Portfolio

Mural of Expert Witness / Forensic Cases

Sample of Projects in our Portfolio Which Highlight a Diversity of Engineering and Legal Cases we’ve Worked On.

For over 40 years, we have assisted numerous clients solve complex problems enabling them to increase production performance, and become more cost efficient. We are constantly updating this page – stop by again!

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  • Aerospace Engineering Projects
  • Civil / Structural Engineering Projects
  • Engineering Consulting Projects
  • Failure Analysis Projects
  • Fatigue Analysis Projects
  • Finite Element Analysis (FEA) Projects
  • Forensic Engineering Expert Witness Projects
  • Mechanical Engineering Projects
  • Technical Services
Typical Solar Panel Array. OCEI performed structural analysis on a solar array support structure.

Analysis of Solar Array Support Rack

Analysis of Solar Array Support Rack Structure issues after subjected to a hurricane
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API 579 / ASME FFS-1 Fitness For Service - FEA Model of PSA Vessel

Fatigue and FFS Evaluations of Pressure Swing Adsorption (PSA) Vessels

Fatigue and API 579 / ASME FFS-1 Fitness-For-Service Evaluations on Pressure Swing Adsorption (PSA) Vessels used in a Waste Facility. These evaluations had not been ...
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Failure Analysis of Tumbler - FEA Analysis Model of Tumbler and Shaft used to Determine Failure

Fatigue Analysis & Design Recommendations on a Chemical Tumbler

Fatigue Analysis & Design Recommendations on the shaft of a Chemical Tumbler.
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Stress & Buckling FEA – Powder Decanter to ASME Section VIII Code

ASME Section VIII Division 1 (FEA) stress and buckling analysis on a decanter used to transfer microscopic materials.
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Structural Analysis of Heat Exchanger Supports - FEA Model

Structural Analysis of Heat Exchanger Supports

Structural Analysis of Heat Exchanger Supports.
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FEA Model - Vibration Analysis of Extruder

Vibration & Modal Analysis of an Extruder

Vibration & Modal Analysis of Extruder and Subsequent Design Recommendations
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Cyclone FEA Model - Failure Analysis & Design Modifications

Weld Cracking Investigation on T Bar Section of Cyclones

Weld Cracking Investigation on T Bar section of Cyclones. Modal FEA Analysis Determined Mode of Failure. Recommended Design Modifications.
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Finite Element Analysis Model of VRU Base Skid

Structural & Modal FEA Analysis of Vapor Recovery Unit (VRU) Base Skid

Structural and modal finite element analysis of a Vapor Recovery Unit (VRU) base skid to ensure structural integrity to ASME Boiler & Pressure Vessel (B&PV) ...
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Structural Analysis of Compressor Skid Nozzles - CAD Model

Structural Analysis of Compressor Skid Nozzles

Structural Analysis of Compressor Skid Nozzles
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Structural Analysis of Waterbox - FEA Analysis Model

FEA Structural Analysis of Waterbox Design Upgrades

FEA Structural analysis of waterbox upgrades for a MAWP increase to 80 psi, and redesign accordingly
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Failure Analysis and Design Modifications of FRP Contactor Vessel

Failure analysis and subsequent design modification on a FRP contactor vessel used to separate hydrogen sulfide from bio-gas & landfill gas.
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Evaluation of Loads on High Temperature Condensate Tank Nozzles

Evaluation of Loads on High Temperature Condensate Tank Nozzles
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Barge collision investigation - showing onboard engine

Forensic Investigation of a Barge Collision

Forensic Investigation of a Barge Collision determined that the air compressed system used to control the engine and steering controls had failed
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FEA Model of the Heat Exchanger using a Single Tube Pass Due to Symmetry

Fatigue Analysis (To ASME Code) of Heat Exchanger Coil

Fatigue Analysis of Heat Exchanger Coil to ASME Code
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FEA Design & Analysis of Chemical Tubular Reactor – To ASME Code

FEA design and (thermal & buckling) analysis was performed on a Chemical Tubular Reactor - to ASME Code
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Engineering and Design Modification of Control Valves in Reactor Recirculation System

Engineering analysis and design modification of control valve removal, reassembly and reinstallation in a reactor recirculation system
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Computational Fluid Dynamics (CFD) Analysis (CFD) of Blowpipe Failure

Blast Furnace Blowpipe Failure – CFD Investigations

Computational Fluid Dynamics (CFD) was used to analyze a blast furnace blowpipe failure.
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Finite Element Analysis Model of Heater Vessel

