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The following is a partial list of cases we have worked on. See some of our other cases here.
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| Coke
Oven Battery Analysis |
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A comprehensive engineering analysis was performed
on a coke oven battery roof and heating walls. Premature grouting
of the roof was a major consideration in evaluating the structural
integrity and projected life expectancy of the battery. O'Donnell
Consulting (OCE) made extensive use of finite element engineering
analysis to calculate temperatures, deflections, strains, and
stresses using time-dependent creep analysis methods to evaluate
the long term integrity of the roof and heating walls.
When in operation, coke oven batteries normally undergo time-dependent
deformations, and creep, due to static and cyclic thermo-mechanical
loads. Using finite element analysis methods, evaluations were
carried out for a 25-year operating period. OCE performed analyses
of the refractory material properties to determine input for engineering
analysis. The boundary conditions are used to model the type
and direction of constraints on the battery. Three dimensional,
non-linear models were developed to quantify the stability of
the heating walls and evaluate the wall stresses. These models
were subjected to cyclic pressure and thermal loading conditions,
due to charging. The effects of operating conditions on the as-built
battery with construction imperfections were evaluated to determine
the battery displacements and stresses vs. time. The finite element
results showed that the battery oven walls would not deflect enough
to induce instability. The construction imperfections had no meaningful
effect on the structural integrity, robustness, or longevity of
the battery. Such studies are quite useful in planning battery
maintenance efforts.
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| Review of Replacement Steam Generator Analysis |
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O'Donnell Consulting performed a third party review of the Babcock & Wilcox (B&W) analyses of the head/divider plate/tubesheet/shell complex
for the replacement steam generators that were being manufactured for Baltimore Gas & Electric. The review was performed, addressing the calculation of effective elastic and plastic material properties to be used in representing the perforated tubesheet
as an equivalent of solid material, material instability strain computations for SB-18, a plastic collapse analysis of the head/divider plate/tubesheet/shell complex, predictions of the maximum divider plate
strain under hydrotest conditions, an estimate of the maximum elastic stress intensity range for cyclic loading, and shakedown analysis.
In addition to the third party review of the B&W analysis, OCE performed
efficient Primary Stress analyses of the BG&E steam generators for design and hydrostatic test conditions using elastic-plastic analyses. An independent finite element model was used to perform these analyses, which had more detail and a
finer mesh density than the B&W models. The results showed that the design met the Primary Stress Allowables of the ASME Code, Section III, Subsection NB.
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| Pollution
Control Equipment |
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The growing need for efficient electric power generation led to the use of pulverized coal as a basic fuel for large steam generating units in the United States around 1920.
The combustion of coal that has been pulverized to tiny particles results in the creation of even smaller ash particles, known as flyash particles. About 80 percent of these flyash particles are swept up by by the moving stream of combustion gas and carried out of the boiler.
Such particles would be discharged from the chimney and create a major air pollution problem in the atmosphere, unless they are removed from the flue gas. Thus, an electrostatic precipitator was used to remove particulate matter (flyash) from the boiler flue gas prior to emission from the chimney.
Electrostatic precipitators immediately achieved wide acceptance for the efficiency removal of flyash. For hot-side precipitator designs, ductwork designs included temperatures exceeding 700 F, which had to allow for "thermal breathing". When these movements are restrained, large forces are created,
which can cause tearing, cracking and buckling of the steel. Sliding supports, expansion joints, and appropriate elevated temperature structural design practices are therefore used to avoid restraining thermal movements. O'Donnell Consulting performed structural and design life analyses
of the electrostatic fly-ash precipitator system, determining errors in the design of the ductwork system.
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| Cracked
Ductwork |
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When reinforced ductwork failed shortly after being placed in service, O'Donnell
Consulting performed an extensive failure analysis. The results
determined that that the ductwork was overly-constrained. Thermal
breathing and bending due to a thermal gradient that existed between
the top and bottom surfaces were constrained, creating high thermal
stresses. Finite element analyses (FEA) were used to quantify the
fracture conditions. During expert testimony, O'Donnell used the finite element analysis results to explain how the ductwork failed - pioneering the application
of FEA technology in litigation.
