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Industrial Equipment Failures and Construction Disputes
July 14, 2021 6:15 pm Leave a Comment
At Warren, we frequently investigate losses involving industrial machinery. Many of the losses involve workplace injuries, fires, or explosions; however, we also analyze industrial machinery and processes for other types of problems. For example, we analyze failures of machinery or industrial processes to perform as expected or disputes that arise from the commercial supply and construction of such systems. This can encompass a range of issues from failure to achieve required levels of product quality or production quantity, to matters concerning unclear specifications or contracts, (more…)
Heavy Machinery Fires Caused by Hydraulic Hose Failures
4:34 pm Leave a Comment
Heavy machinery fires are often caused by hydraulic hose failures. Pressurized hydraulic fluid escaping from a failed hose assembly can be atomized into a fine spray that can be ignited by heated engine surfaces such as the engine exhaust or turbocharger.

Hydraulic hoses near the engine compartment of an excavator that burned.

Hydraulic hoses often fail due to age and wear, requiring regular inspection and replacement of hydraulic hoses to prevent failures. Hoses may also fail if they are misrouted. Misrouting can lead to the hose being pinched or causing it to chafe against a sharp metal surface. (more…)
Interpreting Industrial Incident Data – Lesson Learned
June 17, 2021 12:46 pm Leave a Comment
This is a case study about an incident I investigated involving a major upset in a distillation column. This blog builds on the previous blogs about the Distributed Control System, DCS – Data is the Key.

Distillation is a method of separating mixtures of compounds with differing boiling points. Uncle Bill with his still on the hill separates ethanol, that boils at 173°F, from water that boils at 212°F. If the mixture is heated to above 173°F, but below 212°F, the ethanol will boil, the vapor will travel up out of the unit and then can be condensed and served over ice with an olive… Any mixture of two or more chemicals with different boiling points can be separated in this way. The distillation (more…)
Improper Hearth Extension Leads to Structure Fire
March 25, 2021 3:54 pm Leave a Comment
The fire service affords you the opportunity to witness and observe things that a lot of engineers and even most people do not get the chance to see. An example of this is the situation where extended elevated temperatures combined with poor construction techniques to result in a structure fire.

I have personally observed several occasions where a structure fire was initiated due to improper construction of the fireplace hearth extension. The most recent one followed a multi-day cold snap, at least by South Carolina standards. The thermometer read 17 degrees F as I drove to the call of smoke in a residence (more…)
Heat Exchanger Failures Will Shut Your Process Down
February 26, 2021 11:11 am Leave a Comment
Heat exchangers, as the name implies, are used to bring a process stream to a desired temperature. They can heat or cool either gases or liquids. They are fairly intricate in their construction, therefore not the cheapest piece of equipment to purchase. For that reason, facilities don’t keep “spare” exchangers lying around, so when they fail catastrophically, the entire manufacturing process goes down with them… and stays down until they are fixed or replaced. Ow!

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Proper Construction and Maintenance Can Prevent Deadly Chimney Fires
February 16, 2021 1:52 pm Leave a Comment

There are few things as comforting to me during the winter months as a warm fire burning in the fireplace. And in this case, I am talking the real deal, the kind that warms you multiple times; from cutting, splitting and stacking the firewood until finally lighting a fire in the fireplace. However, just like your parents taught you, fire can be dangerous. And having an actual fire in your home fireplace comes with some required maintenance to ensure you can safely control the fire and keep it where it belongs. (more…)
Major Causes of Wood Truss Failures
February 10, 2021 8:45 am Leave a Comment
Wood truss failures can vary and identifying the cause requires visual inspection as well as a working knowledge of the structural loads and building codes. These truss systems must transfer the gravity and lateral loads to the foundations. Consequently, the framing system and the foundation provide strength and stability for a structure. The most common type of wood-framed construction uses roof trusses, exterior and interior load-bearing walls, beams, girders, posts, and floor framing to resist the gravity and vertical loads. This type of wood-framed construction engages a system of horizontal diaphragms (roof and floors) and shear walls (vertical exterior sheathed walls) to resist the lateral loads. (more…)
Stress Corrosion Cracking of Stainless Steel in Marine Environments
January 29, 2021 3:37 pm Leave a Comment
Stress corrosion cracking involves the slow growth of small, often microscopic, cracks through a metal part in a corrosive environment. The cracking can continue to the point that the part fails suddenly and unexpectedly even though it still appears new and in good condition.

My first experience with stress corrosion cracking happened in the Charleston harbor when the stainless steel rudder suddenly separated from a sailboat during moderate winds. What had been a pleasant evening sail turned instantly into being in a difficult to control boat in the middle of the busy shipping channel. The rudder remained attached only (more…)
Heating System Losses, Part One
January 18, 2021 9:36 am Leave a Comment
When fall and winter arrive and temperatures drop, it is a great comfort to have a heating system to warm your home or office. Several categories of heating equipment exist to provide both primary and secondary heating. Primary heating systems include fuel gas/fuel oil/electric forced air furnaces, heat pumps, hydronic heating/steam systems and even wood-fired heating systems. Secondary heating equipment includes electric, gas and kerosene space heaters of both fixed and portable design, and fireplaces. Each of the different types of heating systems have unique hazards that, uncontrolled, can result in fires, explosions, burn injuries, and carbon monoxide poisoning. (more…)
P&ID’s, If You Please – Piping and Instrumentation Diagrams Explained
November 17, 2020 4:26 pm Leave a Comment
When investigating an industrial incident, one piece of information I always ask for is the relevant P&ID’s for the process. P&ID stands for Piping and Instrumentation Diagram and is defined as “A schematic diagram of the relationship between instruments, controllers, piping, and system equipment.” A set of P&ID’s for an entire facility allows you to trace the entire manufacturing process from raw material unloading to finished product loadout, including utilities like steam, water, fuel, and air. That’s great information to have, but isn’t especially useful (more…)

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