Finite Element (FEA) Analysis on a Heater Vessel

Finite Element (FEA) Analysis on Heater Vessel. We perform FEA analysis on components including heat exchangers and vessels.
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FEA Buckling Analysis Results: Mode Shape 5

Buckling Analysis on an Elevated Temperature Vessel under a Vacuum

Buckling analysis on elevated temperature vessel subjected to vacuum. Instantaneous Linear and Nonlinear buckling and Creep Buckling.
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Forensic Failure Analysis of Damaged Mining Lift Hook

Forensic Failure Analysis of Damaged Mining Lift Hook - Finite Element Analysis was used to determine root cause
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FEA of Rotor

Failure Analysis of Studs on an Electric Turbine Outer Head Cover

Failure analysis of studs connecting the outer head cover to the stay ring of an electric-generating turbine
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Fatigue Analysis on Threads of Base-Ported Pressure Filter

A client had determined that in very dusty environments where their base-ported pressure filter was used, particles can get in between the threads of the ...
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Vibration Analysis on ASTM A514 Grade B Steel Industrial Impeller

Vibration analysis on an industrial impeller (constructed of ASTM A514 Grade B Steel) to determine its natural frequencies.
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Analysis of Cement Kiln - Artist Illustration of Kiln

Analysis of Failed Rotary Cement Kiln

Analysis of a failed rotary cement kiln which occurred during startup. Get analysis & recommendations from Tom O'Donnell 412.835.5007. Rotary kilns run 24/7 and are ...
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Truck 5th Wheel Evaluation and Accident Causation Analysis

Truck 5th Wheel Evaluation and Accident Causation Analysis determining the cause of the separation of a trailer from its tractor.
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Fatigue Analysis on a Rail Coupler to AAR Specifications

Fatigue analysis on a rail coupler performed to AAR Specification M1001.
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Metallurgical Evaluation of Corroded Piping - Pit Seen at Center

Failure Analysis of Corroded Irrigation Piping

Failure analysis and metallurgical evaluations of corroded irrigation piping, and subsequent recommendations.
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API 579 / ASME FFS-1 Fitness For Service on Steel Brewery Tanks

API 510 inspection and API 579-1/ ASME FF-1 fitness for service evaluation performed on glass-lined stainless steel brewery tanks
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Failure Analysis & Redesign on a Refinery Piping Loop that Failed in Startup

Expert failure analysis and redesign of a refinery piping control loop that burst during desulfurizer startup.
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Coke Oven Battery Evaluation in $560 M International Arbitration

Coke Oven Battery Engineering Evaluation - design / construction forensic investigations in $560 M ICC Arbitration.
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API 579/ASME-1 Fitness for Service on Urea Reactor

API 579/ASME FFS-1 Fitness for Service Evaluation on UREA Reactor

API 579 / ASME FFS-1 Fitness For Service evaluation on a multi-wall UREA reactor to API 579 / ASME FFS-1
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Weld Failure Analysis -Closeup of Failed Wire Rope showing surface deformation

Failure Investigation – Wire Rope

Failure investigation on a 6x36G IWRC Grade, non-galvanized wire rope using visual, metallurgical and hardness testing
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FEA - Heat Exchanger Results

Cracked NASA Heat Exchanger – Failure Analysis & Redesign

Failure analysis of cracks around bolt holes of the inlet and outlet tubesheets of a NASA heat exchanger.
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Failed Fifth Wheel Investigation

Forensic Investigation of a Tractor Fifth-Wheel Failure

Forensic investigation on a tractor fifth-wheel failure to determine the cause of the separation of a trailer from its tractor. O'Donnell Consulting Performs Forensic / ...
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Failure Analysis of Overpressurized Storage Tank

Failure Analysis of an Overpressurized Storage Tank. Investigation and repair recommendations
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Metallurgical Image of Landing Gear Actuator Arm at 200x

Metallurgical Evaluation of Cracks in Aircraft Landing Gear

Metallurgical Evaluation of Cracks found in Aluminum Actuator Arm on Aircraft Landing Gear.
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API 579-1 / ASME FFS-1 Fitness For Service on Aging Ash Silo

API 579-1/ASME FFS-1 Fitness For Service Evaluation of a 40 year old ash silo used in an ash handling system.
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Failure Analysis on a Cracked Cylinder Liner