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| Ore
Unloader |
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During the delivery of a shipment of resin, damage
occurred to a storage tank at a production facility in Southwestern
Pennsylvania. Damage to the tank was apparently the result of tank
overpressurization. O'Donnell Consulting performed a failure analysis
of the tank, and determined that overpressurization was due to a
"blow-down" following the transfer of resin from transport
tanks to the storage tank. O'Donnell also inspected the tank and
made recommendations on how best to repair the vessel.
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| Propane
Pump |
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A propane pump explosion killed one worker and injured
three others at a central Ohio factory. The pump was being used
to charge aerosol cans with propane propellant at high pressure.
The accident occurred when gas leaked past the pistons in the pump.
Originally, the pump was built with metal pistons that wore rapidly
against the seals. They were replaced with ceramic seals. Designed
to pump mud, the ceramic components eventually cracked and loose
pieces fell away, causing a massive leak. After examining the crack
pattern and characterizing the ceramic material, O'Donnell engineers
theorized that the cracking was due to the sudden chilling of the
outer ceramic surface. Finite element stress analysis and testing
confirmed the opinion.
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| Gas
Well Pipe |
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O'Donnell evaluated a pipe rupture resulting from
a gas well accident in which a worker lost a leg at a plant, north
of Pittsburgh. The injured well tender, whose leg was severed below
the knee, was initiating a "post-fracking" procedure-blowback operation
to release pressure in the capped well-at the time of the mishap.
When the main valve was opened, the pipe ruptured due to water hammer.
The pipe, set off center, broke loose and whipped around, striking
the well tender. O'Donnell engineers, conducting the evaluation
on behalf of the worker, found that the pipe did not fail because
of faulty material or construction.
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| Tank
Welds |
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O'Donnell Consulting
Engineers performed structural analysis on imperfect welds in an accumulator tank. Metallurgical evaluations were performed in addition
to finite element analysis. OCE determined that the welds met Code Safety Margins, and were able to withstand the anticipated environmental
and vibratory loading conditions.
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| Threaded
Closure Failure |
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O'Donnell Consulting
Engineers investigated the cause of an accident due to a failed threaded closure on a wellhead. Through metallurgical evaluations,
material testing, and engineering analysis, it was determined that the cast iron nut had failed due to fatigue.
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| Panel
Coil |
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Failure of panelcoil components in a large sterilizer
was investigated. A failure specimen was examined, and it was determined
that the cracking was due to fatigue. This observation led to an
investigation of the possibility of the failure being caused by
vibration due to the rotating agitator. Bounding calculations indicated
that the panels possessed natural frequencies between 8 and 100
Hz. The forcing frequency of the six-bladed agitator was 15 Hz and
vibration was therefore identified as the most likely culprit. Concurrently,
finite element dynamic methods were used to established a natural
frequency to account for the immersion of the panel in water, the
frequency was close to 15 Hz. The two independent analyses both
demonstrated the failure was induced by fatigue. Locations were
provided for panelcoils supports to eliminate the lower modes of
vibration. O'Donnell personnel provided further guidance to assure
the adequacy of welding processes and welding materials to achieve
modifications that subsequently performed reliably in service.
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| Coolant
Injection Plate |
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During a shutdown of the Kuosheng 1 plant, Taiwan,
operation of the LPCI system for normal shutdown caused failure
of an LPRM. Testing by G.E. in their (HF)2 facility duplicated the
failure, which has been attributed to flow-induced vibration of
the LPRM. G.E. devised a flow-deflector to prevent cross-flow from
the LPCI across core components. This deflector had to be installed
in Grand Gulf very quickly to avoid delay in fuel loading. In order
to increase assurance that the design, construction, and installation
of the deflector plate were proper, Mississippi Power & Light Company
asked O'Donnell to review the problem and the proposed solution.
O'Donnell analytically determined that the fatigue usage factor,
pump-induced vibration, low-pressure injection system head loss,
fluence at welds, and the diaphragm connection of the LPCI line
to the shroud were adequate. Subsequent testing confirmed the adequacy.
