Root Cause Analysis Services

From Symptoms to Solutions, we’ll help you Identify, Analyze, and Resolve.

Root Cause Analysis & Recommendation for Safe Working

At Ideametrics, we offer comprehensive Root Cause Analysis (RCA) services to identify, analyze, and resolve the underlying causes of engineering failures. Our systematic approach involves using advanced simulation tools, engineering expertise, and industry best practices to thoroughly investigate problems and provide effective solutions. We help clients minimize downtime, improve safety, and optimize the performance of their equipment and processes.

Comprehensive Investigation Approach

Our Root Cause Analysis services involve a structured and detailed process to uncover the reasons behind equipment failures or operational issues. By combining advanced analysis techniques, including Finite Element Analysis (FEA), Computational Fluid Dynamics (CFD), thermal and mechanical simulations, and Non-Destructive Testing (NDT), we provide a deep understanding of the problem and recommend corrective actions.

Common Failure Scenarios We Address

Pressure Vessel and Tank Deformation

We investigate cases where tanks, vessels, or other pressure equipment deform unexpectedly during testing or operation. Our analysis includes evaluating structural integrity, material properties, load conditions, and external factors to pinpoint the cause of deformation and recommend mitigation strategies.

API Tank Deformation, Buckling, and Bulging

We specialize in identifying the root causes of deformation, buckling, or bulging in API Tanks. Our investigations include assessing load distribution, material properties, and support conditions. By simulating real-world scenarios, we determine whether factors like pressure fluctuations, temperature variations, or improper installation are contributing to these issues and suggest corrective actions to prevent recurrence.

Tube-to-Tube Sheet Joint Leaks

Frequent leaks in tube-to-tube sheet joints are a common issue in heat exchangers. We perform detailed thermal and mechanical analyses, along with FEA, to identify factors such as thermal expansion, stress concentration, and improper joint design that may contribute to leakage. Our recommendations focus on design improvements and maintenance practices to prevent recurrence.

Heat Exchanger Failures

For heat exchanger issues, such as tube damage, flow-induced vibrations, or thermal fatigue, we conduct thorough CFD and mechanical analysis to understand fluid flow dynamics, temperature distribution, and stress levels. We provide insights into the root cause of failure and suggest solutions to enhance equipment reliability and performance.

Unexpected Component Failures

When components such as nozzles, bellows, or supports fail unexpectedly, we utilize FEA, material analysis, and NDT methods to investigate factors such as fatigue, corrosion, or manufacturing defects. Our findings help clients make informed decisions regarding material selection, design modifications, or operational adjustments.

Our Analysis Techniques

Computational Fluid Dynamics (CFD)

Helps analyze fluid flow, pressure drops, temperature distribution, and potential flow-induced vibrations, providing insights into issues that could affect equipment performance.

Non-Destructive Testing (NDT)

We employ NDT techniques such as ultrasonic testing, radiographic testing, magnetic particle inspection, and dye penetrant testing to detect surface and subsurface flaws without damaging the component. This helps identify material defects or damage that could lead to failure.

End-to-End Support for Root Cause Analysis

Problem Identification

We work closely with clients to understand the symptoms, operating conditions, and history of the failure. This helps us establish a comprehensive context for the analysis.

Data Collection and Simulation

We gather relevant data and perform advanced simulations (FEA, CFD, etc.) and NDT to recreate the failure scenario, allowing us to pinpoint the root cause accurately.

Failure Analysis and Reporting

Our experts analyze the results, identify the primary factors leading to the failure, and provide a detailed report that includes the root cause, contributing factors, and recommended corrective actions.

Corrective Action and Prevention

We offer practical recommendations for corrective actions, design modifications, or operational changes to prevent future failures. Our solutions aim to enhance equipment safety, reliability, and performance.

Why Choose Ideametrics for Root Cause Analysis?

Expertise Across Multiple Domains:
Our team has experience with diverse industries, including oil&gas,
petrochemicals, power, and manufacturing, allowing us to address a wide range
of engineering problems.
Advanced Simulation and Testing Capabilities:
Utilizing FEA, CFD, NDT, and other sophisticated tools, we provide precise and
detailed insights into the root causes of failures.
Comprehensive Solutions:
We go beyond identifying the root cause by offering practical recommendations and support to implement corrective actions, ensuring long-term reliability and
performance.

Our Root Cause Analysis services are designed to help clients minimize risks, reduce
downtime, and improve the safety and reliability of their operations. Let Ideametrics be your partner in solving complex engineering challenges and preventing future failures.