Business Details
41 Years
experience
Emergency
services
Expert Engineering Analysis & Forensic Solutions
O'Donnell Consulting Engineers has provided engineering design, analysis, troubleshooting, and forensic services for over 40 years, serving clients across energy, petrochemical, aerospace, and other industries. Our team combines expertise in ASME, API, and AWS codes to deliver solutions for equipment failures, design validation, and liability investigations. We specialize in finite element analysis, stress corrosion mitigation, and failure analysis, supporting clients globally through technical challenges and litigation support.Our engineers have contributed to high-profile projects including NASA components, nuclear power plant evaluations, and international arbitration cases. We prioritize client needs by offering tailored engineering assessments that enhance safety, reliability, and cost-efficiency across the product lifecycle. Our reputation for solving complex technical problems has been built through decades of practical experience and rigorous adherence to engineering standards.
Services
Finite Element Analysis
Forensic Engineering
Weld Consulting
Stress Corrosion Mitigation
Expert Witness Services
Fitness for Service Evaluations
Details
- Year established: 1985
Highlights and features
- We offer 40+ years of engineering failure analysis experience
- Our team follows ASME, API, and AWS code-compliant methodologies
- We provide expert witness testimony in litigation cases
- Our client list spans Fortune 500 companies and international organizations
- We deliver comprehensive lifecycle engineering solutions
Associations and certifications
- ASME
- API
What people say
Technical expertise
Timely problem resolution
Clear communication
Litigation support
Global experience
Services
Finite Element Analysis
We perform detailed stress, thermal, vibration, and fatigue analysis using finite element modeling to validate equipment designs against ASME and API standards. Our engineers identify structural weaknesses in components like pressure vessels, heat exchangers, and aerospace structures. Clients receive actionable recommendations that improve safety margins and extend equipment lifecycles while maintaining code compliance.
Forensic Engineering
Our forensic investigations determine root causes of equipment failures through metallurgical testing, weld evaluations, and stress corrosion analysis. We document findings with visual inspections, SEM imaging, and material testing to support legal cases or process improvements. Clients receive comprehensive reports that identify design flaws, manufacturing defects, or operational errors contributing to failures.
Expert Witness Services
We provide expert testimony for legal cases involving equipment failures, product liability claims, and industrial accidents. Our engineers analyze technical evidence, prepare courtroom presentations, and offer deposition testimony based on 40+ years of engineering experience. Clients benefit from clear explanations of complex technical issues tailored for legal audiences.
Stress Corrosion Mitigation
We develop corrosion prevention strategies for industrial equipment through metallurgical evaluations and environmental testing. Our engineers assess SCC susceptibility in materials like stainless steel and nickel alloys, recommending design modifications and maintenance protocols. Clients implement our solutions to prevent costly failures in chemical processing and energy production environments.
Fitness for Service Evaluations
Our API 579 and ASME FFS-1 compliant assessments determine equipment integrity under operating conditions. We combine fatigue analysis with field measurements to evaluate aging components' remaining life. Clients use these evaluations to make informed decisions about repairs, replacements, or continued service of pressure vessels and piping systems.
People
Tom O'Donnell
Principal Engineer
With 30+ years of engineering experience, Tom O'Donnell leads technical projects in failure analysis and forensic investigations. He specializes in ASME code compliance and expert witness testimony, having worked on high-profile cases involving aerospace components and industrial accidents.
Questions
What engineering codes do you work with?
We work with ASME Boiler and Pressure Vessel Code, API standards, AWS welding codes, and AAR specifications for rail components.
Do you provide expert testimony services?
Yes, we offer expert witness services for litigation support in equipment failure cases, including forensic analysis and courtroom testimony.
What industries do you serve?
We serve energy, aerospace, petrochemical, manufacturing, construction, and marine industries with specialized engineering solutions.
Can you analyze equipment failures?
Yes, our failure analysis services identify root causes through metallurgical testing, stress analysis, and operational reviews for preventive solutions.
Do you work internationally?
Yes, we've completed projects in Germany, Spain, Japan, and various other countries with global engineering standards compliance.