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| Space
Telescope |
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O'Donnell Consulting Engineers evaluated the nature of vibratory conditions in the framework
supporting the Hubble Space Telescope. Combined analyses and tests
showed that conditions were due to second order shortening of the
transverse bracing members not found by conventional computer analysis.
The vibration problems were then solved using lateral restraints
on the transverse members.
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| NASA
Space Shuttle Main Engines |
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O'Donnell developed an analytical procedure for predicting
thrust chamber life limited by the small number of firings. In an
operating rocket thrust chamber the hot-gas-wall ligaments separating
the coolant and combustion gas are subjected to pressure loading
and severe thermal cycling. The resulting stresses cause plastic
straining resulting in incremental bulging of the ligaments during
each firing cycle. This mechanism of creep ratcheting was analyzed
considering combined bending and membrane loading. The incremental
permanent deflection and progressive thinning near the center of
the ligaments was evaluated. Creep and tensile instability were
identified as the limiting mode of failure. Results of these analyses
compared favorably with available experimental data and allowed
design changes which extended the design life.
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| Heat
Exchanger Analysis |
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O'Donnell
Consulting performed an extensive engineering analyses of a high-temperature
heat exchanger for NASA. The results showed that the cracks were
caused by excessive cyclic thermal stresses, and a repair redesign
was developed.
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| Maritime
Mooring |
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O'Donnell Consulting
performed structural analyses of a barge mooring that had failed
during a flood condition on the Monongehela River in Pittsburgh,
PA. Engineering and finite element analyses showed that the bow
and stern mooring lines were subjected to excessive loads as the
river water levels increased, causing failure of the u-bolts and
other structural elements of the mooring.
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| Boiler
Tube Failure |
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O'Donnell
Consulting performed an extensive failure analysis of a boiler
tube. The results showed that the tube failed due to a combination
of deposit buildup in the return bend, and excessive cyclic thermal
stresses.
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| Turbine
Exhauster |
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O'Donnell Consulting
investigated an accident involving a turbine exhauster, which is
a high speed, three-stage centrifugal compressor, used to pump exhaust
gases out of a coke oven battery. All three compressor stages are
located on the same shaft and housed in the in a common casing.
The third stage compressor suffered severe damage, and caused subsequent
damage to the facility. O'Donnell performed finite element, engineering
analysis, metallurgical, and material testing on the disk and blades.
It was concluded that small flaws that had been detected earlier
had not been correctly evaluated, and were growing to critical size
during normal operating conditions. As the crack grew, the stresses
in the disk increased - to the point of disk rupture.
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| Lift
Hook |
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O'Donnell
Consulting investigated the failure of a lift hook. A Three
dimensional finite element model consisting of over 75,000
elements and 120,00 nodes was constructed to evaluate the
failure mode. The results determined that the hook failed
by metal fatigue.
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| Large
Diameter Ductwork |
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During operation
of a ferro-silicon furnace in Washington State, a nine foot diameter
duct failed. This duct carried exhaust from furnace stacks to a
baghouse. It was made of one-half inch thick low alloy steel. The
failures were predominantly located at the duct supports. Stress
analysis and material evaluations showed that the cause of these
failures was low cycle thermal fatigue. O'Donnell redesigned the
ductwork and support system to reduce the amount of constraint on
the duct. The rebuilt system has been operating successfully for
many years. O'Donnell later evaluated the work of the original designer
and the depositions of witnesses, and provided legal testimony,
resulting in a $7.4 million verdict on behalf of the claimant.
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| Analysis of Turbine Shafts |
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O'Donnell Consulting performed the structural integrity and the remaining life assessment of the main shafts on a hydroelectric plant.
Inspection of the main shaft had detected linear indications at the outer surfaces of the shaft. Elastic fracture mechanics analyses indicated that the existing cracks could propogate to
unacceptable levels. A solution was then designed, analyzed, and performed to extend the life of the shaft.
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| Conveyor
System |
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A West African bauxite company was awarded $16 million
in a U.S. District Court after a tippler building sustained severe
structural damage. Bauxite was dropped twenty-two feet from rail
cars onto the conveyor of a crusher system in the tippler building.
