ERIC V. SULLIVAN, P.E.
Materials and Metallurgical Engineer

SPECIALIZED PROFESSIONAL COMPETENCE

EQUIPMENT

INDUSTRIES

RECENT WORK

• Failure Analysis — Refinery piping failures, underground steam pipe failures, well
  casing failures for a salt dome natural gas storage facility, industrial gas and diesel
  engines, turbochargers, valves, pumps, gasoline pipeline ruptures, fire protection
  system piping, water piping, and nuclear plant turbines, bolts, valves, and piping
  systems.
• Fire and Explosion Accident Investigation — Evaluation of failures of equipment,
  devices and systems that cause accidents, fires and explosions, including oxygen
  and oxyacetylene systems, refineries, copper smelters, industrial boilers, pump seals,
  pressure tanks, vessels, and natural gas storage facilities.
• Accident Reconstruction — Evaluation of accidents involving oxygen and
  oxyacetylene welding system explosions, oil refinery fires and explosions, personal
  injuries, rocket fuel oxidizer explosions, building explosions caused by leaking
  buried gas pipelines, underground migration of combustible gas.
• Technical Consulting — Engineering analysis and consulting on large legal cases
  involving refinery and chemical plant equipment integrity.

PROJECT EXPERIENCE – METALLURGICAL ENGINEERING

• Failure Analysis — Failure analysis for a wide range of components, including pumps, pressure vessels, machinery, turbines, motor vehicles, electronic components, piping, and medical implants.
• Rotating Equipment — Instrumentation and evaluation of vibration in petrochemical equipment; failure analysis of gas and steam turbines; development of fracture mechanics code for evaluation of defects in steam turbines; fitness-forservice evaluation of inspection indications in turbine rotors; failure analysis of pumps and other machinery.
• Pressure Vessels/Piping — Metallurgical and failure analysis of buried petrochemical pipelines, steam lines, boiler tubes, water and hydraulic piping; evaluation of creep and creep/fatigue of high-temperature components; fitness-for service analysis of weld defects.
• Materials Review
• Testing and Instrumentation — Strain gage analysis of high pressure natural gas storage vessels and hydraulic piping systems; instrumentation of laboratory test setups for computerized data acquisition of strain, pressure, temperature, displacement, and force
• Accident Reconstruction — Explosion analysis of medical oxygen systems and oxyacetylene welding equipment

EDUCATION AND PROFESSIONAL BACKGROUND

• B.S. (Metallurgical Engineering), California Polytechnic State University at San Luis Obispo, California (1980)
• Professional Engineer, Metallurgical, California No. 1771
• Licensed Private Investigator, State of California

  Comprehensive Courses:

  • Hazardous Waste Operations and Emergency Response Training, University of California, Santa Cruz (July 1995)
  • Scanning Electron Microscopy and X-ray Microanalysis, Lehigh University (1992)
  • Hazardous Materials Management, University of California, Santa Cruz (July 1993)
  • BATC Refinery Contractors Process Safety Orientation (May 1999)
    
    
• Recipient of ASM Metallography Award

SELECTED REPORTS, PROJECTS, PUBLICATIONS, AND INVITED LECTURES

Investigation of an Oxyacetylene Welding System Accident, APTECH Report AES 06016056-4-1 (May 2006).

Investigation of Autoclave Hatch Hardware with Magnetic Particle Indications, with M. Cronin, APTECH Report AES 05045769-5-1 (October 2005).

Investigation of a Diesel Engine Failure at the Encina Wastewater Facility, APTECH Report AES 05075872-4-1 (September 2005).

Investigation of Natural Gas Leaks from Dow Well No. 13, with G. Egan and J. Towers, APTECH Report AES 04025297-3-1 (August 2005).

Expert Report of Aptech Engineering Services, Inc. in the Matter of Baillie v. Nautilus/Schwinn Fitness Group, Inc., et al., APTECH Report AES 05065821-4-1 (August 2005).

Expert Report of Aptech Engineering Services, Inc. in the Matter of State Farm General Insurance Company v. Maytag Corporation, et al., with K. Clark and P. Wheeler, APTECH Report AES 04105563-4-1 (July 2005).

Investigation of Corrosion Damage to Coils of Sheet Metal Steel at the Warehouse of Toyota Tsusho America, Inc. in Carson, California, APTECH Report AES 05035729-4-1 (March 2005).

