Design integrity and materials consultancy - Failure investigation consultancy

Union Oil absorber vessel failure resulting from cracks growing in an as-welded repair weld heat affected zone exposed to a hydrogen environment

Failures are an unfortunate fact of life. Successful companies stand out in their positive approach to understanding the events leading to failures and the underlying causes so as to learn and prevent reoccurrence. Investigation of failure is important where claims for compensation are involved, where a product's fitness for purpose is in doubt, and to give clients confidence in their future operations.

Failure investigation is a core TWI service built on unique multi-disciplinary expertise, years of experience and a world-recognised reputation. A rapid response can be made when necessary for an initial assessment after the event. When failures lead to litigation, there is the staying power to prepare and provide expert evidence in court. A professional responsible service is offered to all clients with a duty of care.

TWI has an in-house procedure for conducting failure investigations. A principal investigator, who will be a professionally qualified engineer or metallurgist, will be appointed to lead each investigation and will draw in additional expertise as required. Work may involve other professionals, such as loss adjusters, insurers, lawyers, and the Health and Safety Executive.

Failure investigations are tailored to the objectives of each client whether these be commercial (breach of contract, insurance, liability etc), criminal prosecution (health and safety incidents) or technical (understanding what happened and preventing reoccurrence). An analysis of the circumstances of failure leads to identification of the proximate cause and contributory factors and conclusions. When asked, TWI will assist clients to achieve settlement with other parties through arbitration.

TWI has a pool of engineers, metallurgists and corrosion scientists experienced in failure investigation. They can deal with structures or components that have failed or become defective or corroded in different environments, where welding is of poor quality or contains defects, or where inspection has failed to detect the damage. A mix of skills and knowledge is required when the cause of failure is complex.

Often investigations start with a site visit to inspect the parts in-situ. On other occasions, failed or defective or corroded parts are delivered to TWI for examination. There are comprehensive metallurgical, environmental and non-destructive testing facilities available to determine the mode of failure from examination or replication of the damage and the fracture surfaces. The approach to failure investigation is meticulous and thorough but always with the client's objectives in mind.

Clients may expect a clear report describing the circumstances, identifying the causes, and drawing conclusions. Recommendations to prevent failure reoccurring, and for reinstatement or repair are made when appropriate. Reports are written and presented in a way that could be used as court evidence, should this be necessary. It is normal for TWI to make a verbal presentation of the report to clients and respond to questions.

Where litigation is involved, TWI has standard terms of engagement within its quality assurance system. Selected staff have received training in Expert witness work from the Academy of Experts. A senior manager regularly reviews projects where litigation is a prospect to ensure clients get the priority and service required.

Contact failure.investigation@twi.co.uk.