The conveyor system and concrete support beams were most seriously
affected. O'Donnell engineers determined that the impact loading
of the bauxite boulders weighing up to ten tons had been grossly
underestimated in the design of the building. They concluded that
the structure had been under-designed for the anticipated and applied
loads.
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| Bellows |
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An engineer was seriously burned when a thirty-nine
inch expansion joint ruptured while workman were performing temporary
repairs at a Texas refinery. The ruptured bellows spilled hot catalyst
from a fluidizer catalytic cracking unit on the deck which the engineer
had to cross to reach safety. The plaintiff alleged that the selection
of Type 321 stainless steel by the process designer was unsound,
and led to the rupture. O'Donnell was retained to establish why
the bellows failed. We found that the stainless steel had not been
heat-treated properly during the making of the steel itself and
it was sensitized during fabrication and made susceptible to corrosive
attack.
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| Sprinkler
Analysis |
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O'Donnell Consulting performed a failure analysis of a sprinkler pipe system.
The investigation included structural analysis, metallurgy, and
material testing. Although material thickness was suspect, it
was concluded that the failure of the pipe was due to tensile
overload.
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| Process
Vessel |
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For a major food processing company, O'Donnell engineers
analyzed the failure of a horizontally mounted low pressure process
vessel. The sequential failure of several of the nuts holding the
closure head caused it to blow off, seriously injuring a worker.
A review of the original design showed that the vessel had not been
built with the number of nuts and swing bolts shown on the drawings
or on the Manufacturer's Data Report. Metallurgical analysis of
the nuts which had failed showed that they were fabricated of weaker
material than that originally specified. Information provided by
the operating personnel indicated that several of the nuts were
generally not used because of inconvenient access. A finite element
analysis of the closure head accounted for the maldistributed nuts.
These errors taken together exactly used up the safety-factor of
five required for pressure vessel bolting design.
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| Blower Fan |
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Failure analysis of a blower fan used to cool electronics was performed to determine root cause. The fan failed within the first two months
or approximately 1400 hours of continuous operation. The investigation determined that defective bearings most likely caused unusual bearing loads, and subsequent fan failure.
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| Induction Furnaces |
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Induction heating is caused, as the name implies, by induced electric currents in a material. Just as electrical current can produce a magnetic field which ultimately
can be used to power a motor, so can a magnetic field be used to produce secondary current in a material. The principle is exactly the same one used in constructing a voltage transformer
whereby one AC voltage across the primary windings of a tranformer will induce a different AC voltage (higher or lower) across the secondary windings. The voltage ratio of the transformer is solely dependent
on the ratio of coil windings due to electromagnetic principles, and the frequency is the same for both AC voltages. In an induction furnace, the metal to be heated becomes the "secondary" path.
In a coreless induction furnace, shunts are used to cover a significant portion of the furnace coil which are used to focus the magnetic field back into the crucible/metal. These shunts contain layers, with insulating barriers.
O'Donnell investigated the ongoing issues of such induction furnaces undergoing upgrades.
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| Quartz Tubes |
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O'Donnell performed an independent failure mode analysis to determine the cause of the failure of quartz tubes in a water purification system. The flow conditions around the quartz tube were evaluated using
ANSYS computational fluid dynamics software. Natural vibration frequencies of the quartz tube and stresses for various loading conditions, such as
shell distortion and impact damage, were evaluated using the ANSYS structural software. The natural frequencies of the hollow quartz tube were analyzed, in order to determine the flow rates at which shedding vortices would excite these frequencies.
Mode shapes for each of these frequencies were obtained in order to determine whether the dynamic forces caused by shedding vortices would excite these mode shapes, causing the quartz tube to absorb energy from the flow.
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| Pressure Swing Absorption Vessel |
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For a major chemical producing client, one out of ten PSA vessels had developed a leak after 14 years of cyclic service. O'Donnell performed an independent analysis of
the PSA vessels to quantify fatigue life and recommend either to continue in operation, repiar, or replace the vessels. It was determined that although imperfections in the fabrication
were within ASME Code allowables, stress levels at the longitudinal weldments shortened their fatigue design life. It was recommended that the vessels be replaced.