Inspection of Marine Diesel Engines from the Howard Stapp Tubboat, with S. Torbov, APTECH Report AES 04075475-4-3 (February 2005).

Inspection of Marine Diesel Engine from Acadia Ferryboat, with S. Torbov, APTECH Report AES 04075475-4-2 (February 2005).

Inspection of Marine Diesel Engines, with S. Torbov, APTECH Report AES 04075475-4-1 (February 2005).

Investigation of Cooling Fan Failure at Guadalupe Cooling, Guadalupe, California, APTECH Report AES 04055430-4-1 (July 2004).

Investigation of Diesel Engines Exposed to Contaminated Fuel, with K. Clark and S. Torbov, APTECH Report AES 04045401-4-1 (May 2004).

Investigation of a Diesel Engine Connecting Rod Failure, APTECH Report AES 00104188-4-2 (April 2004).

Investigation of an Accidental Discharge of a Fire Suppression System at the Savis Building in Santa Clara, California, APTECH Report AES 03115227-4-1 (December 2003).

Evaluation of Report Conclusions for Steam Line Venturi Cracking at the Whiting Cogeneration Plant, APTECH Report AES 03125242-4-1 (December 2003).

Investigation of Water Pipe Leak in a Heating, Ventilating, and Air Conditioning Cooling Water System, APTECH Report AES 03095164-4-1 (October 2003).

Rebuttal of Failure Analysis Associates Report, "Warranty Claim Regarding Turbocharger Compressor Wheels," by Roland Huet, with G. Egan and P. Besuner, APTECH Report AES 02114914-4-2 (August 2003).

Engineering and Reliability Analyses of Ross Aluminum Castings for Garrett Turbocharger Wheels, with G. Egan and P. Besuner, APTECH Report AES 02114914-4-1 (June 2003).

Investigation of Portable Oxygen Cylinder Fire Which Occurred at the Texas Department of Criminal Justice on February 11, 2001 - Executive Summary, with C. Lee and K. Clark, APTECH Report AES 03014954-4-2 (May 2003).

Investigation of Portable Oxygen Cylinder Fire Which Occurred at the Texas Department of Criminal Justice on February 11, 2001, with K. Clark and C. Lee, APTECH Report AES 03014954-4-1 (May 2003).

Significance of Surface Rubbing on Stress Corrosion Cracking Susceptibility for Low Pressure Rotors at San Onofre Nuclear Generating Station, Unit 3, with R. Cipolla, APTECH Report AES 01084468-1-1 (April 2003).

Assessment of Root Cause for Low Pressure Turbine Inner Casing Studs at San Onofre Nuclear Generating Station, with R. Cipolla, APTECH Report AES 02104890-1-3 (March 2003).

Metallurgical Analysis of Low Pressure Turbine Inner Casing Studs, San Onofre Nuclear Generating Station, Unit 2, with R. Cipolla, APTECH Report AES 02104890-1-1 (March 2003).

Investigation of a Water Heater Failure, APTECH Report AES 02124930-4-1 (January 2003).

Technical Analysis of Chain Failures for Escalator Step Chains Supplied by ECS Corporation, APTECH Report AES 02044729-4-1 (November 2002).

Investigation of Fire Protection Pipe Leak at Pedro’s Restaurant in San Jose, California, APTECH Report AES 02104887-4-1 (October 2002).

Investigation of Fire Protection System Pipe Failure, APTECH Report AES 02104888-4-1 (October 2002).

Investigation of Potential Design Defect in Generator at Northern California Power Association’s Alameda Power Plant, APTECH Report AES 02074827-4-1 (August 2002).

Engineering Investigation of a Turbine Overspeed Incident at Rosebud Power Plant, Colstrip, Montana, with R. Schreiber and R. Dail, APTECH Report AES 02064794-4-2 (August 2002).

Protocol for Metallurgical Examination of Row 12 Steam Turbine Blades - Rosebud Power Plant - Colstrip, Montana, with R. Schreiber, APTECH Report AES 02064794-4-1 (August 2002).

Site and Evidence Inspection Related to an Accident Involving a Swivel Trim Chute at the Newark Sierra Paper Plant in Stockton, California, APTECH Report AES 01074439-4-1 (July 2002).