An 18-inch replacement cylinder liner was manufactured for an engine used to compress natural gas. During the installation, the liner fractured and fell into the ...
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FEA Design and Analysis – Pressure Vessel Components for Radioactive Waste Cleanup

FEA design and (thermal, stress, vibration and fatigue) analysis - vessels & other components for nuclear radioactive waste cleanup.
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Material Characterizations of AISI-SAE 4140 Miner Torque Shafts

Material characterization (chemical, microstructural and mechanical) performed on three continuous miner drive torque shafts for comparison purposes.
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Engineering Review of Design Changes in Taiwan Nuclear Plant

Engineering Review of the design, construction, and installation of a deflector plate used to prevent cross-flow from the LPCI across core components
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Assessment of Metallurgy & Welding Procedures of P91 Heavy Wall Piping

Assessment of metallurgy & welding procedures on P91 Heavy Wall Piping in a power plant. P91 is a steel for elevated temperature applications
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ANSYS FEA Model showing a Nozzle on the Tank in a Fitness For Service of Brewery Tank

API 579-1 / ASME FFS-1 Fitness for Service on a Brewery Tank

API 579-1 / ASME FFS-1 (2007) Fitness-for-Service evaluation on a tank for a brewery.
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ASME Section VIII Design & Analysis – Vessels Processing Nuclear Waste

ASME Section VIII Design & Analysis - thermal, stress FEA analysis on elevated temperature/ pressure vessels to process nuclear waste.
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Stress and Fatigue Analysis of High Cycle Vessels used to Produce Hydrogen

Stress and Fatigue analysis of high cycle vessels that are used to produce virtually pure hydrogen.
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Frequency Response Testing of Compressor Turbine Vanes

Frequency Response Testing of Compressor Turbine Vanes conducted to prevent mass loading and external damping effects
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Vibration and Shock Analysis of Shipboard Heat Exchanger to Engineering Codes

Vibration and shock analysis on a shipboard heat exchanger. Heat exchangers were to be supported on rigid platforms that are attached to the process deck ...
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Engineering Analysis of Replacement Reactor Coolant Pump Seals

Engineering analysis of replacement reactor coolant pump seals. In addition, a thermal hydraulic analysis was performed.
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Weld Troubleshooting & Redesign of a Stainless Steel Heat Exchanger

Weld troubleshooting & redesign on a stainless steel heat exchanger with a limited fatigue life in a location of high stress concentration.
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Metallurgical Analysis of Failed 3rd Stage Blade

Metallurgical & Engineering Analysis of Failed 3rd Stage Gas Turbine Blades

Metallurgical and analysis to determine the cause of failure on two 3rd stage blades which failed after 11,00 hours in service
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Prediction of Thrust Chamber Life on NASA Space Shuttle Main Engines

Prediction of Thrust Chamber Life due to hot-gas-wall ligaments separating coolant & combustion gas subjected to severe thermal cycling
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Seismic Analysis on Fire Protection Systems to Uniform Building Code

Seismic analysis to Section 132 of the UBC for a client that designs and installs fire protection systems.
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FEA & Fatigue Analysis – Hydroelectric Turbine Shaft

FEA and fatigue / fracture analysis of the turbine shaft on hydroelectric plant exhibiting linear indications.
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FEA Design and Analysis of Large Scale Pressure Vessels under High Energy Impact

FEA design and (impact, thermal shock, and fatigue) analysis of pressure vessels and equipment subjected to high energy impact with a dual phase fluid at ...
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Forensic Failure Analysis of Hunting Bow

Forensic Failure Analysis on Hunting Bow

Forensic failure analysis performed on a hunting bow incident that resulted in an injury. Metallurgical testing / Engineering.
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Failure Analysis & Redesign of Cracked Conveyor Ductwork

Failure Analysis and Redesign of Cracked Conveyor Ductwork
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FEA of Feedwater Heater

ASME Section VIII Division 1 (FEA) Analysis on Feedwater Heater

ASME Section VIII Div. 1 linear elastic finite element (FEA) analysis on a Low Pressure Feedwater Heater
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Failure Investigation on Food Processing Pressure Vessel Head

Failure Investigation of the closure head on a horizontally mounted low pressure food process vessel.
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Failed Oil / Gas Threaded Joint Casing

Failure analysis of threaded joint casing at about 80-100 feet near the drill bit about 30-40 feet from the bottom of the hole.
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Metallurgical Investigation (SEM)- Damaged Compressor Bearing