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| Failure Analysis of a Gearbox |
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O'Donnell Consulting investigated the failure of elevation gearboxes used to control an earth-station antenna.
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| Seismic Analysis - Sprinkler System |
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For a client that designs and installs fire protection systems, O'Donnell Consulting performed a seismic analysis for qualification to Section 132 of the Uniform Building Code.
The fire protection system included pumps, tanks, manifolds, piping, and a structural support frame. Finite element analysis was performed to evaluate the stresses and deflections under seismic loading conditions.
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| Marine
Air Compressor System |
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When an air
compressed system used to control the engine and steering controls
for a marine transport barge failed, O'Donnell Consulting Engineers
performed an extensive analysis of the system. It was determined that the system
contained a defective safety valve which was the primary root cause
for the system failure, which caused a collision with another vessel.
The valve had a latent defect exonerating the ship owner per Maritime
Law.
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| Stress Analysis of Decanter |
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O'Donnell Consulting performed a stress and buckling analysis on a decanter, which is used to transfer microscopic materials from one vessel to another.
The buckling analysis was performed in accordance with Section VIII, Division 1 of the ASME Boiler and Pressure Vessel Code. The stress analysis was performed using ANSYS finite element software,
using ten-node structural tetrahedral solid (Solid 187) elements. For other features, such as the bolts, two-node beam elements were modelled. The model had approximately 99,000 nodes and 53,000 elements.
Various loading conditions (bolt preload, deadweight, and vacuum pressure) were used to verify the structural integrity of the vessel.
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| Fitness-For-Service Analysis - Boiler |
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O'Donnell Consulting performed a Fitness-For-Service evalution of a steam drum pressure component of a wood-fired boiler.
The 30,000 pound boiler (120 psi) was overheated due to a loss of makeup water and a failure of a low-water cutoff control. The consensus standard used for this Fitness-For-Service
evaluation is API 579-1 / ASME FFS-1 as developed by the ASME/API Fitness-For-Service Joint Committee. This standard contains very specific methodolgies for evaluating pressure vessels
that have been damaged or compromised due to operational or environmental factors such as fire, overpressure, corrosion, fatigue, and mechanical damage.
TYpical damage resulting from these factors includes pitting/loss of metal, embrittlement, residual stress, es, cracks, and reduced material properties.
The net result is often reduced vessel integrity, shortened opearting life, or even required repair/replacement.
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| Stress Analysis of a Vessel |
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O'Donnell Consulting performed a buckling analysis on a stainless steel vessel subjected to a vacuum loading at elevated temperature. Both instantaneous (linear and nonlinear)
buckling and creep buckling were investigated. The analysis was performed using ANSYS finite element software, using linear shell elements (Shell 181) with creep capability. The analysis showed that the
vessel maintained a significant safety margin against buckling under a vacuum load, at 1200 degrees F for short periods of time, with up to 1 percent out-of-roundness (measured after post weld heat treatment).
The analysis also showed that the nozzle loads on the vessels had negligible effect on the governing buckling modes.
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| Stress Analysis of an Evaporator |
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O'Donnell Consulting performed an analysis to determine the impact of oversized holes in the tube support plates of a film evaporator in a water treatment plant.
These support plates, which take up over 50 percent of the vessel cross-section, are designed to TEMA standards. During vessel fabrication, the holes for the tubes were found to be outside the
recommended limits. Tube stresses, impact wear, sliding wear and fretting wear were investigated to address the concerns of the oversized holes.
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| Design & Analysis of Pressure Vessels |
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O'Donnell Consulting designed and analyzed two large scale containment pressure vessels and equipment subjected to high energy impact with a dual phase fluid at supersonic speed.
Design conditions included impact, thermal shock, and fatigue loading. Using finite element analysis, vessels, supports, nozzles, and flanged connections were designed and analyzed.
Both vessels utilized removable heads, and thermal sleeves at the inlet nozzles.
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| Actuator Analysis |
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O'Donnell Consulting performed modal and spectrum analyses for a manufacturer's linear variable displacement transducers.
