Engineering Consulting Archives

ASME Section VIII (FEA) Design & Analysis – Vessels Processing Nuclear Waste

Thermal, fatigue, and creep Analysis using ASME Code We performed ASME Section VIII design & analysis – (using thermal, stress and fatigue) finite element analysis of elevated temperature/pressure vessels processing nuclear waste. The vessels were designed to treat radioactive waste to produce a stable, immobilized solid product waste as part of the Idaho Cleanup …

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Fatigue Life Analysis of High Cycle Vessels used to Produce Hydrogen

We performed structural and fatigue analysis on vessels used to produce hydrogen. The client was a manufacturer of systems which filter a mixed inlet gas stream that imposes an extremely high number of pressure cycles on its vessels. We were asked to develop simple methods for determining stresses in the heads, nozzles, support features and …

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Finite Element Analysis of Vapor Recovery Base Skid

Finite Element Analysis Model of Base Skid

FEA Model of Base Skid We performed finite element analysis on a Vapor Recovery Unit (VRU) base skid to determine structural integrity to ASME Boiler & Pressure Vessel Code. The skid package is used to recover process vapor for use as fuel gas – for a plant near Fort McMurray, North Alberta Canada. The …

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

(ANSYS) Finite Element Model of Feedwater Heater FEA of Low Pressure Feedwater Heater to ASME Section VIII Code We performed ASME Section VIII Division 1 analysis on a Low Pressure Feedwater Heater using ANSYS finite element analysis (FEA) software. The vessel is essentially symmetric about the vertical centerline plane; therefore, only one half of the …

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Failed Oil / Gas Threaded Joint Casing

Failure occurred on a threaded joint casing at a shallow depth of about 80-100 feet near the drill bit about 30-40 feet from the bottom of the hole – on the male pin connection at the root of the last thread. We were asked to investigate. The drilling includes two wings that expand once the …

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Cracked NASA Heat Exchanger – Analysis & Redesign

Thermal, Structural and Fatigue Analysis – and Subsequent Redesign of Heat Exchanger A number of cracks were found around the bolt holes of the inlet and outlet tubesheets of a heat exchanger in service at NASA/ Lewis. We performed failure analysis and subsequent redesign to ensure conformance to code. Cracks had initiated at the …

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FEA Design and Analysis to ASME Code – Chemical Tubular Reactor

FEA Model of Chemical Reactor Design & Thermal, Stress and Buckling Analysis to ASME Section VIII Divisions 1 and 2 We performed the FEA design and (thermal, stress and buckling) analysis of a chemical tubular reactor. The reactor was designed to meet the requirements of ASME Section VIII, Division 1 Code. Thermal and structural finite element …

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Design/ Application of Inconel 625 Weld Overlay on a Refinery Vessel

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.

Stress, Vibration and Fatigue (FEA) Analysis on Bellows Design

Analysis Results showing the radial stress (X-Dir) Stress, vibration and fatigue (FEA) analysis was performed on a bellows design. The 28-convolution bellows was intended to last for 5 years, or 13.14 billion cycles. The bellows assembly is installed in a vertical orientation with its bottom end stationary. Its top end is subjected to a …

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Metallurgical & Engineering Evaluations of Cracks in Aircraft Landing Gear

Chemical, tensile and hardness tests were performed, along with SEM. The scanning electron microscope revealed that the fracture had initiated at one location on the inside diameter surface.

316L SS Rotary Valve Impellers – Corrosion / Metallurgical Evaluation

We performed corrosion and metallurgical analysis on two Type 316L SS rotary valve impellers exhibiting pitting. The impellers are used in cheese curd production. The pitting was localized, biased towards the keyed drive end of the rotors, reportedly the same location where convey air is introduced into the valve. The convey air was reported to be …

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Failure Analysis – Cracked Pressure Swing Absorber (PSA) Vessels

Extensive investigation of the cracking was conducted, including UT, RT, and Magnetic Particle (MP) examinations; a joint test protocol for destructive testing on boat samples; chemical composition analyses, metallographic evaluations, and fractographic analyses.

Comparison of Saudi Standard to US, EU and Japanese Standards

We were asked to perform a comparison of a Saudi Aramco Engineering plant layout Standard to US, European and Japanese Standards. These comparisons were relative to siting and spacing from a safety perspective. In addition, estimates were performed on the impact of the differences in the standards on the building costs on the gas treatment …

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Weld Consulting on a Hydroelectric Turbine Shaft Exhibiting Flaws

Initial machining in the area of the Turbine Guide Bearing uncovered a knurled surface just below the outermost shaft material – possibly indicative of a spray or weld metal build-up type of repair.

Engineering (FEA) Analysis & Design Optimization of Formula One Brake Rotors

FEA Model of Brake Rotor We performed engineering and FEA analysis & design optimization on new brake rotor designs for a client that manufactures components for Formula One Race cars, . A few of the assumptions included: (1) Rotors and their associated components CAD models were imported from their native software (ProEngineer or Catia) into …

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Failure Analysis – Quartz Tubes in Water Purification System

We performed failure analysis on quartz tubes used in a water purification system. The flow conditions around the quartz tubes were evaluated using ANSYS Computational Fluid Dynamics (CFD) 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 …

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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

Cracking in a Gypsum Kiln Conveyor Chain

Failed conveyor chain links were fabricated from AISI-SAE 1045 steel

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 root cause failure analysis and developed a redesign.

ASME (FEA) Design and Analysis – Pressure Vessel Components for Radioactive Waste Cleanup

Finite Element Analysis and Computational Fluid Dynamics on Vessels & Components ASME design and (thermal, stress, vibration and fatigue) finite element analysis was performed on pressure vessels and components – as part of the Department of Energy’s radioactive waste cleanup effort. These vessels were subjected to elevated temperatures (>1400 F), seismic loads and deflagration …

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Analysis of Leaking Nickel Cemented Tungsten Carbide (WC) Pump Seals

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 responsible for the leaks, along with widespread mineral debris throughout.

Recertification of Aging Pressure Vessels/ Systems at NASA Facility

We developed a seven-year program for the recertification of aging pressure vessels and pressure systems for the NASA-Glenn Research Center. Some of the vessels and systems were over forty years old, and were part of the original NACA installation. Some were layered vessels for 3-6000 psi service, some were monobloc high pressure vessels, and others …

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

Fitness For Service evaluation on a multi-wall UREA reactor to API 579/ASME-FFS-1

ASME Code Section VIII Calculations – Refinery Contactor Vessel

ASME Code Section VIII Div. 1 calculations were performed on a primary contactor vessel in service at a refinery. The contactor vessel, built in 1950, was based on the 1949 Edition of the ASME Code. The evaluation used the original drawing and design specification, as well as measurements of actual dimensions taken in 1994 and …

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Static & Dynamic Finite Element Analysis – Skate Ramp Modifications

We performed 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. We perform dynamic and fatigue analysis on various types of structures. To learn more, see Finite Element Analysis. Give us a call to talk about your engineering …

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Engineering Consulting