Evaluation of Cracks on a Steam Line Venturi at the Whiting Cogeneration Plant, APTECH Report AES 01104531-2-5 (April 2002).

Evaluation of Steam Leaks at Socket Welds from the Whiting Cogeneration Plant, APTECH Report AES 01104531-2-4 (April 2002).

Metallurgical Evaluation of a Y-Strainer with Leaks at the Connection to a Blow-Off Valve - Whiting Cogeneration Plant, APTECH Report AES 01104531-2-3 (February 2002).

Evaluation of a Cracked Weld Fitting on a Steam Line Venturi at the Whiting Cogeneration Plant, APTECH Report AES 01104531-2-2 (January 2002).

Evaluation of Caustic Cracking in a Heat Recovery Steam Generator Piping System, APTECH Report AES 01104531-2-1 (January 2002).

Investigation of Hydroelectric Turbine Shaft Cracks, APTECH Report AES 00114224-4-1 (June 2001).

Metallurgical Analysis of Low Pressure Turbine Inner Casing Stud San Onofre Nuclear Generating Station, Unit 3, with R. Cipolla, APTECH Report AES 01044365-1-1 (June 2001).

Investigation of Generator Field Problems at the Northern California Power Association's Alameda Unit 2 Power Plant, APTECH Report AES 01054384-4-1 (June 2001).

Investigation of Generator Field Problems at the Northern California Power Association's Roseville Unit 1 Power Plant, APTECH Report AES 01034320-4-1 (June 2001).

Investigation of Galvanizing Kettle Loss at Pacific Galvanizing, APTECH Report AES 00084112-4-2 (April 2001).

Investigation of Generator Field Problems at Northern California Power Association's Lodi Power Plant, APTECH Report AES 01024298-4-1 (April 2001).

Investigation of Generator Field Problems at the Northern California Power Association's Alameda Power Plant, APTECH Report AES 01014264-4-1 (April 2001).

Investigation of General Electric LM6000 Gas Turbine Mechanical Breakdown - Review of Report by Others, APTECH Report AES 00043972-4-2 (February 2001).

Investigation of a Diesel Engine Connecting Rod Failure, APTECH Report AES 00104188-4-1 (January 2001).

Investigation of Cracking in a Stainless Steel End Plate from a Semiconductor Oven, APTECH Report AES 00124239-5-1 (January 2001).

Investigation of an Extruded Gasket from an Automated Closure in a Coker Drum, APTECH Report AES 00114218-5-1 (January 2001).

Evaluation of a Fracture in a 4-Inch Cover Plate, with M. Cronin, APTECH Report AES 00114205-5-1 (January 2001).

Investigation of Cracking in Fan Motor End Plates, APTECH Report AES 00104181-5-1 (November 2000).

Failure Analysis of a Boiler Feed Pump Turbine Blade, APTECH Report AES 00104173-21 (November 2000).

Recent findings and Results for Engineering Investigation of a Fire in an Air-Over-Oil Accumulator Tank, APTECH Report AES 98023324-4-2 (November 2000).

Metallurgical/Root Cause Evaluation of Cracking in Main Steam Piping at the Sundance, Unit 4, Turbine Terminal Point Piping, APTECH Report AES 00084106-2-1 (October 2000).

Investigation of a Galvanizing Kettle Leakage at Pacific Galvanizing Company, APTECH Report AES 00084112-4-1 (September 2000).

Investigation of General Electric LM6000 Gas Turbine Mechanical Breakdown, APTECH Report AES 00043972-4-1 (September 2000).

Examination of Main Steam, Hot Reheat, and Link Piping from Cayuga Station, Unit 2, with J. Yavelak, R. Moser, and T. Kuntz, APTECH Report AES 00044009-2-1 (August 2000).

Trus Joist Hot Oil Pump Fire Investigation, APTECH Report AES 00064049-4-1 (July 2000).

Preliminary Investigation of Apartment Door Lock Failures, with K. Clark, APTECH Report AES 00074067-4-1 (July 2000).

Investigation of the Failure of a 12,000 Volt Switch Connection at New York New York Hotel and Casino, Las Vegas, APTECH Report AES 00054011-4-1 (June 2000).

Investigation of Damage to an Allison 501KB Gas Turbine Which was Operated by York Research, APTECH Report AES 00013875-4-1 (April 2000).