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| Analysis of a Base Skid |
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For a combined cycle power generation facility, O'Donnell Consulting performed a structural integrity analysis of a base skid, which supported a condensor exhauster system.
The design criteria for the structure were obtained from the AISC Code. ANSYS Finite element analysis software was used to model the base skid structure. Equipment mounted to the skid was modelled
using lumped mass elements at corresponding center-of-gravity locations, and the skid itself was modelled with linear shell elements. Stresses and deflections were analyzed under deadweight and seismic loading conditions.
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| Design/Application of Weld Overlay |
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A 9 foot diameter, 60 foot long Stripper Vessel was designed and fabricated to be placed in service at a refinery in the Virgin Islands.
Prior to starting service, the client wished to cover the top 20 feet of the shell inner surface with Inconel 625 weld overlay to protect the shell base metal against corrosion.
O'Donnell accepted the challenge to design a weld overlay process, proper welding sequence, and apply the overlay while controlling the distortion of vessel. The weld overlay of the vessel required preliminary weld qualifications in accordance with
the ASME Code Section IX, Welding and Brazing Qualifications. This dictates the welding of test plates, non-destructive and destructive testing of the test plates, and documentation of all the welding variables and test data.
The welding equipment used in the test cases and in the actual overlay was a very sophisticated Pulse Spray Gas Metal Arc system which is capable of of capturing a specific welding electronic wave form, storing it in unique welding schedules.
Temperature measurements were taken on the back side of the test plates for use in a FEA distortion analysis. The measurements were also used for the design of a water cooling system. Bead overlap, weld travel speeds,
interpass temperature, and other essential welding variables were adjusted and documented during the test welding, and subsequently incorporated into the final Welding Procedure Specification.
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| Brake Rotor Analysis |
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For a client that manufactures components for Formula One Race cars, O'Donnell Consulting performed finite element analyses on new brake rotor designs.
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| Weld Repair of Turbine Blades |
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Turbine blades made from subject castings are in need of weld repairs caused by machining errors. When blades of specific materials are used in hydro-turbine units, they exhibit excellent erosion-corrosion resistance.
Because of dimensional control issues, repairs need to be completed without a post-weld heat treament (PWHT). The purpose of PWHT is to minimize the risk of stress corrosion cracking in service, reduce residual stresses, and control the properties of the weldment.
O'Donnell Consulting assisted in resolving repair procedures.
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| Design/Analysis of an Autoclave |
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O'Donnell Consulting performed the design analysis of an autoclave, for use in the chemical industry. The composite design of the vessel included refractory brick, mortar, membrane system and steel shell.
The vessel was approximately 83 feet long and outer diameter of sixteen feet. Inside the steel shell were three layers of refractory brick. Between the steel shell and outermost brick was
an elastomeric membrane, intended to accomodate geometric variations, as well as brick-to-shell differential thermal expansion.
The vessel was divided into a number of compartments, each with an associated agitator. The important parameters in the design of the autoclave were temperature and stress. Each material of construction had unique properties with respect to temperature.
Finite element analysis was used to determine structural integrity of the vessel under various operating conditions.
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| Failure Analysis of a Hoist |
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O'Donnell Consulting investigated the failure of a 3 ton capacity hoist. It was concluded that improper installation of the intermediate nut had prevented
the accomodation of off-center loads, inducing bending stresses and subsequent failure of the support studs.
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O'Donnell
Consulting Engineers performs a range of engineering
design and analysis services-
- Stress/ Structural Analysis
- Thermal Transient Analysis
- Fatigue & Vibration Analysis
- Buckling/ Instability
- Creep Analyses
as
well as forensic engineering services-
- Failure
Analysis & Metallurgy
- Engineering Expert Witness
<We have been recognized in the American Lawyer Media Top 100 Verdicts of 2006 and
2007>
We
are experts in the fields of materials, metallurgy, mechanical
engineering, civil engineering, and chemical engineering. We have
helped many clients solve complex problems allowing them to increase production
performance, and become more cost-efficient.
Let Us Help You Solve Your Technical Issues
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