Degraded Compressor Bearing – Metallurgical / SEM Investigation

Surface degradation found on an air compressor Tin-copper alloy bearing. Metallographic and SEM techniques were used to determine cause.
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FEA Model of statue base - investigating cause of collapse

Forensic Investigation – Collapse of the 15th Century Statue of Tullio Lombardo’s Adam

Tullio Lombardo's Adam is one of the greatest Venetian 15th-century works of art. Forensic investigation performed after its base collapsed.
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Design & Application of Inconel 625 Weld Overlay on a Refinery Vessel

Design of Weld Overlay on 9 foot diameter 60 ft long Refinery Stripper Vessel
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Stress, Vibration and Fatigue (FEA) Analysis on Bellows

Stress, vibration and fatigue (FEA) analysis on a bellows design. The 28-convolution bellows was designed to last for 5 years, or 13.14 billion cycles.
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SEM Image of Fractured Forklift Cable

Root Cause Forensic Investigation of Forklift Accident

Root cause forensic investigation of forklift accident which resulted in serious injuries. Chemical, metallurgical and other testing on brake cable.
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Root Cause Failure Analysis on Electronics Cooling Fan

Root cause analysis of a failed fan used to cool electronics - that occurred within two months of operation
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Failure Analysis of Barge Mooring in Pittsburgh

Failure analyses of a barge mooring that had broken during a flood condition on the Ohio River
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Investigation of Collapsed Rack Structure - Facility picture

$63 M Award in Litigation over a Newly Constructed Collapsed Paper Rack Storage Facility

Longer than two football fields and 80 feet wide, a large steel paper rack storage facility was constructed with 110 foot tall hollow steel columns ...
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316L SS valve impellers corrosion investigation (SEM Image of Pitting)

316L SS Rotary Valve Impellers – Corrosion / Metallurgical Evaluation

Type 316L SS rotary valve impellers used in cheese curd production were evaluated to determine the cause of pitting corrosion
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Cracked Tube-to-Tubesheet Welds on Chemical Reactor – Failure Analysis

Cracks had developed on tube-to-tubesheet welds on a chemical reactor. We were asked to perform a thermal transient and stress analysis of the welds. This ...
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Failure Analysis – Cracked Pressure Swing Absorber (PSA) Vessels

Failure analysis and repair of Pressure Swing Absorber (PSA) Vessels - in service at a hydrogen plant - found to exhibit chevron cracks
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Comparison of Saudi Standard to US, EU and Japanese Standards

Comparison of a Saudi plant layout Standard to US, European and Japanese Standards - relative to siting and spacing from a safety perspective
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FEA Model of Hydroelectric Turbine Shaft

Hydroelectric Turbine Shaft Exhibiting Flaws – Weld Consulting

Hydroelectric Turbine Shaft Exhibiting Flaws - Weld Consulting including NDE testing, Fracture Mechanics & Weld Repair
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FEA Design Optimization of Brake Rotor

Formula One Brake Rotor FEA Design Optimization

Formula One Brake Rotor FEA Design Optimization
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Quartz Tubes in Water Purification System Failure Analysis

Quartz tubes used in a water purification system - failure analysis. CFD, stress and vibration analysis.
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30 Ton Automotive Forming Press – Failure Investigation

After a Coupling End of a 6-inch Bore Hydraulic Cylinder Failed on a 30 Ton Automotive Forming Press, we were Asked to Investigate
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ASME Section VIII Division 1 Analysis on Storage Drum at a Refinery

ASME Section VIII Division 1 analysis was performed on a de-resining unit storage drum located at a refinery
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Cracking Links in a Gypsum Kiln Conveyor Chain

Failure analysis and subsequent recommendations of cracking in a Gypsum Kiln conveyor chain.
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Forensic Investigation of Coke Oven Battery Construction Issues

Forensic Investigation on Coke Oven Battery Construction – $200 M Litigation

Finite element engineering analysis was used to calculate temperatures, deflections, strains, and stresses using time-dependent creep analysis methods to evaluate the long term integrity of ...
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Failure Investigation and Design Modifications on Cracked Large Capacity Fuel Heaters

Cracks had occurred on Large Capacity Fuel Heaters (LCFH) during a 2000-hour service test after approximately 1000 hours of service testing. O'Donnell Consulting Engineers performed a ...
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SEM image of Leaking Pump Seal

Leaking Nickel Cemented Tungsten Carbide (WC) Pump Seals – Investigation

Excessive wear and leakage was discovered on three nickel cemented tungsten carbide (WC) pump seals. Visual examination identified gouges in the seal surfaces that were ...
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Recertification of Aging Pressure Vessels / Systems at NASA Facility

