The only way to analyze failures without an error is by having an excellent Materials Testing & Analysis Laboratory. Failure analysis involves routine destructive testing facilities such as for hardness, stresses, UTS, impact, bendability, creep and fatigue among others. These tests could be analytical in nature as well such as in a Metallurgical Chemistry Laboratory where the failed material is analyzed. The failure analysis could also involve more sophisticated techniques such as those involving Electron Microscope, Gas Chromatography, and tests for inter crystalline corrosion and resistance to hydrogen embrittlement besides various forms of spectroscopy. In difficult cases you may have to seek the help of Computer Modeling & Simulation techniques when the routine methods are inadequate in yielding satisfactory results pinpointing the cause of failure. To give an example in case while carrying out pipeline inspection a failure of the welded joint is encountered a thorough analysis would establish whether the failure was due to material defect, the quality of welding or higher pressure within the pipeline due to obstruction or some other reasons.
Pipeline inspection is a very painstaking job that requires qualified technicians with great patience and skill. A number of methods of non-destructive testing are used to carry out the inspection of pipelines. These may include Radiographic, Magnetic or Ultrasonic Testing. A common tool is the Magnetic Flux Leakage (MFL) method used for steel pipelines. In this method, a powerful magnetic field is created. The flux lines are then analyzed to yield the areas having flaws in the pipeline.
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