EXPERIENCE

Forensic Metallurgy, Inc. - Worcester, MA (2/18 to Present)

President

Root cause investigation of package boiler subject to tube failures and feedwater pump damage
Investigation of hydro dam sheet piling failure

DPK Metallurgy - Worcester, MA (8/14 to 1/18)

Owner

Root cause investigation, cause and scope of loss of utility boiler over-pressurization
Resolution of contract dispute associated with refurbishment of a utility boiler
Forensic investigation of failures of heat exchangers in multiple solar plants
Failure analysis and root cause investigation of the fracture of a flange in a gas compressor
Forensic investigation of failures of molten salt storage tanks (solar plants)
Investigation of the cause of deformation (bowing) of floor tubes in two package boilers and the development of repair strategy
Analysis of cause of degradation of gas turbines
Failure analysis and root cause investigation of utility generator rotor fracture during high speed testing
Investigation of failure of boiler tube support structure in a utility boiler
Determination of cause of heat related damage to industrial biomass boiler
Analysis of fuel variation on the failure of biomass boiler to fulfill contract requirements

Failure Analysis & Prevention, Inc. (FAP) – North Kingstown, RI (3/09 to 7/14)

Principal Metallurgist

Failure analysis of combustion and steam turbines
Analysis of failures of HRSG components
Investigation of root cause and scope of damage in a coal fired boiler in Panama during commissioning
Determination of scope of damage and impact on schedule due to a gas explosion at a combined cycle plant during construction
Investigation of boiler explosions and determination of property damage
Root cause investigation of rotor of diesel driven 50MW generator
Investigation of thermal barrier coating failure on combustion turbine components
Determination of extent of damage in 900MW coal fired boiler due to low water levels
Investigation of corrosion of 2205 duplex alloy
Forensic investigation of a propane tank explosion
Forensic investigation of failures of chemical reactors
Investigation of mechanical damage to a semi-autogenous grinding mill at a copper mine
Determination of cause and scope of damage to waterwall tubes and piping in a newly constructed coal fired boiler
Root cause investigation of rupture of steam-blow piping
Investigation of leaks in tube/shell heat exchangers
Determination of damage to waste heat boilers
Root cause and scope of damage investigation of explosion in a coal gasification plant
Determination of the extent of damage to piping at a refining facility
Metallurgical evaluation and root cause investigation of natural gas liquid piping failures
Root cause investigation of cracking in a generator rotor in a 450MW
Determination of the cause of nose arch collapse at a utility boiler
Investigation of damage due to slag fall in a utility boiler
Root cause investigation of collapse of superheater pendants and headers during a retrofit
Damage assessment and corrective action for casting defects in low NOx burner systems
Investigation of utility boiler implosion
Analysis of failed plate heat exchanger

Riley Power Inc. – Worcester, MA (3/08 to 3/09)

Chief Metallurgist

Responsible for material related issues associated with design, fabrication, procurement, quality, erection and performance of utility boiler components
Performed investigation of stress induced creep hardening failures in 347H stainless steel tubing
Failure analysis of superheater tubes in a coal fired power plant
Determined the extent of contamination of 1045 steel mixed with 1018 steel in economizer tubing
Developed quality control guidelines for boiler tubing and piping
Performed detailed evaluation of an off-shore boiler fabrication shop
Investigated failures of cast milling equipment
Investigated mechanical equipment failures including fan shafts
Determined the cause of failure during bending of Inconel weld overlay boiler tubes
Coordinated procedures for fabrication of grade 91 material for boilers

Dr. David Kalmanovitch, Consulting Metallurgist, LLC – Worcester, MA (4/04 to 3/08)

Principal Metallurgist

Investigated corrosion of electrostatic precipitator in a coal-fired circulating bed combustor in Puerto Rico
Forensic investigation of the rupture of steam pipe
Investigation of cause of boiler damage as a result of a slag fall
Forensic investigation of a smelt-water explosion in a recovery boiler
Analyzed failures and developed models of the effects of operating and fuel parameters on tube erosion in a circulating fluidized bed boiler
Performed metallurgical evaluations and failure investigations on components manufactured from ferrous alloys including forged, wrought, and cast materials
Evaluated cast, wrought and welded components for applications including structural, mechanical, transportation, pressure parts, coal milling equipment
Performed evaluation of nondestructive and destructive testing data to determine suitability for intended service and compliance with applicable codes
Evaluated and interpreted material performance through laboratory testing including tensile, hardness and fatigue
Developed and performed accelerated corrosion testing of candidate material for rebar service
Investigated degradation and failure of post combustion components in utility systems (air heaters, electrostatic precipitators, SCR catalysis, breaching)
Investigated high temperature corrosion/degradation of coal-fired burner components and pressure parts
Performed field investigation of corrosion fatigue damage in five utility boilers
Determined the extent of leakage in plastic-lined water-tanks and supervised repairs
Investigated non-compliance of ASME Code material from tube manufacturers

Wyman Gordon Co. – Grafton, MA (8/00 to 4/04)