Recertification of aging pressure vessels and pressure systems, including stress, fatigue and fracture analyses to ASME Code - at NASA Lewis
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FEA Analysis Results - Refractory Lined Autoclave

Refractory Lined Autoclave Finite Element Analysis

A refractory lined autoclave finite element analysis was performed for a client in the Chemical Industry. These types of processes often require the use of ...
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FEA Model of Tube to Tubesheet Configuration of the Superheater

Cracked Tube-to-Tubesheet Welds on Sulfuric Acid Plant Superheater

Cracked tube-to-tubesheet welds on an Acid Plant Superheater. Investigation included Design, fabrication and elevated temperature operation.
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ASME Code Section VIII Calculations – Refinery Contactor Vessel

ASME Code Section VIII calculations on a contactor vessel in a refinery.
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Static & Dynamic FEA Analysis – Skate Ramp Modifications

Static and dynamic finite element analysis on various design modifications of skateboard ramps after a client/ manufacturer found permanent deformations on one of its ramps ...
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Finite Element Analysis Model of Offshore Skid

Finite Element Analysis (FEA) on Offshore Process Skid

Finite Element Analysis (FEA) to ASME Code on an Offshore Process Skid
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Forensic Investigation of Premature Weld Cracking in Stainless Steel Exhaust Ductwork

Premature weld cracking had occurred in exhaust ductwork. The cracking occurred in corner weld joints and in stitch welds used to secure the shell to ...
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Cracks in Incinerator Recuperator – Failure Investigation & Repair

Cracks Through the Ligaments of the Tubesheets in a Incinerator Recuperator in a Chemical Plant. Failure Investigation & Repair.
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FEA Analysis of Skid Mounted Heat Transfer System to ASME B31.3

Finite element analysis (FEA) on the piping system of a skid mounted heat transfer system to ASME Process Piping Code (ASME B31.3)
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XL Sprinkler Pipe - Failed Surface

Failure of XL Commercial Sprinkler Pipe – Root Cause Analysis

After the Failure of XL Commercial Sprinkler Pipe System Occurred, we were asked to Perform Structural Analysis and Metallurgical Testing.
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Wellhead Threaded Closure Failure Investigation and Design Modifications

Wellhead Threaded Closure Failure Investigation. Metallurgical evaluations, material testing, and engineering analysis.
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Inelastic Thermal Analysis of Mold Plate in Continuous Casting Process

Inelastic thermal analysis of mold plates due to wear and distortion of the copper plates in the mold in the operation of continuous casters.
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Forensic Failure Analysis – Flight Control Aircraft Stabilizer Trim Motor Bearing

Forensic Failure Analysis - Boeing 737 Flight Control System Aircraft Stabilizer Trim Motor Bearings.
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Development of Elevated Temperature Design Criteria – Nuclear Components

Development of elevated temperature design criteria for nuclear components - methods for fatigue evaluation and design for cyclic service.
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FEA Analysis of Mine Door to determine structural integrity

Finite Element Analysis (FEA) of Mining Bulkhead Doors

An independent FEA analysis was performed on water tight mining bulkhead doors to determine structural integrity. The assessment included the bulkhead doors, the stress transfer ...
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Structural Analysis of FRP Piping System using FEA

FEA Analysis of FRP Piping in Flue Gas Desulfurization System

FEA Analysis of Fiberglass Reinforced Piping (FRP) - Limestone Slurry Recycle segments of Flue Gas Desulfurization System
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FEA Model of Crane seat

Finite Element and Fatigue Analysis on Crane Seat

Finite element and fatigue analysis performed on a crane seat to ensure it would last its intended design life.
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API 579/ ASME FFS-1 Fitness For Service on Overheated SA 213-T2 Boiler Tubes

API 579-1/ASME FFS-1 Fitness For Service on Overheated SA 213-T2 Boiler Tubes. The boiler tubes in Hatfield's Ferry plant were exposed to overheating, which resulted ...
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Thermal Analysis of Busway

Thermal FEA Analysis of 400 Ampere Busway System

Thermal finite element analysis (FEA) of a 400-ampere busway in power distribution system.
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$16 Million Award for Collapsed Bauxite Conveyor System – Forensic Investigation

$16 Million award in U.S. District Court over Collapsed Bauxite Conveyor System - Forensic Investigation.
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(412) 835-5007

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