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:
Failure analysis and repair of Pressure Swing Absorber (PSA) Vessels – in service at a hydrogen plant – found to exhibit chevron cracks
Failure Analysis – Cracked Pressure Swing Absorber (PSA) Vessels Read More »
Quartz tubes used in a water purification system – failure analysis. CFD, stress and vibration analysis.
Quartz Tubes in Water Purification System Failure Analysis Read More »
After a Coupling End of a 6-inch Bore Hydraulic Cylinder Failed on a 30 Ton Automotive Forming Press, we were Asked to Investigate
30 Ton Automotive Forming Press – Failure Investigation Read More »
Failure analysis and subsequent recommendations of cracking in a Gypsum Kiln conveyor chain.
Cracking Links in a Gypsum Kiln Conveyor Chain Read More »
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.
Failure Investigation and Design Modifications on Cracked Large Capacity Fuel Heaters Read More »
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.
Leaking Nickel Cemented Tungsten Carbide (WC) Pump Seals – Investigation Read More »
Cracked tube-to-tubesheet welds on an Acid Plant Superheater. Investigation included Design, fabrication and elevated temperature operation.
Cracked Tube-to-Tubesheet Welds on Sulfuric Acid Plant Superheater Read More »
Cracks Through the Ligaments of the Tubesheets in a Incinerator Recuperator in a Chemical Plant. Failure Investigation & Repair.
Cracks in Incinerator Recuperator – Failure Investigation & Repair Read More »
After the Failure of XL Commercial Sprinkler Pipe System Occurred, we were asked to Perform Structural Analysis and Metallurgical Testing.
Failure of XL Commercial Sprinkler Pipe – Root Cause Analysis Read More »
Wellhead Threaded Closure Failure Investigation. Metallurgical evaluations, material testing, and engineering analysis.
Wellhead Threaded Closure Failure Investigation and Design Modifications Read More »
Forensic Failure Analysis – Boeing 737 Flight Control System Aircraft Stabilizer Trim Motor Bearings.
Forensic Failure Analysis – Flight Control Aircraft Stabilizer Trim Motor Bearing Read More »
$16 Million award in U.S. District Court over Collapsed Bauxite Conveyor System – Forensic Investigation.
$16 Million Award for Collapsed Bauxite Conveyor System – Forensic Investigation Read More »
Repair of Cast ASTM A743 Grade CN6NM Turbine Blades exhibiting imperfections
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.
Repair Process of Cast ASTM A743 Turbine Blades Exhibiting Imperfections Read More »
Investigation of leaking and failure on a 1 inch stainless steel (SS) ball valve in a pipeline to determine the cause.
Investigation of Leaking Stainless Steel Ball Valve in a Pipeline Read More »
Failure analysis & repair of a Panel Coil in a Sterilization Process – 15 Hz forcing frequency of the six-bladed agitator was evaluated.
Failure Analysis – Panel Coil in a Sterilization Process Read More »
Relay Bar Call Tom O’Donnell, PE to Discuss Your Engineering Challenges We were asked to perform the structural integrity and fatigue life of an original and modified longwall mining relay bar. Longwall mining is used to more efficiently remove underground coal deposits in large rectangular blocks. After a “pass” of coal has been mined, the
Structural and Fatigue Analysis of Buckled Longwall Mining Relay Bar Read More »
For hot-side precipitator designs, ductwork designs included temperatures exceeding 700 F, which allow for “thermal breathing”. When these movements are restrained, large forces are created.
Structural Analysis of Design Errors in Electrostatic Precipitator Read More »
A client had a leaking / failure of a 2 inch diameter floating ball valve in a midstream pipeline and asked us to to determine the root cause
Leaking 2 inch Ball Valve in Midstream Pipeline Read More »
Analysis of Defects on 304 Stainless Steel Mixer Blades – found to be a uniformly sized foreign metallic contaminant averaging 0.028 inches deep
Analysis of Defects on 304 Stainless Steel Mixer Blades Read More »
Risk assessment on cracking gyratory-reciprocating mineral separators. FEA, Fatigue, weld investigation and analysis.
Risk Assessment of Cracking Mineral Separator Units Read More »
A manufacturer of a Thin Film Heat Exchanger (TFHE) – which is used in conjunction with other components in high temperature coating applications such as caramel coated popcorn – found cracks in their units.
Failure Analysis on Cracked Thin Film Heat Exchanger (TFHE) Read More »
Failure analysis & design modifications on cracked 1,400 ton hydraulic press frame. Call Tom O’Donnell about your engineering needs.
Failure Analysis & Design Modifications on a Cracked 1,400 Ton Hydraulic Press Read More »
Failure analysis on cracked brass fittings exhibiting in a closed loop HVAC system. Call Tom O’Donnell, PE
Failure Analysis of Cracked & Leaking Brass Fittings in a Chilled Water HVAC System Read More »
Heavy corrosion was found during inspection of a conveyor at a refinery. We investigated & recommended remediation measures.
Corrosion Investigation on Various Structures in a Refinery Read More »
Root cause investigation of a gas well pipe rupture – Well tender was initiating a “post-fracking” procedure-blowback operation to release pressure.
Root Cause Investigation of Gas Well Pipe Rupture Read More »
