Failure Mode & Effects Analysis for Water and Wastewater Equipment

influent loading variability from storm events and I&I means equipment operates across a wide range of conditions; many assets are submerged or in confined spaces. In this environment, equipment failures cause permit exceedances, boil-water advisories, sanitary sewer overflows (SSOs), and consent decree violations. Our systematic FMEA and criticality analysis program specifically targets raw water intake pumps, aeration blowers, clarifier drives, sludge pumps, UV disinfection systems, and lift station pumps — the assets where early detection has the greatest impact on NPDES permit compliance rate and energy cost per million gallons treated. We also account for variable loading patterns driven by weather events and seasonal demand cycles, adapting our measurement approach to maintain data quality despite these operating conditions.

Yes. Water & Wastewater facilities must comply with EPA Clean Water Act, Safe Drinking Water Act, state NPDES permits, and AWWA standards. Our systematic FMEA and criticality analysis program generates the condition documentation needed for epa discharge permit compliance documentation; sso reporting and prevention program records. Beyond compliance, the condition data drives measurable improvements in NPDES permit compliance rate and energy cost per million gallons treated by converting unplanned failures into scheduled repairs. Most water & wastewater clients see meaningful reductions in permit exceedances within the first 12 months of program implementation.

Baseline is analysis on new assets and after major modifications. Water & Wastewater environments often justify tighter intervals on a subset of assets — specifically those most exposed to pump cavitation, blower bearing failure, corrosion-driven failures. The FMEA program scope at most Water & Wastewater sites we work with covers 30 to 80 critical assets in detail, with broader screening on the supporting equipment. Cost works out to $2K-$8K per major asset analysis for the detailed assets.

Run the math against $2K-$15K/hour for treatment train for downtime cost. A single avoided unplanned shutdown on a critical asset usually pays for six to twelve months of program cost. Most Water & Wastewater sites we work with see 3:1 to 6:1 program ROI inside year one, with higher figures at sites with higher hourly downtime costs. Sites with very high downtime costs ($100K/hr+ in some Water & Wastewater operations) can see 10:1 or better.