Investigation of Damaged Slide Valve on Screw Type Gas Compressor, APTECH Report AES 00023892-4-1 (March 2000).

Investigation of Bearing Failure at Pomona Paper Company, APTECH Report AES 00013881-4-1 (February 2000).

Engineering Investigation of Damage to a Turbine Lube Oil Pump - Insured: Turbo Mechanical, Inc., APTECH Report AES 99113841-4-1 (December 1999).

Investigation of Problems with Pumping Plants Built by C. R. Fredrick, APTECH Report AES 99083773-4-1 (October 1999).

Satellite Shaker Table Explosion Investigation, APTECH Report AES 99073751-4-1 (August 1999).

Investigation of Engine Components Failure, APTECH Report AES 99053702-4-1 (June 1999).

Investigation of Multiple Breakdowns in an Allison 501 KB5 Gas Turbine Anderson Lithograph, APTECH Report AES 99023629-4-1 (March 1999).

ASTM A320 Grade B8 Class 1 Bolting Issues, with T. Kuntz, et.al., APTECH Report AES 98123578-3-1 (January 1999).

Investigation of Cracks in a Forge Press Hydraulic Cylinder, APTECH Report AES 98063431-4-1 (August 1998).

Investigation of Silane Gas Fire at Matheson Gas Products, APTECH Report AES 97103196-4 (February 1998).

Investigation of Structural Steel Collapse, Chino Basin Municipal Water District Water Reclamation Plant 4, APTECH Report AES 97063107-4-1 (August 1997).

Project Findings for the Investigation of the Explosion of High Pressure Natural Gas Filter Separator at McDonald Island, California, APTECH Report 93102025-4-5 (October 1996).

Evaluation of Safety Bolt Thread Stripping Strength and Effect of Length of Thread Engagement, APTECH Report AES 93102025-4-4 (August 1996).

Investigation of the Collapse of a Conveyor Structure at Sims-Lmc Recyclers, APTECH Report AES 96012628-4-1 (February 1996).

Evaluation of a Turbine Blade Failure at Mt. Poso Cogeneration Facility, APTECH Report AES 95052456-4-1 (July 1995).

Investigation of Unit 1 Power Transformer Failure and Fire at Colgate Hydroelectric Generation Station, Dobbins, California, APTECH Report AES 95052449-4-1 (June 1995).

Investigation of Mazak Laser Cutting Machine, APTECH Report AES 94052184-4-2 (May 1995).

Metallurgical Evaluation of a Failed Fastener from Puna CT-3 Power Turbine, APTECH Report AES 94112314-2-2 (March 1995).

Investigation of a Pinhole Leak in a Petroleum Products Pipeline, Declaration of Mechanisms Which Could Cause a Through Wall Penetration in Carbon Steel Pipeline Material, Trial Declaration of Facts, APTECH Project AES 94112317-4 (February 1995).

Investigation of the Explosion of an Abandoned Natural Gas Pipeline, Project Notes, APTECH Project 95012355-4 (January 1995).

Evaluation of a Natural Gas Pressure Vessel Failure (Explosion), APTECH Report AES 93102025 4-2 (October 1994).

Graphitization Evaluation Program for the High Temperature Steam Lines at P.T. Badak, Bontang, Indonesia, APTECH Report AES 94032136-3-2 (August 1994).

Analysis of a Failed Electro Hydraulic Servo Valve, APTECH Report AES 93021851-2-1 (March 1993).

Failure Analysis of Type 304 Stainless Steel Feedwater Heater Tubes From a Heat Recovery Steam Generator, APTECH Report AES 92061711-2 (June 1992).

Estimation of Critical Flaw Sizes and Failure Probabilities for Check Valve Swing Arms at Palo Verde Nuclear Generating Station, with E. Zebroski, APTECH Report AES 90031209-1Q-2 (September 1991).

Evaluation of Service Suitability [Nuclear] of Borg-Warner Bolted-Bonnet Check Valve Swing Arms, with P. Lindsay and J. Grover, APTECH Report AES 90031209-1Q-1 (April 1991).

Failure Analysis of a Fractured High Pressure Gas Connector Fitting, APTECH Report AES 90101328-3-1 (November 1990).

Examination of Damaged Cooper-Bessemer Diesel Engine Crankshaft and Evaluation of Feasibility of Proposed Repairs, APTECH Report AES 90081295-4 (October 1990).