Fatigue / Failure Analysis & Design Recommendations on Chemical Tumbler
Fatigue Analysis & Design Recommendations on the shaft of a Chemical Tumbler.
Fatigue / Failure Analysis & Design Recommendations on Chemical Tumbler Read More »
Failure Analysis Projects
Failure Analysis Projects – Investigations and Developing 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.
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
- Turbine Head Cover
- Rotary Kiln
- NASA Heat Exchanger
- Hydroelectric Turbine Shaft
- Cracked Ductwork
- Barge Mooring
- Cracked Tube-to-Tubesheet Welds in a Chemical Reactor
- Cracked PSA Vessels
- 30 Ton Press
- Cracked Tube-to-Tubesheet Welds in a Sulfuric Acid Plant
- Cracks in Incinerator Recuperator
- XL Commercial Sprinkler Pipe
- 1,400 Ton Hydraulic Press
- Cracks in Fittings in HVAC System
- Fracking Pump
Weld Cracking Investigation on T Bar Section of Cyclones
Weld Cracking Investigation on T Bar section of Cyclones. Modal FEA Analysis Determined Mode of Failure. Recommended Design Modifications.
Weld Cracking Investigation on T Bar Section of Cyclones Read More »
Failure Analysis and Design Modifications on FRP Contactor Vessel
Failure analysis and subsequent design modification on a FRP contactor vessel used to separate hydrogen sulfide from bio-gas & landfill gas.
Failure Analysis and Design Modifications on FRP Contactor Vessel Read More »
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
Engineering and Design Modification of Control Valves in Reactor Recirculation System Read More »
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 Analysis of Studs on an Electric Turbine Outer Head Cover Read More »
Analysis of Failed Rotary Cement Kiln
Analysis of a failed rotary cement kiln which occurred 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.
Analysis of Failed Rotary Cement Kiln Read More »
Failure Analysis on Corroded Irrigation Piping
Failure analysis and metallurgical evaluations on corroded irrigation piping, and subsequent recommendations.
Failure Analysis on Corroded Irrigation Piping Read More »
Failure Analysis & Redesign on a Refinery Piping Loop that Failed in Startup
Failure analysis and redesign of a refinery piping control loop that burst during desulfurizer startup.
Failure Analysis & Redesign on a Refinery Piping Loop that Failed in Startup Read More »
Failure Investigation – Wire Rope
Failure investigation on a 6x36G IWRC Grade, non-galvanized wire rope using visual, metallurgical and hardness testing
Failure Investigation – Wire Rope Read More »
Cracked NASA Heat Exchanger – Failure Analysis & Redesign
Failure analysis of cracks around bolt holes of the inlet and outlet tubesheets of a NASA heat exchanger.
Cracked NASA Heat Exchanger – Failure Analysis & Redesign Read More »
Failure Analysis of Overpressurized Storage Tank
Failure Analysis of an Overpressurized Storage Tank. Investigation and repair recommendations
Failure Analysis of Overpressurized Storage Tank Read More »
Metallurgical Evaluation of Cracks in Aircraft Landing Gear
Metallurgical Evaluation of Cracks found in Aluminum Actuator Arm on Aircraft Landing Gear.
Metallurgical Evaluation of Cracks in Aircraft Landing Gear Read More »
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
Failure Analysis on a Cracked Cylinder Liner Read More »
Engineering Review of Design Changes in Taiwan Nuclear Plant
Engineering Review of the design, construction, and installation of a deflector plate used to prevent cross-flow from the LPCI across core components
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.
Engineering Analysis of Replacement Reactor Coolant Pump Seals Read More »
Weld Troubleshooting & Redesign of a Stainless Steel Heat Exchanger
Weld troubleshooting & redesign on a stainless steel heat exchanger with a limited fatigue life in a location of high stress concentration.
Weld Troubleshooting & Redesign of a Stainless Steel Heat Exchanger Read More »
Metallurgical & Engineering Analysis of Failed 3rd Stage Gas Turbine Blades
Metallurgical and analysis to determine the cause of failure on two 3rd stage blades which failed after 11,00 hours in service
Metallurgical & Engineering Analysis of Failed 3rd Stage Gas Turbine Blades Read More »
FEA & Fatigue Analysis – Hydroelectric Turbine Shaft
FEA and fatigue / fracture analysis of the turbine shaft on hydroelectric plant exhibiting linear indications.
FEA & Fatigue Analysis – Hydroelectric Turbine Shaft Read More »
Failure Analysis & Redesign of Cracked Conveyor Ductwork
Failure Analysis and Redesign of Cracked Conveyor Ductwork
Failure Analysis & Redesign of Cracked Conveyor Ductwork Read More »
Failure Investigation on Food Processing Pressure Vessel Head
Failure Investigation of the closure head on a horizontally mounted low pressure food process vessel.
Failure Investigation on Food Processing Pressure Vessel Head Read More »
Failed Oil / Gas Threaded Joint Casing
Failure analysis of threaded joint casing at about 80-100 feet near the drill bit about 30-40 feet from the bottom of the hole.
Failed Oil / Gas Threaded Joint Casing Read More »
Degraded Compressor Bearing – Metallurgical / SEM Investigation
Surface degradation found on an air compressor Tin-copper alloy bearing. Metallographic and SEM techniques were used to determine cause.
Degraded Compressor Bearing – Metallurgical / SEM Investigation Read More »
Root Cause Failure Analysis on Electronics Cooling Fan
Root cause analysis of a failed fan used to cool electronics – that occurred within two months of operation
Root Cause Failure Analysis on Electronics Cooling Fan Read More »
316L SS Rotary Valve Impellers – Corrosion / Metallurgical Evaluation
Type 316L SS rotary valve impellers used in cheese curd production were evaluated to determine the cause of pitting corrosion
316L SS Rotary Valve Impellers – Corrosion / Metallurgical Evaluation Read More »
Cracked Tube-to-Tubesheet Welds on Chemical Reactor – Failure Analysis
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.
Cracked Tube-to-Tubesheet Welds on Chemical Reactor – Failure Analysis Read More »
