1 July 2022

CALCULATION OF CRITICALITY INDEX FOR CRITICAL EQUIPMENT

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CALCULATION OF CRITICALITY INDEX FOR CRITICAL EQUIPMENT IDENTIFICATION AS PER CLASS A, B AND C FOR PROCESS /MANUFACTURING INDUSTRY….

EQUIPMENT TOTAL CRITICALITY INDEX SCORE % CONTRIBUTION TO TOTAL CRITICALITY INDEX SCORE NO OF EQUIPMENTS INDIVIDUAL CRITICALITY INDEX RATING
Class – A 2474.5 30.80 26 >=60
Class – B 5096.93 63.45 128 22.5 to <60
Class – C 461.75 5.75 34 <22.5
Total 8033.18 100.00 188

 

Criteria for Criticality Index
Criticality index is based on following elements:
1 Effect on Generation – (G)
Effect on the element Score
No significant consequences on generation due to failure 1
Generation loss < 20% 2
Generation loss < 50% 3
Unit tripping 4
Station tripping 5
2 Effect on Environment and Safety – (E)
Effect on the element Score
No effect on Environment and Safety 1
Very minor effect 2
Failure leads to an accident or significant
impact on environment 3
3 Effect on Service Level – (S)
Effect on the element Score
Failure will not affect the work of succeeding equipment 0
Failure will affect the work of succeeding equipment 1
4 Effect on Efficiency & Aux Power (A)
Effect on the element Score
No effect on Efficiency & Aux Power 0
Very minor effect 0.5
Failure leads to a major effect on Efficiency & Aux P 1
5 Redundancy Factor (RF)
Effect on the element Score
If there is no standby unit for the failed equipment 1
If the number of standby unit is 1 0.5
If the number of standby unit is 2 0.33
Criticality Score = (G+E+S+A) X RF
Where:
G  =  Effect on Generation
E  =  Effect on Environment and Safety
S  =  Effect on Service Level
A  =  Effect on Efficiency & Aux Power
RF  =  Redundancy Factor
1 Frequency of Failure- (FF)
Effect on the element Score
Once per year or rare 1
Twice in a year or once per six months 2
Four times in a year or once in ¾ months 3
Frequent failures or more than 4 failures in a year 4
2 Average Down Time- (ADT)
Effect on the element Score
If Down Times is 0 to ½ Day 1
If Down Times is 1/2 to 1 Days 2
If Down Times is 1 to 3 Days 3
If Down Times is 3 to 7 Days 4
If Down Times is more than 7 Days 5
3 Spare Parts Cost – (SPC)
Effect on the element Score
Cost of spares up to Rs 25,000/- 1
Cost of spares from   Rs 25,000/- to 50,000/- 2
Cost of spares from   Rs 50,000/- to 1,00,000/- 3
Cost of spares from Rs 1,00,000/- to 5,00,000/- 4
Cost of spares from Rs 5,00,000/- to 10,00,000/- 5
Cost of spares from Rs 10,00,000/- to 50,00,000/- 6
Cost of spares from Rs 1,00,00,000/- to 5,00,00,000/- 7
Cost of spares above Rs 5,00,00,000/- 8
4 Man Power Cost   (MPC)
Effect on the element Score
If Cost of Man Power to attend the
failure is Rs 10,000/- or less 1
If Cost is form Rs 10,000/- to 1,00,000/- 2
If Cost is above Rs 1,00,000/- 3
Priority Score = (FF x SPC) + (ADT x MPC)
where
FF  = Frequency of Failure
SPC  = Spare Part Cost
ADT  = Average Down Time
MPC  = Man Power Cost

 

 

 

 

 

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