ODonnell Consulting
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Portfolio

Following are a few example projects highlighting a diversity of engineering and legal cases we have 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.

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All Design & Analysis Engineering Failure Analysis Mechanical Expert Witness Civil/Structural Technical Services Aerospace
We performed (finite element) design and thermal, stress and fatigue analysis of an elevated temperature/pressure…
A de-resining unit storage drum located at a refinery was evaluated in accordance with ASME…
We performed design and thermal, stress, vibration and fatigue analysis on vessels and components to…
A commercial heating and air conditioning (HVAC) company had a closed loop chilled (40 ºF)…
A buckling analysis was performed on an elevated temperature stainless steel vessel subjected to a vacuum…
For a major food processing company, O'Donnell Consulting analyzed the failure of a horizontally mounted low…
  Tullio Lombardo's Adam is the greatest Venetian 15th-century work of art in America. The…
During a shutdown of the Kuosheng 1 plant, Taiwan, operation of the LPCI system for…
O'Donnell Consulting performed the design and structural analysis of two large scale containment pressure vessels…
For a client that designs and installs fire protection systems, O'Donnell Consulting performed a seismic…
A comprehensive engineering analysis was performed on a coke oven battery roof and heating walls…
Turbine blades made by a particular manufacturer are a complex shape that requires them to…
We were requested by a client to perform a stress, vibration and fatigue analysis on a bellows…
A third stage blade on a gas turbine had failed after 11,00 hours in service.…
A 1,400 ton hydraulic press frame had experienced cracks in high stress critical locations. Structural…
O'Donnell Consulting was asked to perform a fatigue analysis on a rail coupler, in accordance…
  Chemical, microstructural, and mechanical property characterizations were performed on three continuous miner drive torque…
New and failed sections of a conveyor chain used for material transfer in a gypsum…
The studs connecting the outer head cover to the stay ring of an electric-generating turbine…
An incinerator recuperator in a chemical plant developed severe leakage due to cracks through the…
A propane pump explosion had killed one worker and injured three others at a central…
O'Donnell Consulting performed an investigation of a Shipboard Compressor System Fire incident that occurred on…
We investigated the cause of leaking/failure in a 2" diameter floating ball valve in a…
During the delivery of a shipment of resin, damage occurred to a storage tank at…
An engineer was seriously burned when a thirty-nine inch expansion joint ruptured while workman were…
The growing need for efficient electric power generation led to the use of pulverized coal…
After a gas well accident in which a worker lost a leg at a plant,…
We were asked to investigate defects on the blades of a 304 Stainless Steel mixer.…
We were asked to perform an API 579-1/ASME FFS-1 Fitness For Service Evaluation of a…
A Monel Series 3800 Pressure Relief Valve in oxygen service was destructively evaluated to determine…
A Fitness-for-Service evaluation was conducted on a tank for a brewery. The evaluation was conducted in…
We performed API 579-1/ASME FFS-1 Fitness For Service on Overheated Boiler Tubes. The boiler tubes…
O'Donnell Consulting performed a seven-year program to recertify pressure vessels and pressure systems for the…
For a major utility, O'Donnell provided engineering analysis of replacement reactor coolant pump seals. In…
A 9 foot diameter, 60 foot long Stripper Vessel was designed and fabricated to be…
ASME Code Section VIII Division 2 analysis was performed using ANSYS finite element analysis on…
We performed a structural analysis on a skid mounted system (aboard a floating offloading and storage facility)…
O'Donnell Consulting was asked to provide an assessment of the welding metallurgy and details on…
Wear and distortion of the copper plates in the mold is a major concern in…
O'Donnell Consulting performed a third party engineering review of the Babcock & Wilcox (B&W) analyses…
Induction heating is caused, as the name implies, by induced electric currents in a material.…
O'Donnell Consulting performed a finite element analysis of a refractory lined autoclave, for use in…
We developed an analytical procedure for predicting thrust chamber life on the Space Shuttle Main…
Stress corrosion cracking can occur on low pressure (LP) turbine disks which operate at or…
Cracking and failure of Control Rod Guide Tube (CCRGT) Support Pins (Split Pins) was encountered…
We performed a forensic investigation on an injury from a forklift accident, which occurred due…
Cracks were occurring in the running surface of the Newark International Airport monorail guideway. Some…
The head of a pressure vessel used to manufacture crystals for use in devices including…
A West African bauxite company was awarded $16 million in a U.S. District Court after…
We were asked to perform a failure analysis on a pump used in fracking operations. The…
  O'Donnell Consulting was asked to perform a design analysis of a high temperature pressure…
For the Westinghouse Electric Corporation, Advanced Reactors Division, a method of bounding the accumulated plastic…
OCE has developed elevated temperature design criteria which have become part of the ASME Boiler…
During startup of a desulferizer at an oil refinery in the Virgin Islands, piping failed…
    O'Donnell Consulting was engaged to investigate corrosion in various structures of a refinery…
O'Donnell Consulting was retained by an insurance company to perform a root cause analysis of…
O'Donnell Consulting was engaged to perform a comparison of a Saudi Aramco Engineering plant layout…
A client had designed and built four shell and tube heat exchangers for use in…
O'Donnell Consulting was retained to perform failure analysis, repair and modifications on a vessel used…
O'Donnell Consulting performed the design calculations for the piping system of a skid mounted heat transfer…
O'Donnell Consulting was asked to design a welded connection between a wind turbine monopole tower…
Stress and fatigue analysis was performed on a crane seat to ensure it would last…
