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Equpment Functional Criticality Index

This document describes a Criticality Index method for assessing the criticality of equipment based on the impact of breakdowns. The Criticality Index is calculated using a Criticality Score and Priority Score. The Criticality Score considers factors like the effect on generation, efficiency, safety, and environment. The Priority Score factors in maintenance costs like failure frequency, downtime, spare parts costs, and manpower costs. Equipment is classified into A, B, or C classes based on their contribution to the total Criticality Index. Resources are focused on improving A-class equipment first to reduce the overall Criticality Index and reliability. This process is repeated to continuously improve performance.

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Ranjit Rjt
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286 views18 pages

Equpment Functional Criticality Index

This document describes a Criticality Index method for assessing the criticality of equipment based on the impact of breakdowns. The Criticality Index is calculated using a Criticality Score and Priority Score. The Criticality Score considers factors like the effect on generation, efficiency, safety, and environment. The Priority Score factors in maintenance costs like failure frequency, downtime, spare parts costs, and manpower costs. Equipment is classified into A, B, or C classes based on their contribution to the total Criticality Index. Resources are focused on improving A-class equipment first to reduce the overall Criticality Index and reliability. This process is repeated to continuously improve performance.

Uploaded by

Ranjit Rjt
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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EQUPMENT FUNCTIONAL

CRITICALITY INDEX
FOR ASSESSING CRITICALITY BASED
ON THE EFFECT OF BREAKDOWN OF
EQUIPMENT TO IMPROVE
RELIABILITY

CRITICALITY & PRIORITY


CRITICALITY INDEX IS DEPENDENT ON
CRITICALITY SCORE & PRIORITY SCORES.
CRITCALITY SCORE IS BASED UPON
EQUPMENTFAILURE CONSEQUENCES ON
GENERATION,AUX.POWERCONSUMPTN.,
EFFICENCY, SAFETY & ENVIRONMENT,
EFFECT ON OTHER EQUIPMENT AND
REDUNDANCY

CRITICALITY & PRIORITY


PRIORITY SCORE IS DEPENDENT ON
FREQUENCY OF FAILURE,AVERAGE
DOWNTIME,COST OF SPARES AND MAN
POWER COST.
CRITICALITY SCORE GIVES
IMPORTANCE TO GENERATION COST
PRIORITY SCORE EMPHASISES ON
MAINT. COST

CRITICALITY SCORE
1)EFFECT ON GENERATION(G)
FAILURE HAS NO EFFECT ON
GENERATION
GENERATION LOSS <20%
GENERATION LOSS 20% 50%
UNIT TRIPS
STATION TRIPS

1
2
3
4
5

CRITICALITY SCORE(CONTD)
2) EFFECT ON EFFCY.& AUX. POWR.(A)
NO EFFECT
MINOR EFFECT
MAJOR EFFECT

0
0.5
1

CRITICALITY SCORE(CONTD)
3) REDUNDANCY FACTOR (RF)
NO STAND BY FOR EQUIPT1
ONE STAND BY EQUPMT.

0.5

TWO STAND BY EQUIPMTS.

0.33

CRITICALITY SCORE(CONTD)
4)EFFECT OF FAILURE ON ASSOCIATED
OR RELATED / OTHER EQUIPT.(S)
NO EFFECT ON
OTHER EQUIPTS

FAILURE EFFECTS
OTHER EQUIPTS

CRITICALITY SCORE(CONTD)
5) EFFECT ON SAFETY& ENVIRONMENT (E)
NO EFFECT

MINOR EFFECT

LEADS TO ACCIDENT OR
HAS SIGNIFICANT IMPACT
ON ENVIRONMENT

CRITICALITY SCORE(CONTD)
AFTER ASSIGNING THE ABOVE
FACTORS CRITICALITY SCORE IS
CALCULATED BY THE FORMULA
CRITICALITY SCORE =(G+A+S+E) x RF

PRIORITY SCORE
1)FREQUENCY OF FAILURE (FF)
ONCE A YEAR OR LESS

TWICE A YEAR

FOUR TIMES A YEAR

MORE THAN 4 TIMES A YEAR

PRIORITY SCORE(CONTD)
2)AVERAGE DOWN TIME(ADT)

DOWN TIME 0 - DAY


1
DOWN TIME - 1 DAY
2
DOWN TIME 1 3 DAYS
3
DOWN TIME 3 7 DAYS
4
DOWN TIME MORE THAN A WEEK

PRIORITY SCORE(CONTD)
Spares cost (SPC)

spares Cost up to 25,000/spares Cost 25,000/-to 50,000/spares Cost 50,000/- to 1 lac


spares Cost 1 lac to 5lacs
spares Cost 5 lacs to 10lacs
spares Cost 10 lacs to 50lacs
spares Cost above 50lacs

1
2
3
4
5
6
7

PRIORITY SCORE(CONTD)
MANPOWER COST (MPC)
MANPOWER COST <10,000/-

MANPOWER COST 10,000 to 1 LAC

MANPOWER COST >1 LAC

PRIORITY SCORE(CONTD)
SIMILAR TO CRITICALITY SCORE THE
PRIORITY SCORE IS CALCULATED BY THE
FORMULA
PRIORITY SCORE = (FF x SPC) + (ADT x MPC)

CRITICALITY INDEX
CRITICALITY INDEX (CI) IS A PRODUCT OF
CRITICALITY & PRIORITY SCORES

CI = CRITICALITY SCORE x PRIORITY


SCORE

AFTER CALCULATING THE CI OF ALL


EQUIPMTS THEY ARE SORTED IN
DECENDING ORDER OF CI & CI TOTAL OF
ALL EQUIPMENTS IS OBTAINED &
EQUPMENT IS CLASSIFIED AS BELOW.
ACLASS EQUIPTS. WHICH CONTRIBUTE
OF CI TOTAL
BCLASS EQUIPTS. WHICH CONTRIBUTE
1/3 OF CI TOTAL
CCLASS EQUIPTS. WHICH CONTRIBUTE
TO REST OF CI TOTAL

A CLASS EQUPMENT ARE ASSIGNED ALL


THE RESOURCES TO IMPROVE THEIR
PERFORMANCE AND RELIABILITY
WHICH RESULTS IN REDUCTION OF
THEIR INDIVIDUAL CI . WHICH IN TURN
REDUCES THE TOTAL CI. NOW THE
TOTAL EXERCISE IS STARTED AFRESH TO
IDENTIFY DIFFERENT EQUIPMENTS
WHICH MIGHT HAVE BEEN B/ C CLASS
EARLIER.THIS CYCLE GOES ON AND ON
TO IMPROVE THE PERFORMENCE.

BENEFITS REAPED
MAINT. RESOURSES ARE OPTIMISED
IMPROVED OVERALL PERFORMANCE
REVIEW / REVISION OF O&M PRACTICES
EMPHASIS ON EARLY DETECTION
OF DEFECTS

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