Final Year Project Supporting Documentation

UNIVERSITY OF MALTA

Faculty of Engineering

Department of Manufacturing

FINAL YEAR PROJECT

B.ENG. (Hons.)

Supporting Documentation

MAY 2011

Design of a Portable Water Purification System

by

Lawrence Farrugia

Table of Contents

Section Page

Quality Function Deployment Matrix 2

Function Means Tree 4

Conceptual Designs 7

Material Selection for Pipe Segments 12

Material Selection for Structural Frame 23

Failure Mode and Effects Analysis 32

Technical Drawings 34

System Renders 64

2

Quality Function Deployment Matrix

3

9

3

1

Phase

e es nput

acity

ion

e bly

mbly

alability

oring

nits

Planning and Design Manufacturing Use

Impo

rtan

ce

Redu

ndancie

Total Pow

er In

Material

Processin

g Cap

Mass

Size

Standardisa

ti

Selling

Price

Quick Assem

b

Simple Assem

Upgrade

ability/Sca

Ease of M

onito

Washable Un

Easy to Operate 2Mobility 6Mobility 6Compact 6Low Cost 8Low Energy Consumption 5Safe to operate 8Assembly of individual modules carried out by unskilled personnel 6Weather proof 4Effective Treatment of Water 10Durable 4Durable 4Cater for peaks in the demands 4Interchangable parts 7Self Suffecient 8

Total 215 242 180 111 139 220 274 598 86 110 110 141 83

e same water

ess

y day

e 5000

Euros

l and

flow

s pressure

cal U

nit P

rocesess with

in th

etreatm

ent stage

Less th

an 200

0 W

Material Selectio

n Proce

2100

litres of w

ater every

Less th

an 300

kg

Less th

an 1 cub

ic m

etre

mum

Selling Price Less th

an

ndard mechanical, electrical

interface

asuring instrumen

ts su

ch as

gauges

Iden

tic

Maxi m

Stan

Mea

4

Function Means Tree

5

To treat water originating from freshwater body

Portable Water Treatment

System

To provide mobility to the

system

To Treat Water for

Microbiological Contamination

Structural Frame

UV Irradiation

To Treat Water for Inorganic

Contaminants

Chlorination

Ozone

Reverse Osmosis

Nano Filtration

Ion Exchange

Coagulation and Flocculation

To Treat Water for Organic

Contaminants

Micro Filtration

Ultra Filtration

To transport the system

Air

Land

Sea/Lake

To have water with low turbidity

Multimedia filters

To have water free from chlorine

Micro Filtration

GAC

To provide assembly of

system elements

To have water with low turbidity

Slow Sand Filtration

Micro Filtration

To have water free from chlorine

GAC

Mounting Clamps

Cable Ties

Clips

To provide chemical

DisinfectionChemical

A

Rapid Gravity Filtration

Function

Means

6

A

To Remove large debris from

Water

Coarse Screening

Fine Screening

To Treat Water for Taste and

Odour

Aeration

Adsorption

To Provide fluid at a specific

pressure

Submersible Pump

Booster Pump

To provide electrical power

PhotoVoltaic Cell

Internal Combustion

Engine

Mains Operated

To generate internal

combustionFuel

To Store Electrical Energy

Batteries

To Treat Water for Turbidity and

Colour

Rapid Gravity Filtration

Slow Sand Filtration

Coagulation and Flocculation

Microfiltration

To cause coagulation of

collodial particles

Chemical Coagulant

Wind Turbine

Water Turbine

7

Conceptual Designs

8

Membrane Modules

Concept C2.1 External Thread of Membrane End Caps

Concept C2.2 External Threaded Fittings for End Caps

Concept 2.3 End Caps fitted with screw threads

Concept 2.4 Eccentric Internal Lock of End‐Cap

Concept C2.6 Geometrical Constrain

Concept C2.5 Straps

Geometrical Constraints

V Shaped Support

Flexible Strap

Threaded Membrane End Caps Adapter Collar

with internal

End Cap

Eccentric Lock

End Cap

Membrane Module

9

CartridgeModules

Concept 3.1 Internal Screw Thread

Concept 3.2 U‐Clamps

Concept 3.3 Hinges

Concept 3.4 Straps

Ultra Violet Membrane Modules

Concept 4.1 U Clamp

Concept 4.2 U Clamp (style II)

U Type Clamps

Cartridge Filter Housing

Screw Insert


Cartridge Filter Cap


Hinges

Flexible Strap

V Shaped Support

UV Filter

U‐Type Clamp

U‐Type Clamp

10

;

