For safety as well as for economic reasons, the prevention of failures plays a central role in the plant engineering. Such errors can be corrosion, fatigue, brittle collapse, plastic collapse, spalling of coatings or missing joint integrity. Before starting with failure prevention, the exact exposure to loads and environmental influences of the different components must be known. In the next step design, materials and manufacturing processes have to be chosen by using appropriate safety factors, screening methods and feasibility studies. The choices made have to be assessed and verified by using various tools. Such tools are design reviews, proposals and demands in appropriate codes, standards and regulations and the implementation of failure mode and effects analysis (FMEA). Furthermore, inspection and maintenance intervals have to be defined and the lessons learned have to be implemented continuously.

Reducing the number of failures

From years of experience, the meticulous quality assurance of materials, the manufacturing processes and the continuous implementation of the lessons learned in design and manufacturing specifications, significantly reduce the number of failures through preventive measures at BHDT GmbH.

BHDT GmbH supports its customers to a large extent in determining the cause of damage to system-related failures (in cooperation with national and international academic research institutions) and then provides customized technical solutions to prevent further cases of damage and failures.

Failure Prevention

The left figure shows the crack initiation at a score mark originating from honing in a high-pressure cylinder. In the right view, the surface of a stem from a control valve made of a cobalt-based alloy can be seen, which was destroyed by combined corrosion and erosion.