Failure Analysis & Design Recommendations on a Chemical Tumbler
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
- Cyclone
- Contactor Vessel
- Mining Lift Hook
- Turbine Head Cover
- Rotary Kiln
- Corrosion of Irrigation Piping
- Wire Rope
- NASA Heat Exchanger
- Hydroelectric Turbine Shaft
- Cracked Ductwork
- Compressor
- 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
- Bellows
- Fracking Pump
FEA & Recommended Design Modifications on Failing Cyclone
Modal FEA Analysis & Recommended Design Modifications on Cracking Cyclone
Failure Analysis and Design Modifications of FRP Contactor Vessel
Failure analysis and subsequent design modification on a FRP contactor vessel used to separate hydrogen sulfide from bio-gas & landfill gas.
Engineering and Design Modification of Control Valves in Reactor Recirculation System
Engineering analysis and design modification of control valve removal, reassembly and reinstallation in a reactor recirculation system
Failure Analysis of Studs on an Electric Turbine Outer Head Cover
Failure analysis of studs connecting the outer head cover to the stay ring of an electric-generating turbine
Failure Investigation of Rotary Cement Kiln Accident
Failure investigation of a rotary cement kiln accident during startup. Get analysis & recommendations from Tom O’Donnell 412.835.5007. Rotary kilns run 24/7 and are stopped only for a few days for essential maintenance. This is important because of heatup and cool down thermal transients.
Failure Analysis of Corroded Irrigation Piping
Failure analysis and metallurgical evaluations of corroded irrigation piping, and subsequent recommendations.
Failure Analysis & Redesign on a Refinery Piping Loop that Failed in Startup
Failure analysis and redesign – refinery piping control loop which had burst during startup of a desulfurizer.
Failure Investigation – Wire Rope
Failure investigation on a 6x36G IWRC Grade, non-galvanized wire rope using visual, metallurgical and hardness testing
Cracked NASA Heat Exchanger – Failure 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 …
Cracked NASA Heat Exchanger – Failure Analysis & Redesign Read More »
Failure Analysis of Overpressurized Storage Tank
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 …
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Metallurgical & Engineering Evaluation 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.
Failure Analysis on a Cracked Cylinder Liner
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
Engineering Review of Design Changes in Taiwan Nuclear Plant
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 Review of Design Changes in Taiwan Nuclear Plant Read More »
Engineering Analysis of Replacement Reactor Coolant Pump Seals
Engineering analysis of replacement reactor coolant pump seals. In addition, a thermal hydraulic analysis was performed.
Weld Troubleshooting & Redesign of a Stainless Steel Heat Exchanger
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
Metallurgical Analysis of Failed 3rd Stage Gas Turbine Blades
A third stage blade on a gas turbine had failed after 11,00 hours in service
FEA & Fatigue Analysis – Hydroelectric Turbine Shaft
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 …
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Failure Analysis & Redesign of Cracked Ductwork
Reinforced ductwork failed shortly after being placed in service
Failure Investigation on Food Processing Pressure Vessel
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 Investigation on Food Processing Pressure Vessel Read More »
Failed Oil / Gas Threaded Joint Casing
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 …
Degraded Compressor Bearing – Metallurgical / SEM Investigation
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.
Failure Analysis on Electronics Cooling Fan
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. Â We perform failure analysis on equipment for clients in industries including energy, …
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 …
316L SS Rotary Valve Impellers – Corrosion / Metallurgical Evaluation Read More »
Failure Analysis of 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.
