Failure Analysis-Q11


Local universities graduates are encouraged to take parts in business opportunity in Malaysia. As materials engineering graduate, knowledge and skills in failure analysis seems having a large potential to be commercialised internationally. To set up a consultation firm that specialist in failure analysis services of engineering materials, you have to apply RM500,000 from Graduate Entrepreneur Schemes. To realize this intention, you have to make a proposal based on following inquiries.
a)              Explain the definition of failure in term of materials engineering?
  [10 Marks]
Inability of a materials or a components to
    1. perform the intended function
    2. Meet performance criteria although it may still be operational
    3. Perform safely and reliably even after deterioration.
Examples
  1. Yielding
  2. Wear
  3. Buckling (elastic instability)
  4. corrosion
  5. fracture
 
b)              In term of economy, convince the Graduate Entrepreneur Schemes evaluation committee panels on the important and the value of failure analysis that will be offered to potential industry customers.
 [40 Marks]
#      Identify corrective actions based on a determination of the root cause of the failure.
#      Minimize future failures of the same type.
#      Tool that can be used to
Ø      reduce maintenance costs,
Ø      increase system availability,
Ø      reduce the potential losses involved in catastrophic failures.
#      Potential savings will vary on a case by case basis.
#      Used to identify the party at fault.
3      Financial losses resulting from a failure can often be recovered when
Ø      deficiencies in design,
Ø      workmanship or
Ø      materials
               can be identified as the root cause of the failure.
 

c)            In your proposal, list down and justify the procurement of the scientific equipments that necessitate to purchased to implement failure analysis consultation services
[30 Marks]
1)      Photography
2)      Optical Microscopy up to 600X
3)      Scanning Electron Microscopy (SEM) over 10,000X
4)      Chemical Analysis
Ø      SEM/EDS
Ø      Spark Emission Spectroscopy
Ø      Fourier Transform Infra Red (FTIR)
5)      Mechanical Testing
Ø      Hardness, micro-hardness, tensile, shear, physical testing
6)      Stress Analysis / FEA
Ø      Magnitude, principal direction, sensitivity
7)      Instrumentation
Ø      Strain Gages, accelerometers, thermocouples, ect.
8)      Non-Destructive Testing (NDT)
b)              Recommend the types of potential industries that needs your consultation services
[20 Marks] 
      
  1. Upstream and Downstream Oil & Gas
  2. Petrochemical
  3. Refining
  4. Power generation
  5. Marine
  6. Medical Instruments
  7. Commercial Properties
  8. Government Agency
  9. Alloy Producers
  10. Equipment Manufacturers
  11. Ship and Ship Building
  12. Water and Wastewater
 



Failure Analysis: MidTest - Marking Schema


A process engineer responsible for the operation of petrochemical plant noticed a significant pressure drop which indicates that the boiler tubes might have experienced some damage problem. Primary witness report by inspection engineers found that the water content in steam tanks was reduced by as much as 15%. There are the some pitting marks were observed at tensioned side at the bend area of the boiler tube (refer Figure 1) results the vaporizing out of water vapour. The tube was then removed and sends to your consultancy firm for further investigation.







To initiate the failure investigation, you have to make a site visit to that petrochemical plant to get some background information. Identify the important information needed from plant engineers that helps you getting some primary clues. [30 marks]



1. Location,

2. name,

3. Part No,

4. Description,

5. Manufacturer or fabricator

6. Function of item

7. Maintenance procedures

8. Maintenance history

9. Cleaning procedures

10.Cleaning history

11.Operational procedures (temp./ pressure etc)

12. Type of materials (Chemical composition)

13. Operational documentation (standard, temp./ pressure etc)

14. Service deviations

15. Normal stress orientations

16. Extent of incident

17. Precipitating events

18. Drawings

19. Photographs

20. Previous inspections reports,

21. Opinions of related personnel

ii) Considering chemical composition of boiler tube as shown in Table 1,



a) What your hypothesis regarding the root cause of the tube failure [25 marks]



1. Residual stress resulted from bending works

2. Corrosion attacks originate from water, believed resulted from application of untreated water

3. Lower content of Mo (lower pitting index no.) contributes to pitting corrosion

4. All of the above factors contribute to the stress corrosion cracking (SCC).



b) Calculate the tube pitting index number [20 marks]




Pitting Index (PI) = wt.% Cr + (3.3)(wt.% Mo)

= 17.585 + 3.3(0.396) = 18.89




c) Recommend the new materials to prevent the same future failure. [25 marks]




Further upgrades are out of the realm of the stainless steels and into high-alloys steel. Eg Pitting resistance metals such as

Ø high-molybdenum SS

Ø Incoloys,

Ø Inconels, or

Ø Hastelloys


Jawatan Kosong sebagai Pegawai Penyelidik



Saya memerlukan seorang pembantu penyelidik bagi menjalankan kerja-kerja penyelidikan dalam bidang kakisan yang bertajuk “Development of Biofriendly Sacrificial Anode from Magnesium Alloys for Underground Structure Corrosion Protection”.




Syarat Umum



  1. Diploma/ Ijazah sarjanamuda Kejuruteraan atau Sains dalam bahan, fizik @ kimia
  2. Mempunyai semangat tinggi dan minat yang mendalam dalam bidang kakisan dan penuangan logam Magnesium
  3. Mempunyai kenderaan sendiri
  4. Mempunyai daya kreativiti yang tinggi
  5. Gaji: RM 1700 sebulan (Ijazah Sarjanamuda)
  6. Tempoh kontrak 1 tahun
  7. Mempunyai kemahiran analitik
  8. Sanggup bekerja di UniMAP, Perlis
  9. Perhubungan komunikasi yang baik sesame manusia




Tanggungjawab



  1. Mempelajari dan memahani konsep elektrokimia kakisan
  2. Membuat penyelidikan dalam makmal berkaitan elektrokimia kakisan
  3. Memfabrikasi aloi Magnesium menggunakan teknik peleburan dan penuangan logam
  4. Membangunkan aloi Magnesium yang berkeupayaan menghasilkan open circuit potential dan anode efficiecy melebihi 1.8V vs SCE
  5. Sanggup outstation ke institusi penyelidikan lain untuk menjalankan analisis komposisi kimia dan analisis lain yang perlu.

Jika berminat sila hubungi saya seperti maklumat dibawah;



Shaiful Rizam Shamsudin
Pusat Pengajian Kejuruteraan Bahan
Universiti Malaysia Perlis (UniMAP)
Tel: 04-9798663
H/P: 019-6405116
E-mail: rizam@unimap.edu.my @ srizam@gmail.com
Skype: srizam

Replica-Q14

What is the qualitative thermal degradation indexes considered in metallographic analysis?
  • Tendency to pearlite/ bainite spheroidisation
  • Coarsening of precipitates in the ferritic matrix and at grain boundaries,
  • Broadening of denuded zones (no precipitates) along grain boundaries.

Replica-Q13


What is Creep or creed deformation?


Creep is a phenomenom of a sample to deform against time at particular temperature. Creep is the tendency of a solid material to slowly move or deform permanently under the influence of stresses. It occurs as a result of long term exposure to levels of stress that are below the yield strength or ultimate strength of the material. Creep is more severe in materials that are subjected to heat for long periods, and near the melting point
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