Flow Modules

Concept C1.1 Pipe Flange

Concept C1.2 Pipe Thread

Concept C1.3 Push Fits

Concept C1.4

Concept 4.3 U clamp (snap fit)

Concept 4.4 Straps

Flexible Strap

U type clips

UV Modul

V Shaped Support

11

Structural Module

Concept 5.1 Butt Joint

Concept 5.2 Geometrical Fitting

Concept 5.3 Concept 5.4

Male to Female screw thread

Concept 5.5 Geometrical Constraint

Butt Joint

12

Material Selection for Pipe Segments

13

14

15

16

17

18

19

20

21

22

Total Weight Relative Total WeightDensity 1 0 0 0 1 0 0 1 3 8.3Price 0 0 0 0 1 1 1 1 4 11.1Tensile Strength 1 1 0 0 1 1 1 1 6 16.7Corrosion resistance to fresh water 1 1 1 1 1 1 1 1 8 22.2Corrosion resistance to sea water 1 1 1 0 1 1 1 1 7 19.4Resistance to Degradation by UV 0 0 0 0 0 1 1 1 3 8.3Resistance to Strong Acids 1 0 0 0 0 0 1 1 3 8.3Resistance to Strong Alkalis 1 0 0 0 0 0 0 0 1 2.8Recycleable 0 0 0 0 0 0 0 1 1 2.8

Total 36

Stainless Steel Soda‐lime glass Silica glass Polyvinylchloride (PVC) PTFE Nickel‐based super alloys Borosilicate Glass Weight

Density 8.3 2.263 7.363 8.258 11.603 8.333 2.119 7.971Price 11.1 1.483 11.111 1.780 10.565 0.642 0.594 0.030Tensile Strength 16.7 16.667 1.076 1.563 1.413 0.694 13.889 0.764Corrosion resistance to fresh water 22.2 22.222 22.222 22.222 22.222 22.222 22.222 22.222Corrosion resistance to sea water 19.4 19.444 19.444 19.444 19.444 19.444 19.444 19.444Resistance to Degradation by UV 8.3 8.333 8.333 8.333 8.333 6.667 8.333 8.333Resistance to Strong Acids 8.3 6.667 6.667 8.333 6.667 8.333 6.667 6.667Resistance to Strong Alkalis 2.8 2.778 2.778 2.778 2.778 2.778 2.778 2.778Recycleable 2.8 2.778 2.778 2.778 2.778 2.778 2.778 2.778

78.824 70.987Total Score 82.635 81.773 75.490 85.803 71.892

23

Material Selection for Structural Frame

24

25

26

27

28

29

30

31

Weight Tensile Strength 1.1 3.8 2.2 2.1Specific Cost 1.3 7.7 7.7 4.8Density 1.9 18.5 18.5 18.5Corrosion Resistance to Fresh Water 1.7 16.7 16.7 16.7Corrosion Resistance to Weak Acids 0.4 3.7 3.7 3.7Corrosion Resistance to Weak Alkalkis 0.4 3.0 3.0 3.0Resistance to Degradation by UV 1.3 13.0 13.0 13.0Weldabilty 0.7 4.4 4.4 4.4Machinability 0.7 7.4 7.4 7.4Formability 0.2 1.4 1.4 1.4Recycleable 0.4 2.8 2.8 2.8

Non Age Hardening

78

Age Hardening Wrought Al

Cast Al Alloys

Total Score 82 81

Total Weight Relative Total WeightTensile Strength 0 0 0 1 1 0 1 1 1 1 6 1.1Specific Cost 1 0 0 0 1 1 1 1 1 1 7 1.3Density 1 1 1 1 1 1 1 1 1 1 10 1.9Corrosion Resistance to Fresh Water 1 1 0 1 1 1 1 1 1 1 9 1.7Corrosion Resistance to Weak Acids 0 0 0 0 1 0 0 0 0 1 2 0.4Corrosion Resistance to Weak Alkalkis 0 0 0 0 0 0 0 0 1 1 2 0.4Resistance to Degradation by UV 1 0 0 0 1 1 1 1 1 1 7 1.3Weldabilty 0 0 0 0 1 1 0 0 1 1 4 0.7Machinability 0 0 0 0 1 1 0 1 1 0 4 0.7Formability 0 0 0 0 1 0 0 0 0 0 1 0.2Recycleable 0 0 0 0 0 0 0 0 1 1 2 0.4

