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.
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 …
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 …
Cracked NASA Heat Exchanger – Analysis & Redesign Read More »
Tin-copper alloy bearing surfaces obtained from an air compressor were examined using visual, metallographic and scanning electron microscopy techniques to determine the cause of surface degradation.
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, …
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.
FEA Model of Barge and Mooring O’Donnell Consulting performed failure analyses of a barge mooring that had broken during a flood condition on the Ohio River in Pittsburgh, PA. Engineering and finite element analyses showed that the bow and stern mooring lines were subjected to excessive loads as the river water levels …
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 …
316L SS Rotary Valve Impellers – Corrosion / Metallurgical Evaluation Read More »
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.
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.
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 …
Failure Analysis – Quartz Tubes in Water Purification System Read More »
A root cause investigation was performed on a failed coupling end of a 6-inch bore hydraulic cylinder of a 30 ton automotive forming press. A visual examination of the shaft showed surface polishing along one edge at the bearing surface, which is most likely due to non-axial loading during service. The fracture appearance is consistent …
Failed 30 Ton Automotive Forming Press – Root Cause Investigation Read More »
Failed conveyor chain links were fabricated from AISI-SAE 1045 steel
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.
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.
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 …
The startup of a plant involved transient conditions when saturated steam suddenly entered the hot tubes of a superheater – causing damage, and subsequent extensive damage to equipment further down the process line.
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 …
Failure Analysis on Overpressurized Storage Tank Read More »
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 …
FEA & Fatigue Analysis – Hydroelectric Turbine Shaft Read More »
Closeup of Failed Pipe Surface Thickness of the Pipe Failure Surface Piping Failed at a Tee Junction A XL commercial sprinkler pipe system had failed at a pipe-to-pipe tee junction. We were asked to perform a root cause investigation. Allied XL pipe is a strong, thin wall pipe manufactured specifically for sprinkler system applications. NFPA …
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 …
Failure Investigation and Design Modifications of Wellhead Threaded Closure Read More »
Investigation of aircraft stabilizer trim motor bearing
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 has been attributed to flow-induced vibration of the LPRM. G.E. devised a flow-deflector to prevent cross-flow from the LPCI across core components. …
Engineering Review of Design Changes in Taiwan Nuclear Plant Read More »
A West African bauxite company was awarded $16 million in a U.S. District Court after a tippler building collapsed and suffered sustained severe structural damage. Bauxite was dropped twenty-two feet from rail cars onto the conveyor of a crusher system in the tippler building. The conveyor system and concrete support beams were most seriously affected. …
$16 Million Award for Collapsed Bauxite Conveyor System Read More »
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.
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 …
Engineering Analysis of Replacement Reactor Coolant Pump Seals Read More »