When ball-type control valves in a reactor coolant system were found to be sticking during…
O'Donnell Consulting investigated a fifth-wheel device to determine the cause of the separation of a…
A client that designs and fabricates a variety of electrical power distribution systems asked us to perform a thermal…
Longwall mining is used to more efficiently remove underground coal deposists in large rectangular blocks.…
Turbine blades made from subject castings were in need of weld repairs caused by machining…
O'Donnell Consulting performed a structural analysis and remaining life assessment of the main shafts on…
O'Donnell Consulting performed a failure analysis on a mining lift hook. A three dimensional finite…
We were requested to perform a forensic investigation on a steel tube chair that had failed…
O'Donnell Consulting was commissioned to conduct an independent safety review of paving equipment that was…
We performed engineering analyses of nuclear propulsion plant components for Virginia Class submarines. This work…
A Plaintiff general mechanical contractor with a history with a petrochemical company was involved in…
After a fan used to cool electronics failed within the first two months or approximately…
         Cracks had occurred on Large Capacity Fuel Heaters (LCFH) during a…
A number of cracks were found around the bolt holes of the inlet and outlet…
We performed a finite element stress analysis on condensate receiving tanks - including the shells…
We performed a structural analysis of a base skid, which supported a condensor exhauster system in…
A client had determined that in very dusty/dirty environments where their base-ported pressure filter is…
An 18-inch replacement cylinder liner was manufactured for an engine that is used to compress…
For a client that manufactures components for Formula One Race cars, we performed analysis and…
O'Donnell Consulting performed failure analyses of a barge mooring that had broken during a flood condition on…
When reinforced ductwork failed shortly after being placed in service, we were asked to perform…
A supplier of large diameter Fiberglass Reinforced Plastic (FRP) abrasion-resistant piping contacted O'Donnell Consulting as…
A manufacturer of systems which filter a mixed inlet gas stream and produce virtually pure…
A manufacturer of a Thin Film Heat Exchanger (TFHE) - which is used in conjunction…
A Fitness-For-Service evaluation of a steam drum pressure of a wood-fired boiler was performed. The…
O’Donnell Consulting Engineers, Inc. performed a failure analysis, repair and modifications of a contactor vessel.…
Numerous ASME Section VIII Code Pressure Swing Absorber Vessels were found to contain about 1300…
We were asked to perform a failure analysis to determine the cause of the corrosion…
A manufacturer had contacted us to perform a structural analysis of an "S" type ladle…
O'Donnell Consulting investigated a hunting bow incident that resulted in an injury. We performed metallurgical…
    O'Donnell Consulting Engineers evaluated the nature of vibratory conditions on the framework supporting…
O'Donnell Consulting performed a vibration (modal and spectrum) analysis for a manufacturer's linear variable displacement…
Failure of panel coil components in a large sterilizer was investigated. A failure specimen was…
After a manufacturer found permanent deformations in one of its skate ramps, it asked O'Donnell…
  O'Donnell Consulting performed finite element design and static/vibration analysis on a 2 foot thick…
  Cracks in an aluminum actuator arm on an aircraft landing gear had occurred during…
        Longer than two football fields and 80 feet wide, a large…
Premature weld cracking had occurred in exhaust ductwork. The cracking occurred in corner weld joints…
    An air compressed system used to control the engine and steering controls for…
      A failure analysis of a commercial sprinkler pipe system was performed. The…
O'Donnell Consulting performed a structural analysis to determine the impact of oversized holes in the…
O'Donnell Consulting performed a failure analysis of elevation gearboxes used to control an earth-station antenna.  …
O'Donnell Consulting investigated a failed a turbine exhauster, which is part of a high speed,…
  O'Donnell Consulting was retained by an attorney to provide forensic engineering services (fire cause…
A fire/explosion occurred at pipeline LPG Dehydration facility, and we were subsequently asked to investigate.…
We were asked to perform a failure analysis on a threaded joint casing at a…
Two rotary valve impellers fabricated from Type 316L SS that were used in cheese curd…
We served as technical consultants in an International Chamber of Commerce ($ 560 M) binding…
Cracks had developed on tube-to-tubesheet welds on a chemical reactor. We were asked to perform…
A manufacturer of water and wastewater treatment products, systems, and chemicals as well as high…
O'Donnell Consulting Engineers (OCE) performed an analysis and redesign on a heater that had a…
A cement rotary kiln consists of a slightly inclined tube made from steel plate and…
Excessive wear and leakage was discovered on three nickel cemented tungsten carbide (WC) pump seals.…
OCE performed a vibration analysis on an industrial impeller (constructed of ASTM A514 Grade B…
Westinghouse Power Generation Business Unit (PGBU) Combustion Turbine Division (CT) had developed an Advanced Combustion…
A client had designed and fabricated two types of above-ground tanks, originally intended to be…
  A coupling end of a 6-inch bore hydraulic cylinder from a 30 ton forming…
A stress and buckling analysis was performed on a decanter, which is used to transfer…
O'Donnell Consulting Engineers investigated the cause of an accident due to a failed threaded closure…
We were asked to investigate the failure of a key component on a Boeing 737…
  O'Donnell Consulting was asked to assess the structural integrity of a base skid containing…
  The structural integrity of bulkheads was a very important issue in safely operating mines…
O'Donnell Consulting performed ASME Code Section VIII Division 2 calculations on feedwater heaters. In modelling…
An investigation was performed on a 1-inch stainless steel (SS) ball valve in a pipeline to…
An independent analysis was performed to determine the cause of the failure of quartz tubes…