Understanding the Bigger Picture When Critical Systems Fail
When critical systems like turbines, compressors, or boilers fail, the fallout can be catastrophic—escalating costs, operational disruptions, and even legal implications. At EDT, we specialize in uncovering the root causes of these failures, helping insurance professionals, attorneys, and facility operators mitigate risks and manage complex claims.
Through decades of forensic engineering experience, one thing is clear: understanding how every piece of the system connects is essential to preventing future disasters.
The Hidden Risks of Stop-and-Go Operation
Start. Stop. Fail. Traditionally, large turbines in power generation were designed for baseload operation (continuous use at a steady output). However, today’s energy demands often require these machines to operate in mid-merit (loading the turbines up and down with demand) or in peaking service (frequent start-ups and shutdowns during high demand periods).
While this may seem like a great way to save money, the thermal cycling (repeated heating and cooling) from each start-up and shutdown can cause significant wear and tear.
Every time a turbine starts, its hot components expand. When it shuts down, they cool. Over time, this process leads to metal fatigue (weakening of the material from repetitive stress), cracks, and other damage that wouldn’t occur under steady operating conditions.
Understanding this transition from baseload to peaking operations is vital for assessing how long equipment will last and when equipment maintenance is required.
Lessons from the Field: What Happens When One Failure Triggers Another
A few investigations stand out as reminders of how interconnected systems and overlooked details can lead to failures.
Blade Failures in Peaking Turbines
EDT investigated a set of turbines installed in the early 1970s and used for peaking service. One turbine experienced a catastrophic blade failure, throwing a blade nearly a quarter mile. The operator argued that the turbine hadn’t even reached its "first major scheduled maintenance," as it had logged relatively few hours. However, each start-up placed stress equivalent to several hours of continuous use. By the time of the failure, the turbine blades had exceeded their expected service life.
Despite warnings, the operator neglected to address the issue in the other turbines. Six months later, a second turbine failed in an identical manner, resulting in another costly incident. This case highlights that stop-and-go operation can have significant and often underestimated stress on systems originally designed for steady use.
A Chain Reaction of Failures
In another incident, a gas turbine suffered damage due to a failed blade. The repair cost was already steep—around $12–15 million. While EDT was wrapping up the damage assessment of the blade, the turbine was inadvertently restarted.
Unfortunately, a broken instrument line allowed an undetected flame out into the turbine, filling the heat recovery steam generator (HRSG/boiler) with natural gas. The gas ignited, causing an explosion that warped the boiler in seconds. This added over $100 million in damages.
At first, these problems seemed unrelated. But on closer inspection, both failures were linked by issues in how the system was set up. A small oversight, like a broken instrument line, and a programming error so the controls did detect the flame-out triggered a chain reaction with devastating consequences. This case shows how all parts of a system—fuel lines, turbines, controls, steam systems—are connected. Even a tiny mistake can lead to massive failures.
Offshore Turbine Corrosion
In one particularly destructive case, turbine blades on an offshore platform eroded from four inches in length to just two inches within months. The culprit? Diesel fuel contaminated with seawater.
During transport, barges used seawater as ballast, which mixed with the diesel and created a corrosive fuel mixture. The turbines, operating at 2,500 degrees Fahrenheit, were destroyed by the salt corrosion. What appeared to be a simple fuel issue was ultimately a design oversight that failed to account for environmental realities.
All of these cases highlight a critical truth: failures rarely happen in isolation. Understanding the broader system and the cumulative impact of operational decisions is essential to preventing disasters and managing risk.
Actionable Insights for Insurance & Legal Professionals
Preventing failures requires a proactive approach and an understanding of interconnected systems. Here’s what insurance and legal professionals can do:
- Look at the Whole Picture: Investigate maintenance history, design flaws, environmental factors, and operational practices. Even if you suspect a blade failure or worn-out part, there’s almost always a bigger story.
- Lean on Your Engineer: A good forensic engineer knows how to communicate complex details without jargon. Ask questions early so you understand the root cause before making coverage or legal decisions.
- Don’t Overlook Small Clues: Seemingly minor details, such as a loose instrument line or skipped maintenance, can be pivotal in understanding what went wrong.
- Maintenance Matters: Aging equipment doesn’t fail simply because it’s old. Failures often stem from improper or neglected maintenance. If the operator or facility can’t prove they’ve kept up with recommended service intervals, that’s likely your prime suspect.
Translating the Technical
EDT considers our forensic engineers to be translators: we turn engineering-speak into clear, concise findings. Instead of drowning people in acronyms or design specs, we focus on the essential facts:
- What exactly happened?
- Why did it happen?
- What is the extent of the damage?
- How can it be fixed or replaced?
Often, insurance adjusters want to know immediately, “How much is this going to cost?” That’s understandable—dollars and cents matter. But to get there accurately, we must put the engineering puzzle together first. Once we determine those facts, adjusters and attorneys can better determine how coverage, liability, or legal strategies apply.
Final Takeaways: Connecting the Dots on Failure Prevention
Failures rarely happen in isolation. They result from a combination of factors, often hidden within the intricacies of a system. By understanding how these systems are interconnected and addressing the root causes, professionals can mitigate risk, protect their clients, and avoid costly disasters. If you’re facing a complex failure or want to prevent one, reach out to EDT for expert insights and practical solutions.
About the Author
Timothy B. Hatch, B.S.M.E., P.E. is a Consulting Engineer with EDT’s Houston office. He has over two decades of hands-on experience dissecting equipment failures, conducting industrial accident investigations, and determining repair or replacement costs, especially for rotating machinery like gas and steam turbines. Tim holds professional engineering licenses in more than 30 states, and he earned his mechanical engineering degree from California Polytechnic State University in San Luis Obispo.