Failure Mode and Effects Analysis (FMEA)

FMEA was done by scoring major components on basis of (S)everity, (O)currence and
(D)etectibility. These values are multiplied to determine a Risk Priority Number,which allows the
failure effects of each component to be compared.
Because of the number and complexity of system components, a typical single-stage, mechanically
coupled centrifugal pump can fail in approximately 600 ways (Mechanisms). To narrow pump
failure modes to the most likely component failures, it was assumed that the most likely causes of
pump failure would take place in the moving parts of the system, located along the shaft. The
stationary components were assumed to be less susceptible to fatigue and stress failure, unless noted
in the dissection and use study as in the case of the inlet nozzle and pump casing.
The inlet nozzle, the motor, the pressure switch and the mechanical shaft seal were determined to
have the highest combined RPN value. The inlet nozzle is crucial for pump function and was
observed to fail under long term use. The motor is the most complicated assembly and can be
dangerous if it fails due to overheating or if water leaks in. The mechanical shaft seal both have
multiple modes of failure and can easily become fatigued or broken with pump misuse.
It was noted during the dissection and use study that the tip of the inlet nozzle was broken off inside
the housing, indicating fatigue as a mechanism of failure for the nozzle. The inside of the pump
housing chamber was extremely rusted and the water circulated through the pump became
contaminated, which is a system failure for intended use as a well pump.
To prevent overall component failure, it is most important to properly assemble the pump and have
narrow tolerances, particularly on the shaft components because a misaligned component will be
subjected to high stresses and causes vibrations in the system. It is also important to prime the pump
before use because mechanical seals will overheat and permanently fail due to increased friction.
Debris in the water is a cause of multi-component failure because an occlusion in any part of the
pump will result in high system pressure. The addition of a filter and rust-prevention measures, such
as internal coating or an easy way to empty the pump of water would be beneficial to include in
redesign. It would also be beneficial to redesign the pump such that it is easy to disassemble and
replace fatigable parts, such as the shaft seal. However there are trade-offs because the addition of
these design changes would increase system cost.
Item and
Function
Mechanical Shaft
Seal: water tight
coupler from
output shaft to
impeller

Failure
Mode

Effects of S Causes of O Design D RP Recommend

Failure
Failure
Controls
N
ed Actions

Rubber
Seal is
8
Heat
overheats broken,
generated
or
fluid leaks
by
fatigues into motor,
increased
pump stops
friction
working
(dry
running
pump or
running

Pressure 3 96
Sensor
prevents
pump
operation
under
high
pressures

Prime pump
before use

pump
beyond
limits)

Mechanical Shaft
Seal

Spring
Fatigue

Impeller:Centrifug
Plastic
ally accelerates
deforms
water

Inlet Nozzle:
Delivers water to
impeller

Fatigue
weakens

Iron Housing:
circulates
pressurized water
to outlet

Rust

Motor: generates

Metal

Increased
torque on
spring
(pump
running
Pressure
Seal is
beyond
Sensor
broken,
limits);
prevents
fluid leaks 8 Increased
pump
2
3 48
into motor,
system
operation
pump stops
vibrations
under
working
(worn
high
bearings,
pressures
misaligned
shaft
component
s)

Replace
mechanical
seal
periodically;
Decrease
assembly
tolerances

Flow rates
High
decrease or
pressure;
stop; Pump
high liquid
vibrations 8 temperatur
1
increase
es;
due to
becomes
unbalances
occluded
rotation
by debris

Filter water
at inlet;
decrease
assembly
tolerances

Pump
cannot
circulate
water

3 24

tip breaks
due to
Pump can
fatigue and
be bolted
Securely bolt
vibrations;
down to
down pump
4 Increased
3 reduce 9 108 before use;
back
mechanic
filter water
pressure
al
before inlet
due to
vibrations
debris
occlusion

Material
Contaminat 3
rusts over
es water
time

Increased

Pressure
Sensor
cuts
power to
motor if
pressure
exceeds
limit

Improper

n/a

1 24

2 Switch on 9 126

Coat inner
chamber to
prevent rust;
Empty
housing
when not in
use
Decrease

rotational
friction on
motor shaft
torque for impeller fatigue of overheats
rotation
bearings
motor,
possibly
stopping
pump

assembly
resulting in
high
bearing
stress and
high
system
vibration

shaft that
cuts
electricity
to motor
under
high shaft
stress

assembly
tolerances;
Use robust
bearings

Inaccurate
pressure
Diaphrag
input to
m Seal
pressure
Pressure Switch:
rubber
switch;
2
cut motor circuit at
stiffens
water
set pressure limit
or
leakage to
ruptures
electrical
component
s

Aged
rubber;
Rust
deposits
corrode
rubber

Diaphrag
m is
2
3 12
replaceabl
e

Prevent rust
by coating
inner
chamber;
Replace seal
periodically

Pump
doesn't
Inlet tube
respond to 2
becomes
changes in
occluded
water
pressure

Debris in
water

9 36

Filter water
before inlet

Switch
becomes
uncalibrate
Switch
If
d; Pump
Fatigue (if
undamage
doesn't shut
pump is
d, spring
off under 3 improperly
can be re
3
6 54
high
run and
calibrated
pressures
switch
by
or switch is
repeatedly
tightening
permanentl
activates)
nut
y in "off"
position

Run pump
consistently
within limits

Pressure Switch

Pressure Switch

Springs
Fatigue

n/a

Design For Environment (DFE)

The DFE analysis showed that the pump system can easily be recycled and does not waste many
materials. The motor and pressure sensor do not appear to be specifically designed for this system
and so they could potentially be used in other products. The pumps iron casing can be recast and the
plastic parts can be recycled. The entire system was not built to be disassembled because it is
difficult to take apart and a seal has to be broken in order to fix any internal parts. The chosen
materials are robust, therefore it seems that it was meant to last a long time without failure, but not

be fixed after breaking. There are several suggestions for improving the design. Possibly make the
pump solar powered or have a battery pack that could be charged using solar power. The iron casing
could be made thinner as the current component could withstand extraordinary pressures. Also
instead of using iron, aluminum would still be strong enough and since its lighter, would cut down
on shipping costs. The pump could be redesigned to only have one chamber, which would cut down
on materials, assembly time, and shipping costs.