Failure Analysis

Failure analysis is the process of collecting and analyzing data to determine the root cause should your equipment or asset fail or not perform as expected.

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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Cracked Tube-to-Tubesheet Welds on Chemical Reactor

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.

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.

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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Failure Investigation – Wire Rope

Closeup of Failed Wire Rope showing surface deformation

Surface Deformation and Fractures Low Magnification SEM Image of Fractures Higher SEM Magnifcation of Fracture We performed a failure investigation on a 6x36G IWRC Grade, non-galvanized wire rope using visual, metallurgical and hardness testing. Metallographic and Vickers 500gr micro-hardness results identified the wires as cold drawn and exhibited converted Rockwell C values of 54 to …

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Failure Investigation and Design Modifications of Wellhead Threaded Closure

O’Donnell Consulting Engineers investigated the cause of an accident due to a failed threaded closure on a wellhead. Through metallurgical evaluations, material testing, and engineering analysis, it was determined that the cast iron nut had failed due to fatigue. Design modifications were then recommended.   We perform Failure Analysis Services for clients in industries including …

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Engineering Analysis of Replacement Reactor Coolant Pump Seals

O’Donnell Consulting provided engineering analysis of replacement reactor coolant pump seals for a major utility. In addition, a thermal hydraulic analysis was performed, providing thermal history curve for each seal, including a detailed analysis of thermal changes in the seals during a loss of cooling water incident.   We perform design, analysis and engineering troubleshooting …

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