Questions? – Call Tom O’Donnell, PE (412) 835-5007 TL;DR Fatigue analysis evaluates pressure vessels under cyclic loading using ASME Section VIII methodologies, preventing catastrophic failures while enabling more economical designs through rigorous engineering justification. The process involves defining operating cycles, performing FEA stress analysis, calculating equivalent stress ranges, evaluating against material fatigue curves, and assessing […]

Engineering Design by Analysis v. Design by Rule Questions? Call Tom O’Donnell, PE (412) 835-5007 When a pressure vessel fails, the question investigators ask first isn’t what broke — it’s how it was designed. Design by Rule offers speed and simplicity, and for straightforward, well-understood applications it delivers exactly what’s needed. But when operating conditions

Comprehensive guide to ASME design approval process and certification for pressure vessels, covering ASME B&PV Code requirements

Improper Application of Design Codes and Standards A very common mistake in pressure vessel design & analysis is the incorrect or incomplete application of industry standards such as the ASME Boiler and Pressure Vessel Code. Engineers may misinterpret code requirements, apply outdated versions, or neglect important clauses. This can lead to inadequate safety margins or

Stress Analysis of Thin Walled Pressure Vessels We Perform Pressure Vessel Analysis Call Tom O’Donnell 412.835.5007 Introduction The Safe Design, Analysis, Installation, Operation, and Maintenance of Pressure Vessels are Performed in Accordance with Codes such as American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code. Therefore, great emphasis should be placed on analytical

Providing Solutions to Questions – Including: “My Equipment Failed – Now What?” – When critical equipment breaks down, you need answers fast. Was it design, materials, maintenance, or operations? We investigate the root cause and provide solutions to prevent recurrence.   “Will This Design Hold Up?” – Before you build, manufacture, or install, you need

FEA of Heater Vessel FEA of a Vessel with Nozzles Call Tom O’Donnell to Get Started (412) 835-5007 What is Finite Element Analysis (FEA)? Finite Element Analysis (FEA) is a computer simulation technique used to evaluate the structural integrity of components and systems. It is a powerful method capable of modeling both simple and complex

Failed Wire Rope Weld Failure Failure Analysis – The Basics Questions? – Call Tom O’Donnell, PE (412) 835-5007 Failure Analysis is the Process of Understanding the Root Cause of Materials / Equipment Failure. One of the first steps to take after equipment damage / failure should be to check similar in-service components. Damage may consist

Weld Defects and Failures: Quantifying Fitness For Service – How Finite Element Mathematical Simulations can Mitigate Risk and Cut Costs Article by Dr. William J. O’Donnell, PE, President – O’Donnell Consulting Engineers Fatigue in Welded steel components is often initiated by mathematical vibration, corrosion and thermal cycling. Fitness for service analysis is the most viable

Fitness-for-Service analysis is the most viable step in determining the safety and financial risk factors related to component repair or replacement. This Stainless Steel World article (written by Bill O’Donnell, Sr.) shares insight about managing risk specific to weld failures. Bill, Sr. began his professional career at Westinghouse Bettis Atomic Power Laboratory, where he designed

FEA Model of Vessel at Nozzles Vessel Design & Analysis: Guide to ASME Code Compliance Give us a Call (412) 835-5007 Why Pressure Vessel Design Failures Cost Lives and Millions in Damages Pressure vessels operate under extreme internal pressures and temperatures. A single design flaw can trigger catastrophic failure—resulting in explosions, toxic releases, facility shutdowns,

When Welds Fail: Understanding Fatigue in Welded Structures Fatigue cracking represents the single most common failure mode in welded structures—accounting for approximately 90% of all weld-related failures across industries. From pressure vessels and piping systems to offshore platforms and power generation equipment, fatigue can turn a seemingly sound welded joint into a catastrophic failure. At

We’ve updated our Links Page which lists professional societies, engineering books and resources, and as well as other links of interest.

See Murals Page – that were painted by a local artist, depicting stories of various engineering and legal cases.

See updates to our Portfolio Page – we are continually adding to it. Above is a finite analysis element analysis (FEA) model of a base skid containing a Vapor Recovery Unit.

We continually updating updated our Events Page concerning engineering conferences.

Cracks Found in Brass Fitting of an HVAC System   When to Call a Metallurgist Calll Tom O’Donnell, PE (412) 835-5007 “Call a Metallurgist!” When components made of metal fail, this is typically the first reaction. It’s a fact of life – things break. Learn more about when to call a metallurgist and what’s involved.

See Resume Summaries of our Senior Engineers at Our Team. See Also: Who We Serve to see a List of a Few of our Clients Popular Links to see What’s Trending No Time? – Call Tom O’Donnell, PE (412)-835-5007

GlobalSpec Article on a Forensic Investigation O’Donnell Consulting Performed on a Ductwork Failure in a Pittsburgh-local School. Call Tom O’Donnell to Discuss Your Forensic Engineering Issues (412) 835-5007

Technical explanation of primary stress and secondary stress classifications in ASME Boiler and Pressure Vessel Code, covering definitions, fundamental characteristics, design implications….

Bill O’Donnell, Sr., recently published “Handbook of Lessons Learned In Engineering, Design, Manufacturing and Construction.” It is intended for engineers, designers, manufacturers and constructors – depicting failures from thermal, structural, vibration, corrosion and other failure mechanisms. Read a sample of this book, Section 1 Designers’ Lessons. This book can be purchased at Amazon.com.

GE Hitachi Nuclear Energy (GEH) and NuScale Power, two leading companies in the race to build small modular reactors (SMRs) for power generation, have recently announced deals that could result to new plants being constructed in Europe. See the Power Magazine article.

See Our Links Page to find resources on engineering associations, books, and more.

Advantages of Dual Linear Array Probes for Corrosion Inspection. The power generation industry is among those whose aging infrastructure contributes to increased safety concerns, and can lead to costly unscheduled maintenance and shutdowns. Facilities must be vigilant about monitoring corrosion in their in-service pipes and vessels to help ensure their integrity. Read the Power Magazine

The reliability and integrity of equipment, structures and piping can suffer because of vibration and dynamic responses. These depend mainly on excitation forces, stiffness, mass distribution and damping. Modal analysis, which focuses on natural frequencies and associated modal shapes, provides an important tool in understanding potential issues. Indeed, usually the first step in checking for