Total 54

32

Failure Mode and Effects Analysis

33

Deformation of Housing

Considerable Leakage of Water

8Pressure inside vessel

exceeds design specification

Pressure Relief Valve 6Pressure Relief Valve

becomes engaged 2 96

Monitor and record pressure readings

Deformation of Housing

Restriction of Flow 5Detachment of UV unit

from Module Assembly

Multiple straps used to attach the unit to the

straps 3 Quality Assurance 4 60

Samples should be taken and tested

RustingIncrease in pressure losses as a result of

increase in the surface 2 7

Testing for prolonged exposure to high

intensity UV 5 70

Monitor and record pressure readings

Rusting

Output water contains microbiological

contaminats due to ineffective UV

irradiation

10 7Testing for prolonged exposure to freshwater

3 210Visual Inspection of internal vessel walls

Degradation by UV Water leakage 6Prolonged exposure to

high intensity UV Irraidaiation

Material Selection - Excellent resistance to

degradation by UV Irrddiation

6


intensity UV Irradiation

5 180Consider using more

rigid material constrints

Implement UV lamp check, during

preventive maintanace.Implement sampling

point, for water quality testing

Pressure Relief Valve Washable Filter

Tearing of Filter Material

Permeation of Contaminated Water

10Presence of large solid

particles in water source

Preliminary Fine Screens as a pretretment

2Visual Inspection of Water output from

process 2 40 Replace/Wash Filter

Activated Carbon Adsorpion

Improvement Taste,colour and Odour

No more adsorption is possible - filter is

completely impregnated with

contaminants

Permate Water with unaccaptable Taste,

Colour and/or Odour3 Filter lifetime exceeded 5

Testing of Water Samples

5 75 Filter Replacement

Pressure Relief ValvesMaterial Seletion -

High Tensile Strength

Degradation by UV Water leakage 7 UV Degradation



6



3 126Change of Material -

use more rigid /specific material constraints

Fouling of Membrane Filter

Increase in pressure losses

3Feed water with very

high turbidity

Provide Sediment filters as a pre-

treatment 7

Pressure Measurement from Pressure Gauge

2 42Wash Membrane Filter

and Install Sediment Filters

Fouling of Membrane Filter

Increase in pressure losses

3Biological Growth of

Bacteria

Use of Anti-Fouling Chemicals during

membrane cleaning8

Visual Inspection of Membrane Filter

3 72

Wash Filters and ensure constant

monitoring of pressure losses

Tearing of Membrane Material


10Presence of very large

particulate

Design Guideline - Finse Screens are

always employed as a pre-treatment for membrane filters

4Water Sampling Points

and Pressure Measurements

8 320Replace Membrane

immediately

Degradation of Membrane Material


10Presence of high

chlorine Concentration

Design Guideline - Activated Carbon

Adsorption as a pre-treatment

5 Water Sampling Points 5 250Visual Inspection of

Membrane




6





Tearing of Vesssel Wall

Considerable Leakage of Water

8Pressure inside vessel exceeds design limit

Pressure Relief Valve 6Pressure Relief Valve

Engaged 2 96

Ensure Correct Setting of pressure relief valve

Tearing of pipe wallConsiderable Leakage

of Water 8

Pressure inside vessel exceeds design limit

Material Seletion - High Tensile Strength

6Testing of Water Pipes, under designed water

pressure4 192

Change of Material - use more rigid /specific

material constraints

Loose Pipe Connections

Water leakage 3Incorrect pipe

connection during assembly

Selection of Interfaces 7Inspection after

Assmebly 4 84

Position pipe duct correctly



degradation by UV Irradiation

6





Deformation of Frame Compromised

Structural Integretity7

Compressive Loads Exceed beyond

Material Specifications

Materials Selection - High Compressive

Strength 1

Testing of Frame Under Compressive

Load 3 21

Change Frame Specification and

verify that material supplied is as specified

Plate Tearing Reduced strength of

mechanical connections

8

Material Subject to Tensile Loads that are beyond the material

specification

Material Seletion - High Tensile Strength

1 Testing of Frame 3 24

Change Frame Specification and

verify that material supplied is as specified

Proved connections between structural

frames Shearing of Rivet

Reduced strength of mechanical connections

8Excessive Tensile

StressMaterial Selection and

Rivet Dimension1

Testing of Frame Under Shear Load

3 24Change Rivet Diamater and verify that material supplied is as specified

Bearing Failure of Rivet Material

Rivet Material Deformed

Reduced strength of mechanical connections

7Excessive Compressive

Stress

Material Selection - High Compressive

Strength1

Testing of Rivet Under Compressive Load

3 21Change Rivet Diamater and verify that material supplied is as specified

Ensure that setting of pressure relief valve is set at a value which is

168Implement more rigid

