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Catastrophic Engineering Failure

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Catastrophic Engineering Failure

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Catastrophic Engineering Failure

  1. 1. Technology Training that Workswww.idc-online.com/slideshare Catastrophic Engineering Failure: What it means and what you can do about it
  2. 2. Technology Training that Workswww.idc-online.com/slideshare Technology Training that Workswww.idc-online.com/slideshare EIT Micro-Course Series • Every two weeks we present a 35 to 45 minute interactive course • Practical, useful with Q & A throughout • PID loop Tuning / Arc Flash Protection, Functional Safety, Troubleshooting conveyors presented so far • Upcoming:  Electrical Troubleshooting and much, much more….. • Go to: http://www.idc-online.com/slideshare • You get the recording and slides
  3. 3. Technology Training that Workswww.idc-online.com/slideshare
  4. 4. Technology Training that Workswww.idc-online.com/slideshare  What is catastrophic Failure?  Examples  What to do about it Topics
  5. 5. Technology Training that Workswww.idc-online.com/slideshare  Sudden catastrophic failure of a system  Recovery is impossible  Often leads to cascade systems failure  Often used for structural failure  Extended to other engineering failure What is catastrophic Failure ?
  6. 6. Technology Training that Workswww.idc-online.com/slideshare Examples • BP Gulf of Mexico • Columbia Space Shuttle • Ray Rail bridge • South Fork dam • De Havilland Comet • Space Shuttle Challenger
  7. 7. Technology Training that Workswww.idc-online.com/slideshare Tay Bridge
  8. 8. Technology Training that Workswww.idc-online.com/slideshare Tay Rail Bridge Disaster of 1879 • Centre half mile of bridge destroyed • When the train was crossing in a storm • Terrible design • Replacement was a separate structure
  9. 9. Technology Training that Workswww.idc-online.com/slideshare South Fork dam in 1889 • Located near South Fork Pennsylvania, USA • 20 million tons of water burst through • Less than well-engineered repairs to old dam • Raised the lake level • Several days of unprecedented rainfall • Dam broke and water destroyed several towns • 2209 people killed • Change to legislation from fault based to strict liability
  10. 10. Technology Training that Workswww.idc-online.com/slideshare De Havilland Comet
  11. 11. Technology Training that Workswww.idc-online.com/slideshare De Havilland Comet • World's first commercial jet liner to reach production • Aerodynamically clean design with four de Havilland Ghost turbo jet engines buried into wings • Low noise pressurised cabin • Catastrophic metal fatigue leading to aircraft tearing apart in mid flight • Cause traced to window installation methodology plus pressurisation • Initially, onboard fire was blamed
  12. 12. Technology Training that Workswww.idc-online.com/slideshare Space Shuttle Challenger
  13. 13. Technology Training that Workswww.idc-online.com/slideshare Space Shuttle Challenger • Twenty fifth flight of the American Space Shuttle Program • Destruction of Challenger 73 seconds after lift-off • Death of all 7 crew members • Failure of an O-ring seal on one of the solid rocket boosters • Flamethrower-like flare impinged upon one of the two after booster attach struts • Catastrophic structural failure
  14. 14. Technology Training that Workswww.idc-online.com/slideshare Space Shuttle Columbia
  15. 15. Technology Training that Workswww.idc-online.com/slideshare Space Shuttle Columbia • Space Shuttle mission launched by NASA • Multidisciplinary microgravity and science research mission • Seven member crew • Disintegration during re-entry • Piece of foam that broke off during launch and damaged thermal protection components causing excessive heat buildup
  16. 16. Technology Training that Workswww.idc-online.com/slideshare Do you have any examples of catastrophic failure ? • List any examples that you can think of by typing in the text area to the left of this • Any suggestions – great or small - would be great AND – if you can... • A suggested cause And • A suggested fix to prevent this happening in future
  17. 17. Technology Training that Workswww.idc-online.com/slideshare Primary causes of Engineering Disasters • Human factors • Design flaws • Materials failures • Extreme conditions or environments • Combinations
  18. 18. Technology Training that Workswww.idc-online.com/slideshare Primary causes of Engineering Disasters • Insufficient knowledge .....................36% • Underestimation of influence ............. 16% • Ignorance, carelessness, .................. 14% • Forgetfulness, error ................................. 13% • Relying upon others without sufficient control . 9% • Objectively unknown situation .....................7% • Imprecise definition of responsibilities .......... 1% • Choice of bad quality ................................ 1% • Other ................................................ 3%
  19. 19. Technology Training that Workswww.idc-online.com/slideshare As engineering professionals: • We have to strive ALWAYS for a zero accident environment. • Our most important task at all times • No matter what the situation
  20. 20. Technology Training that Workswww.idc-online.com/slideshare Conclusion • Risk Management critical • Lateral thinking • Anticipating the totally unexpected • Re-assess original assumptions • Cross check • Multiple teams solving one problem • Fail safe • And as Robert de Niro remarked: • If there is any doubt – there is NO DOUBT
  21. 21. Technology Training that Workswww.idc-online.com/slideshare Thank You For Your Interest If you are interested in further training, please visit: IDC Technologies Short Courses: Two-day practical courses available to the public: http://www.idc-online.com/slideshare

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