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
Analysis of Solar Array Support Rack
Analysis of Solar Array Support Rack Structure issues after subjected to a hurricane
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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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Fatigue / Failure Analysis & Design Recommendations on 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
Structural Analysis of Heat Exchanger Supports.
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Vibration & Modal Analysis of an Extruder
Vibration & Modal Analysis of Extruder and Subsequent Design Recommendations
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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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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
Structural Analysis of Compressor Skid Nozzles
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FEA Structural Analysis on Waterbox Design Upgrades
FEA Structural analysis on waterbox design upgrades for a MAWP increase to 80 psi - and redesign accordingly
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Failure Analysis and Design Modifications on 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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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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Fatigue Analysis of a Heat Exchanger Coil to ASME B&PV Code
Fatigue Analysis of Heat Exchanger Coil to ASME B&PV Code Section VIII Div. 2 Part 5
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FEA Design & Analysis of Chemical Tubular Reactor – To ASME Section VIII Code
FEA design and (thermal & buckling) analysis was performed on a Chemical Tubular Reactor - to ASME Section VIII 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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CFD Analysis – Blast Furnace Blowpipe Failure
Computational Fluid Dynamics (CFD) analysis of a blast furnace blowpipe failure.
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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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Buckling Analysis on 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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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 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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Failure Analysis on Corroded Irrigation Piping
Failure analysis and metallurgical evaluations on 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
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 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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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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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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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 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
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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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 & 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 Rocket 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 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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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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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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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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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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Forensic Investigation of Barge Mooring in Pittsburgh
Forensic investigation of a barge mooring that had broken during a flood condition on the Ohio River
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$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 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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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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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 B&PV 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 concerning cracking in a Gypsum Kiln conveyor chain.
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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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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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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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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 Div. 1 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 (FEA) on Offshore Process Skid
Finite Element Analysis (FEA) on an Offshore Process Skid to ASME Code
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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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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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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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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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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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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 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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