quality checks Electrical Terminals

Provide Electrical Connection between a unit and power source

Loose Electrical Connections

7 Selection of Interfaces

Failure Modes and Effects Analysis

Permeation of Microbiological Contaminants

10 High water trubidity 6

Internal walls of UV unit, subject to a

prolonged exposure to water and other

chemicals

Blockage of filter pores 8Pressure Gauge Setting

on Pressure Releif 2 64 Replace/Wash FilterDirty Filter Pressure Build-up 4

Source of UV Irradiation

UV Lamp

Design Guideline - Sediment Filter is

always a predecessor of UV Filter

Low UV Radiation Intensity

Elimination of Colloidial Particiales

Sediment Filter

Housing

UV

Uni

t Pro

cess

es Material Selection -

Excellent resistance to degradation by

freshwater

Encapsule UV Lamp

Testing of Water Samples

5 300

Encapsule Sediment/Carbon Adsorption/Ion

Exchange Filters

Housing

Pressure inside vessel exceeds design limit

5Pressure Releif valve

engaged 2 808

OccurenceCurrent Design

Controls DetectionDetection RPN

Recommended Action(s)

Part FunctionPotential Failure

Mode Potential Effects of

Failure Severity

Potential Cause(s) of Failure

Current Design Controls Prevention

In correct connection during assembly

6Power Check after

Assembly 4

Mem

bran

e U

nit P

roce

ssC

artr

idge

Fil

ter

Uni

t Pro

cess

es

Provide Treatment for a wide variety of

contaminants Membrane Filter

Str

uctu

ral F

ram

e E

lect

rica

l C

onne

ctio

ns

No electircal signal transmitted

Pip

ewor

k

Pipelines

Tearing of Vessel WallConsiderable Leakage

of Water

Encapsule Membrane Filters

Membrane Filter Housing

Square Sections Provide support to system elements

Rivets

Convey Flow from one water treatment stage

to another

Wat

er T

reat

men

t Uni

t Pro

cess

ess

Wat

er T

reat

men

t Uni

t Pro

cess

ess

Failure Modes and Effects Analysis

34

Computer Aided Design Drawings

35

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCTP

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SIZE

Lawrence Farrugia

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TITLE

Membranne Filter Module

10/04/2011

24/03/2011

1:8

1197,79

1143,00

900,00

240,00

240,

00

82,00

63,5

0

160,00

Permeate

Feed

Concentrate

Water Sampling Valve

Horizontal Support (1)


Vertical Support

36

A ( 0.40 : 1 )



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Membranne Filter Module

10/04/2011

24/03/2011

1:5

A

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TITLE

Ultra Violet Filter Module

10/04/2011

24/03/2011

1:6

350,52

560,00

722,02

240,

00

88

,90

Water In

Water Out


Short Horizontal

Support

Long Horizontal Support

Short Vertical Support

38

B ( 1 : 2 )



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Ultra Violet Filter Module

10/04/2011

24/03/2011

1:4

B

39



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TITLE

Cartirdge Filter Module

10/04/2011

24/03/2011

1:6

240,00

222,00

306,28

Vertical Support

Horizontal Support


435,

37

360,

00

40



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Cartirdge Filter Module

10/04/2011

24/03/2011

1:4 41



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TITLE

Booster Pump Module CME 1-6

10/04/2011

24/03/2011

1:6

377,00

371,

7421

0,00 41

7,00

Water In

Water Out

141,

00

340,00

Booster Pump




Vertical Support

Integrated Pump Controller

42



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Booster Pump Module CME 1-6

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TITLE

Submersible Pump Module SP 1A-9

10/04/2011

24/03/2011

1:6

160,00

120,

00

101,

00

191,

00

480,00

Water Inlet Water Out



Vertical Support

900,00

44



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TITLE


10/04/2011

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10/04/2011

24/03/2011

1:5

360,

00

140,

00

100,

84240,00

116,00 44,00

80,00

203,00

21,0

0

Horizontal Support

Vertical Support

46

D ( 1 : 2 )

C ( 1 : 2 )



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10/04/2011

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1:4

D

C

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Pressure Relief Valve

10/04/2011

24/03/2011

1:2

57,15

92,04

154,

69

63,50

Pressure Gauge

Water OutWater In

42,1

1

45,7

2

48

E ( 1.33 : 1 )



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Pressure Relief Valve

10/04/2011

24/03/2011

2:3

E

49



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System Configuration 1

10/04/2011

24/03/2011

0.07:1

908,

24

878,761197,79

50



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TITLE


10/04/2011

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0.15:1 51



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Final Year Project Supporting Documentation

Documents