No.

Process Step

1 Assembling
Heat
exchanger

Potential Failure
Mode

Potential Failure
Effect

Potential Causes

OCC Current Process

Controls

DET

RPN

Actions Recommended

10 Impropper construction
of HX

7 Sealing the leaking areas

10 Bent Copper Tube not

giving proper area of
contact to fluid

4 Verify and fix the copper

tubing

280 Straighten copper tube using

table and other instruments and
inspect it before installing it into
the heat exchanger.

10 Perforated inner copper

core

4 Change copper piping

160 Inspect copper tube of any holes

or damages before assembling
the Heat Exchanger. If It has
holes, Cut another piece of
coper tube that is in perfect
conditions to perform the task.

10 Not using the right glue,

not using the right pvc
couplers diameters
therefore the measures
will be harder to get.

4 If the read of the

thermocouples are good it
means that its something
wrong with the heat
transfer capabilities of the
exchager

40 Asses every possible

manufacturing error by
identifying leaks, brittle fixtures
and overheating.

10 The analysis is not

accurate with the reality
because of the difficulty
to calculate the speed
and the mass flow that
the heat exchanger is
using.
7 actually
The k> 0.5
of the

5 Make several tests,

measuring the mass flow
by using chronometers and
test tube in order to get
times and volume. This
tests may not be accurate
are a
good insullations
4 but
Testing
several

200 Prove there is a constant flow by

using a standard flow output with
constant pressure.

112

4 Testing Heat
Exchanger

Leaks begin to bear on Possible change in

the heat exchanger
mass flow and Temp.
also inadequate work
environment

SEV

Failure on the heat

transfer of the
exchanger

Project objectives
not reached

Melting of components Melting due to

excessive heating
and thus becoming
innoperable

8 Connecting
Heat
Exchangers

Improper fit between

Heat Exchangers

Possible change in
mass flow and
pressure

10

Leakage between
Heat exchangers

insullation of the heat

exchanger is not working
as calculated, this is
more probable to appear
as the initial tests are
4 running
Above melting point
temperatures.

70 Applying inked flow to

connections and testing tube
with air flow to verify and
bubbles coming out

material until finding the

proper one.

4 Have a manual
temperature control
located at a safe distance
from burner

16 Never leave the system witout

water and calculate if the
container can handle the
temperature that the burner
outputs.

4 No agreement on
diameter specifications

4 Visually noticeable
diameter variations
between HXs

16 Agree with a standard PVC and/

or copper diameter to prevent
changes in mass flow

7 Making wrong
connections between
inner temperatures and
outer temperatures

4 Have a mark or label the

inlets and outlets of the
heat exchanger

28 Label fluid inlets and outlets on

each HX

4 Use of wrong adaptors

and also impropper
cutting of copper tube
causes imperfections at
the momento of
connecting heat
exchangers

7 Clean cut the connecting

copper and PVC tubes
before connecting

28 Agree on having a standard

conection between each heat
exchanger and inspect on
having clean connections rather
than rough connections by doing
an impropper cutting

All PE

"Add risk assesment and practical

solution columns.
Use the following risk metrics:
1, LOW
4, MEDIUM
7, MODERATE
10, HIGH

!Be strictly punctual on every FMEA

case. Leave no room for ambiguity or

misinterpretation. Send your team's
FMEA sheets to the project manager
for review two days before the CDR
1 due date."

Project Engineers

"Providing documental proof of

physical prototyping and its
compliance with the theoretical
hypotesys stated on the previous
review.

!Prototyping materials will be available

from Wed 4/15 in the Mechatronics

Lab. Project Engineers please schedule
your working dates on Asana. Two
2 teams per day max."
All teams

Create performance maps (as seen on

class) based on theoretical system
iterations and prototyping results.
Provide proof of system simulations on
specialized software. Validate all
theory by experimentation.
PE's & Analysts
Support every comment and design
decision with hard data, and back up
that hard data using trustworthy
sources.

Al PE's