Failure Analysis & Design Recommendations on the shaft of a Chemical Tumbler.
Failure Analysis Projects
Although failure investigations may appear to look easy – they typically are not. Quite often, failures occur due a number of variables. A few variables (such as corrosion) may be evident, while others may require deeper investigation. A multidisciplinary approach is often used to perform a root cause investigation. For a structural failure – an engineer, materials/ metallurgical professional and a welding specialist are often necessary. In addition, engaging an expert who is knowledgeable with the process/ factors important to the design and the performance of the equipment is strongly recommended.
Our projects have included:
- Chemical Tumbler
- Contactor Vessel
- Mining Lift Hook
- Turbine Head Cover
- Rotary Kiln
- Corrosion of Irrigation Piping
- Wire Rope
- NASA Heat Exchanger
- Hydroelectric Turbine Shaft
- Cracked Ductwork
- Barge Mooring
- Cracked Tube-to-Tubesheet Welds in a Chemical Reactor
- Cracked PSA Vessels
- Quartz Tubes in Water Purification System
- 30 Ton Press
- cracked Welds in Gypsum Kiln
- Cracked Tube-to-Tubesheet Welds in a Sulfuric Acid Plant
- Cracks in Incinerator Recuperator
- XL Commercial Sprinkler Pipe
- Buckled Longwall Mining Relay Bar
- 1,400 Ton Hydraulic Press
- Cracks in Fittings in HVAC System
- Fracking Pump
Failure analysis and subsequent design modification on a FRP contactor vessel used to separate hydrogen sulfide from bio-gas & landfill gas.
Engineering analysis and design modification of control valve removal, reassembly and reinstallation in a reactor recirculation system
Failure analysis and redesign – refinery piping control loop which had burst during startup of a desulfurizer.
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 …
During the delivery of a shipment of resin, damage occurred to a storage tank at a production facility in Southwestern Pennsylvania. The tank damage was apparently the result of tank overpressurization. O’Donnell Consulting performed a failure analysis of the tank, and determined that overpressurization was due to a “blow-down” following the transfer of resin from …
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.
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 engine block, causing damage
During a shutdown of the Kuosheng 1 plant, Taiwan, operation of the LPCI system for normal shutdown caused failure of an LPRM. Testing by G.E. in their (HF)2 facility duplicated the failure, which was attributed to flow-induced vibration of the LPRM. G.E. devised a flow-deflector to prevent cross-flow from the LPCI across core components. This …
Engineering analysis of replacement reactor coolant pump seals. In addition, a thermal hydraulic analysis was performed.
Imperfections in fabrication processes such as welding, forming and assembling parts for welding and cutting can contribute to the concentration of strains in localized areas to a degree that significantly shortens the fatigue life
A third stage blade on a gas turbine had failed after 11,00 hours in service
We performed structural and fatigue / fracture analysis on the main and upstream shafts in a hydroelectric plant. Inspection of the main shaft had detected linear indications at the outer surface of the shaft. The circumferential cracks initiated at pits propagated into the wall of the hollow shaft. The UT examination was performed with transducers …
Reinforced ductwork failed shortly after being placed in service
For a major food processing company, we performed a failure investigation of a horizontally mounted low pressure process vessel. The sequential failure of several of the nuts holding the closure head caused it to blow off, seriously injuring a worker. A review of the original design showed that the vessel had not been built with …
Failure occurred on an oil/gas 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 …
We were asked to perform a failure analysis on an electronics cooling fan that malfunctioned within the first two months, or approximately 1400 hours of continuous operation. The investigation determined that defective bearings most likely caused unusual loads, and subsequent fan failure. We perform failure analysis on equipment for clients in industries including energy, …
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 …
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 included the startup, controlled heatup and cool-down processes on the reactor with respect to the potential for creating leaks through the tube to tubesheet welds.