Senior R&D Engineer

Failure analysis and root cause analysis of forged components, dies, and mechanical/hydraulic components
Weld repair of mechanical and hydraulic components
Development and implementation of heat treatment programs for steel, titanium, and nickel-based aerospace and turbine components
Performed failure analysis of turbine components made from various superalloys
Application of Six-Sigma procedures and techniques to open die and heat treatment processes
Developed method to evaluate titanium forged components using advanced image analysis techniques

Altran Corporation – Boston, MA (9/97 to 8/00)

Senior Project Engineer

Failure analysis, condition assessment, and root cause analysis of components and equipment primarily in the utility industry (fossil and nuclear)
Utilized Auger and X-ray photoelectron spectroscopic techniques to understand and control oxide locking phenomenon in utility safety relief valves
Investigated the extent of degradation of utility tunnel components (piping, electrical, support systems, etc.) at a large nuclear power facility
Failure analysis and root cause investigation of a utility transformer including the determination of the cause of PCB release
Developed ultrasonic testing techniques for piping systems at elevated temperatures.
Investigated steam distribution piping degradation and failures
Failure analysis and root cause investigation of a gas-fired utility boiler explosion
Investigated microbiologically induced corrosion in water piping systems

Thielsch Engineering, Inc. – Cranston, RI (3/96 to 8/97)

Senior Metallurgical Engineer

Performed laboratory and field investigations, cause and origin analyses, and failure analyses for plant owners, contractors, insurance companies and law firms
Evaluated the effects of fires and explosions on the structure, properties and structural integrity of materials and components such as process equipment, pressure vessels, piping, valves, etc.
Performed evaluation of nondestructive and destructive testing data to determine suitability for intended service and compliance with applicable codes
Provided recommendations for the repair of failed equipment. The repair methods included welding or brazing and various mechanical methods such as bolting, metal stitching, banding, etc. Supervised repairs of turbine casings and steam piping

Riley Stoker Corporation (now Riley Power, Inc.) – Worcester, MA (12/89 to 3/96)

Corporate Consultant, Materials

Supported boiler design and manufacturing activities
Material selection and evaluation for multi-solid fluidized bed and circulating fluidized bed combustors
Participated in workshops and EPRI programs related to material corrosion/erosion in fluidized bed combustors (bubbling and circulating)
Failure analysis and condition assessment of boiler tubes, piping components, milling equipment, fans, refractory, welds, and pressure parts
Consulted on repair, replacement and maintenance of boiler components
Investigation of major boiler and pipe failures including flow accelerated corrosion
Performed condition assessment of five Russian boilers in Mongolia for USAID
Evaluated components for compliance to the applicable ASME Boiler and Pressure Vessel Code
Trained engineers in failure analysis and condition assessment
Selected material and suppliers of code-related materials

LITIGATION SUPPORT

Property Damage: Damage to chemical plant due to rupture of pipe due to corrosion. Expert testing, report, testimony (deposition and trial) for the Plaintiff.
Property Damage: Damage to utility boiler due to on-line explosive cleaning process. Expert testing and report for the Defendant.
Personal Injury: Boiler explosion in a recovery boiler at a paper mill. Expert testing, report and testimony (deposition) for the Plaintiffs (injured and deceased)
Personal Injury: Carbon monoxide poisoning (one fatality and multiple injuries) at a university residence due to improper repair of furnace equipment. Expert witness and support for the Defendant.
Personal Injury: Burns sustained as a result of slag fall and resulting explosive release of steam in a boiler. Expert report and support for the Defendant.
Personal Injury: Burns sustained as a result of steam/ash released from a boiler. Expert support for the Defendant.
Property Damage: Fire damage as a result of explosion of a 500 gallon propane tank. Forensic investigation and expert support for the Defendant.
Property Damage: Corrosion of electrostatic precipitator at a utility power station. Expert support for the Defendant.
Subrogation: Damage as a direct result of incorrect control logic at a fertilizer plant. Forensic investigation, expert report and support for Plaintiff.
Personal Injury: Injury sustained during operation of a motorcycle. Expert support for the Defendant.
Personal Injury: Due to casting defect in hydraulic equipment. Expert witness report for Plaintiff.
Contract Dispute: Fuel requirements for a biomass-fired boiler.
Property Damage: Flooding damage due to rupture of water pump in a hospital. Expert testing/report for Defendant.
Property Damage: Damage due to coolant leak from HVAC system. Expert testing for Defendant.

PRESENTATIONS AND PUBLICATIONS

Presented courses on inspection of boiler systems and degradation of boiler materials to Tennessee Valley Authority
Lectured (invited) at Brigham Young University, Queen’s University (Canada), University of Alberta, and Montana State University
Presented the keynote address to the 1996 Australian Black Coal Utilization Conference in Brisbane.
Awarded one U.S. Patent (1992) and one European patent (1994)
Authored and co-authored hundreds of technical reports.
Taught course on high temperature corrosion processes in utility boilers for the Electric Power Research Institute

OTHER PROFESSIONAL

Participates in ASME Boiler and Pressure Vessel Code Committee Meetings
Member - ASME Corrosion and Erosion Subcommittee
Member - ASME
Chair – ASM Worcester MA Chapter, 2000
External Examiner – Masters Thesis, University of Queensland
Department of Energy Project Review (Fossil) Committee (invited) 1994 and 1995
Six-sigma Gold Belt

Experience