracking; align with API RP 571 damage mechanism catalogue; conduct visual / macroscopic examination.

Laboratory Analysis & Characterisation

Conduct laboratory analysis — metallography, fractography (SEM, EDX), chemical analysis (OES, XRD), hardness profile, mechanical testing; identify root failure mode (initiating mechanism) vs contributory factors; align with ASTM E series test methods.

Causal Chain Analysis

Apply systematic causal analysis — Why Tree / TapRoot / Apollo / Causal Chain per ISO 17776 / IEC 62740; identify physical root (immediate), latent root (system / management), organisational / cultural factors; align with CCPS / OSHA accident investigation methodology.

Corrective Action Development

Develop corrective actions per hierarchy of controls — elimination, substitution, engineering, administrative, PPE; specify monitoring KPIs for corrective action effectiveness; align with MOC for engineering / procedural changes; integrate with PHA revalidation.

Lessons Learned & Recurrence Prevention

Issue investigation report with executive summary, evidence pack, causal analysis, corrective actions, and recurrence-prevention strategy; share lessons learned across sites and corporate; integrate with API RP 754 PSE indicators and CCPS RBPS Incident Investigation element.

Failure Analysis & Root Cause Analysis (RCA) — Scope
Scope of work

Every deliverable — from basis to handover

Complete Failure Analysis & Root Cause Analysis (RCA) scope — every calculation, drawing, specification, and construction support activity.

Evidence preservation per chain-of-custody — photography, samples, operating data, maintenance records
Visual examination — macroscopic fractography, deposit / corrosion pattern, deformation
Metallographic examination — optical microscopy, SEM-EDX, hardness, microstructure
Chemical analysis — base material, deposits, corrosion products, contamination
Fractographic interpretation — fatigue striations, brittle cleavage, ductile dimples, SCC
Damage-mechanism identification per API RP 571 — typically 3–6 candidate mechanisms per case
Sequence-of-events reconstruction from DCS / SCADA / maintenance records
Structured causal analysis — TapRooT / Apollo / Cause Map / TRIPOD with multi-layer logic
Latent-cause identification — programmatic gaps, MOC failures, training deficits, design margin
Recommendation development addressing immediate, programmatic, and learning-organisation dimensions
Engineering outcomes

Outcomes of Failure Analysis & Root Cause Analysis (RCA)

Root Cause & Recurrence Prevention
  • Prevents recurrence at the failed site and at sister facilities
  • Surfaces programmatic gaps that single-failure responses miss
  • Anchors damage-mechanism awareness across operations and engineering
  • Builds organisational learning from individual events
API 689 / IEC 62740 RCA Defence
  • OSHA PSM 1910.119(m) incident investigation audit-defensible
  • Withstands CSB / HSE / equivalent regulator forensic examination
  • Supports prosecutor / litigation defence with chain-of-custody evidence
  • Aligns with CCPS RBPS incident-investigation element
Reliability Improvement Action Quality
  • Identifies MOC / training / inspection gaps from single failures
  • Drives realistic operator awareness through failure-mechanism communication
  • Builds organisational learning culture
  • Supports vendor warranty / product-defect dialogue
Repeat Failure Cost & Downtime Reduction
  • Avoids repeat-failure cost — sister-asset incidents typically 5–10× original loss
  • Reduces insurance loadings through demonstrated learning capability
  • Supports vendor warranty claims and product-defect litigation
  • Trims business-interruption exposure
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