Failure Analysis Projects – Investigations and Engineering Solutions on Equipment & Structures to Prevent Recurrence. Our team of experts in engineering, metallurgy & welding investigate the root cause of structural failures due to thermal / transients, vibrations, thermal fatigue, etc., to ensure structural integrity, and maximize equipment reliability – ultimately controlling costs for owners/ users.
See our Blog on Failure Analysis.
Some of our projects have included:
Failure analysis and repair of Pressure Swing Absorber (PSA) Vessels – in Service at a Hydrogen Plant – Found to Exhibit Chevron Cracks
Failure Analysis – Cracked PSA (Pressure Swing Absorber) Vessels Read More »
Quartz tubes used in a water purification system – failure analysis. CFD, stress and vibration analysis.
Quartz Tubes in Water Purification System Failure Analysis Read More »
After a Coupling End of a 6-inch Bore Hydraulic Cylinder Failed on a 30 Ton Automotive Forming Press, we were Asked to Investigate
30 Ton Automotive Forming Press – Failure Investigation Read More »
Failure Analysis and Subsequent Solutions Concerning Cracking in a Gypsum Kiln Conveyor Chain
Failure Analysis of Cracking Gypsum Kiln Conveyor Chain Read More »
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.
Failure Investigation and Design Modifications on Cracked Large Capacity Fuel Heaters Read More »
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.
Leaking Nickel Cemented Tungsten Carbide (WC) Pump Seals – Investigation Read More »
Cracked tube-to-tubesheet welds on an Acid Plant Superheater. Investigation included Design, fabrication and elevated temperature operation.
Cracked Tube-to-Tubesheet Welds on Sulfuric Acid Plant Superheater Read More »
Cracks Found Through the Ligaments of the Tubesheets in a Incinerator Recuperator in a Chemical Plant. Failure Investigation & Repair.
Cracks in Incinerator Recuperator – Failure Investigation & Repair Read More »
After the Failure of XL Commercial Sprinkler Pipe System Occurred, we were asked to Perform Structural Analysis and Metallurgical Testing.
Failure of XL Commercial Sprinkler Pipe – Root Cause Analysis Read More »
Wellhead Threaded Closure Failure Investigation. Metallurgical evaluations, material testing, and engineering analysis.
Wellhead Threaded Closure Failure Investigation and Design Modifications Read More »
Forensic Failure Analysis – Boeing 737 Flight Control System Aircraft Stabilizer Trim Motor Bearings.
Forensic Failure Analysis – Flight Control Aircraft Stabilizer Trim Motor Bearing Read More »
$16 Million award in U.S. District Court over Collapsed Bauxite Conveyor System – Forensic Investigation.
$16 Million Award for Collapsed Bauxite Conveyor System – Forensic Investigation Read More »
Repair of Cast ASTM A743 Grade CN6NM Turbine Blades exhibiting imperfections
Turbine blades made by a particular manufacturer are a complex shape that requires them to be manufactured by casting. Imperfections such as “tares and scabs” are formed during the casting process.
Repair Process of Cast ASTM A743 Turbine Blades Exhibiting Imperfections Read More »
Investigation of leaking and failure on a 1 inch stainless steel (SS) ball valve in a pipeline to determine the cause.
Investigation of Leaking Stainless Steel Ball Valve in a Pipeline Read More »
Failure analysis & repair of a Panel Coil in a Sterilization Process – 15 Hz forcing frequency of the six-bladed agitator was evaluated.
Failure Analysis of Panel Coil in a Sterilization Process Read More »
Structural and fatigue analysis of a buckled longwall mining relay bar and subsequent redesign.
Structural and Fatigue Analysis of Buckled Longwall Mining Relay Bar Read More »
For hot-side precipitator designs, ductwork designs included temperatures exceeding 700 F, which allow for “thermal breathing”. When these movements are restrained, large forces are created.
Structural Analysis of Design Errors in Electrostatic Precipitator Read More »
A client had a leaking / failure of a 2 inch diameter floating ball valve in a midstream pipeline and asked us to to determine the root cause
Leaking 2 inch Ball Valve in Midstream Pipeline Read More »
Analysis of Defects on 304 Stainless Steel Mixer Blades – found to be a uniformly sized foreign metallic contaminant averaging 0.028 inches deep
Analysis of Defects on 304 Stainless Steel Mixer Blades Read More »
Risk assessment on cracking gyratory-reciprocating mineral separators. FEA, Fatigue, weld investigation and analysis.
Risk Assessment on Cracking Mineral Separator Units Read More »
A manufacturer of a Thin Film Heat Exchanger (TFHE) – which is used in conjunction with other components in high temperature coating applications such as caramel coated popcorn – found cracks in their units.
Failure Analysis on Cracked Thin Film Heat Exchanger (TFHE) Read More »
Failure analysis & design modifications on cracked 1,400 ton hydraulic press frame. Call Tom O’Donnell about your engineering needs.
Failure Analysis & Design Modifications on a Cracked 1,400 Ton Hydraulic Press Read More »
Failure analysis on cracked brass fitting,in a closed loop HVAC system. Call Tom O’Donnell, PE
Failure Analysis of Cracked Brass Fitting in a Chilled Water HVAC System Read More »
Heavy corrosion was found during inspection of a conveyor at a refinery. We investigated & recommended remediation measures.
Corrosion Investigation on Various Structures in a Refinery Read More »
Root cause investigation of a gas well pipe rupture – Well tender was initiating a “post-fracking” procedure-blowback operation to release pressure.
Root Cause Investigation of Gas Well Pipe Rupture Read More »
