Padasale, B.Kulkarni, G.S.Rakshan Kumar, J.K.Cadambi, S.Hegde, S.R.2026-02-042022Engineering Failure Analysis, 2022, 142, , pp. -13506307https://doi.org/10.1016/j.engfailanal.2022.106766https://idr.nitk.ac.in/handle/123456789/22288This work presents failure investigation of a fire water jockey pump shaft that is installed in the fire-station of a petrochemical plant. The jockey pump is driven by a 130 kW motor at about 1480 RPM whose shaft and the coupling key are made of 40C8 steel and 55C8 steel respectively. The drive-shaft of one of the pumps fractured after running for approximately 110 h, while its twin remained functional. The failure analysis involves visual inspection, hardness measurements, metallography, fractography, analytical design calculations, and numerical stress analysis. The analysis concludes that usage of square-ended key in the round-ended keyway is the primary cause, and usage of dissimilar materials for the shaft and the key is the secondary cause for the premature failure. The present work recommends a modified key design and use of the same grade of steel for both the shaft and the key to avoid such failures in the future. © 2022 Elsevier LtdDissimilar materialsFailure (mechanical)Fire extinguishersFracture mechanicsPetrochemical plantsPumpsStress analysisDesign of shaftFailure investigationFire fightingFire fighting pumpFire stationHardness measurementJockey pumpsPump shaftsShaftVisual inspectionFailure analysis