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We perform structural design and stress, fatigue, fracture, and corrosion analysis services to support nuclear component integrity. Initially founded as O'Donnell & Associates in 1970's to support the nuclear power industry, we have subsequently evolved into O'Donnell Consulting Engineers, Inc., earning a world-wide reputation for solving problems in operating plants.

Members of our professional engineering staff are experts in design, materials, thermal analysis, fatigue, vibration and seismic analyses, and fracture mechanics. Several hold patents utilized extensively in the power generation industry. Dr. William J. O'Donnell, President, invented the Mechanical Stress Improvement Process used to relieve stresses in welded joints subjected to stress corrosion cracking. The process has been applied in many nuclear power plants throughout the world. He is also Chairman of the ASME Subgroup on Fatigue Strength, and is a member of the Subcommittee on Design. See his resume.

We have performed:

• Structural Design and Analysis
  Three dimensional finite element analyses were used to design numerous Class 1 nuclear components. Stress indices were developed for pressure and external loadings on piping components in simplified design procedures.
• Tube-and-Tubesheet Analysis
  General methods for calculating stresses and strains due to mechanical and thermal - induced loads were developed for tubesheets. Extensive development work has been completed on tube-to-tubesheet joints. Inelastic analyses were used to quantify the hydraulic pressures needed for the expanded tubes, and the pressure needed in the neighboring tubes to protect the ligaments.
• Design Criteria
  The U.S. Nuclear Regulatory Commission (NRC) and Westinghouse jointly chose Dr. O'Donnell to develop design criteria and methods for the acceptance of flaws using fracture analysis of perforated tubesheets in steam generators to satisfy NRC requirements. The solution applied finite element methods to determine nominal stresses in the tubesheet subjected to thermal and mechanical loads. Failure modes for leaks and criteria for failure were investigated.
• Steam Generator Tubing Wear
  Steam generators at a particular client site were experiencing tube wear due to flow induced relative motions between the tubes and the stabilizing spacers (batwings). Flow induced vibration analysis methods were applied to analyze local wear conditions and provide a method of quantifying tube wear rates and predicting expected tube life.
• Mechanical Stress Improvement Process
  Dr. O'Donnell and Dr. Porowski were co-inventors of the Mechanical Stress Improvement Process (MSIP). In considering the stress corrosion cracking problem in the heat affected zone of field welds in BWR primary pumping, they developed a reliable mechanical stress improvement process which applies compressive stresses and is easy to control and verify. MSIP was developed with supporting finite element analysis and tests which show that it provides compressive stress fields in both the axial and circumferential directions at the inner surface of weldments. The Process was developed for pipe-to-pipe, pipe-to-discontinuity (such as valve body) and pipe-to-vessel nozzle configurations. MSIP has been performed at 40 nuclear power plants worldwide:
  

Utility	Plant	Year	Pipe & Fittings	Nozzles & SE's	Total	Notes
CeCo	Dresden 3	1986	50	2	52
CeCo	LaSalle 2	1987	25	29	54
CeCo	Quad Cities 1	1987	36	2	38
CP&L	Brunswick 2	1988	0	15	15	1
CeCo	Quad Cities 2	1988	43	4	47
Nuclenor	Santa Maria de Garona	1988	24	0	24
OKG Aktiebolag	Oskarshamn	1988	1	0	1	1
CP&L	Brunswick 1	1988	0	10	10
CeCo	LaSalle 1	1988	15	15	30
CeCo	LaSalle 2	1988	8	0	8
CeCo	Dresden 2	1988	82	22	104
PeCo	Limerick 2	1989	2	16	18
Northeast	Millstone 1	1989	0	22	22
Detroit Edison	Fermi 2	1989	6	21	27
CeCo	Quad Cities 1	1989	28	12	40
CP&L	Brunswick 2	1989/1990	16	20	36	2
CeCo	Quad Cities 2	1990	30	14	44	2
Teollisouden Voima Oy	TVO	1990	5	0	5
Niagara Mohawk	Nine Mile Pt 2	1990	0	1	1
Taiwan Power	Kuosheng 2	1990	2	0	2	1
CP&L	Brunswick 1	1990/1991	10	24	34	2
Northeast	Millstone 1	1991	34	9	43
Iberdrola	Cofrentes	1991	0	42	42
Boston Edison	Pilgrim 1	1991	16	0	16	2
PeCo	Peachbottom 3	1991	10	0	10
PeCo	Limerick 1	1992	0	7	7
Cleveland Elec.	Perry 1	1992	0	27	27	1
TVA	Browns Ferry 3	1992	71	29	100	2
GPU	Oyster Creek	1992	70	0	70	2
Georgia Power	Hatch 1	1993	18	11	29
TVA	Browns Ferry 2	1993	12	0	12	2
PP&L	Susquehanna 2	1993	8	6	14
PeCo	Limerick 1	1994	4	14	18
Georgia Power	Hatch 2	1994	0	18	18
PP&L	Susquehanna 2	1994	7	5	12
GSU	River Bend	1994	0	28	28
WPPS	WNP-2	1994	6	38	44
GPU	Oyster Creek	1994	39	16	55
			678	479	1157

(1) Some weldments with pre-existing cracks
(2) Weldments for replacement piping made of SCC immune materials

• Pipelock
  Our senior staff invented, built, and installed a pipelock on an elbow degraded by stress corrosion cracking in the primary system of a nuclear power plant.
• Thermal Shield Repair
  Flow induced vibrations were evaluated in the thermal shield of the San Onofre Nuclear Plant. O'Donnell designed a support system which was installed to control the amplitude of vibrations within acceptable limits.
• Design and Analysis
  Reactor systems & internals; steam generators; reactor coolant pumps; seals; motors; safety systems; containment structures; piping & supports; turbines; generators; valves & other components.

In accordance with our Nuclear Quality Assurance Program, a comprehensive independent review is conducted for all of our safety-related work. This provides additional assurance of technical excellence and efficiency. Registered professional engineers, qualified and experienced in the work being performed, supervise the engineering, design analysis, testing and drafting work being performed. All of our Class-1 safety-related projects are subjected to our nuclear QA Program.

Our staff has successfully served clients from England, Germany, Japan, France, Spain, Italy, as well as across the United States. We serve major utilities and all the US Nuclear Steam Supply System manufacturers.