• Asset Criticality Analysis

  • Our Introduction

    AMCO Integrity Pty. Ltd is an independent company registered in Australia. It is a highly innovative engineering and consulting company engaged in state of the art R&D and product development in the energy sector, including renewable and small scale energies, and in high temperature plant issues in general…

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  • EDSE Technology

    The Electric Discharge Sampling Equipment (EDSE) was developed by our UK based partner in collaboration with international partners to aid in the condition and life assessment of components. The sampling of in-service components has long been seen as an effective way of determining actual material properties and sub-surface material
    condition.…

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  • Portable SFM Technology

    The Portable Scanning Force Microscope (Integrity-Scanning Force Microscope) has been developed for early stage damage detection such as creep cavitation (especially in P91 & P92 steels) which will not be found using traditional replication techniques.…

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  • Obikou

    Obikou is an on-site service for power, process and other high temperature plant and has shown to achieve creep life extension by a factor of about 4. It simply involves quickly reinforcing a potentially vulnerable or creep damaged pipe with multiple layers of thin high-temperature alloys strip that is wound/wrapped around a pipe thus halting/ reducing the development of creep damage….

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    AMCO has excellent expertise through its in-house R&D, plant service/technical
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Asset Criticality Analysis is a process by which assets are assigned a criticality rating based on their potential risk. Asset dependent organizations need to be continually educated and diligent about the importance of classifying assets in terms of the impact of asset failure on the organization. The aim is to identify the consequence and likelihood of failure of an asset to perform its function. The results of the asset critically analysis can be used to develop an appropriate and cost effective maintenance strategy to manage organisational risk.

What is Asset Criticality Ranking?
The asset criticality ranking, is the combination of three important elements:

Consequences: The consequence of failure (including the impact on production, safety, environment, and quality, and the replacement/repair cost)
Reliability: The reliability of the asset (the likelihood that it will develop a fault condition that would lead to functional failure such that we would experience those consequences)
Detectability: The detectability of the fault condition (how likely it is that we will detect the onset of failure and thus avoid those consequences)

At one extreme we could have an asset that is unreliable, with no means of detecting imminent failure, with dire consequences if failure occurs. That asset poses a serious risk. That asset will achieve a high asset criticality ranking. At the other extreme, if the consequence of failure is very low, and the reliability is high, and we will be warned when failure is imminent, then it poses almost no risk and there is no point in taking any preventative action. We can probably let that asset run to fail.

Therefore, rather than having a criticality ranking scheme that simply declares that an asset is critical, essential, or nonessential (or some other categorization), it is important to develop a numerical scoring system that enables you to make important decisions.

Ranking the Consequence of Failure

You would then define five levels of severity in each of those areas. For example, for maintenance the five levels could be:

Insignificant: Minimal damage to equipment. No effect on other equipment. Spare held on site.
Minor: Moderate damage to equipment. Minimal damage to other equipment. Spare held in region.
Moderate: Major damage to equipment. Damage to other equipment. Spare available in less than one day.
Major: Destruction of equipment. Major damage to other equipment. Spare held in state but available in more than one day.
Extreme: Destruction of equipment. Destruction of other equipment. Spare not held in state.

When assessing the failure risks to determine equipment criticality, there are four key tips for achieving a robust, but streamlined process.

  • Realise that risk relates to events – not equipment
  • Select only one event – the event
  • Assess only one risk dimension – the one with the highest level of risk
  • Start at the top of the equipment hierarchy and work down

  • Identify the inventory of assets.
  • Assign a Probability of Failure (PoF) to each asset based on knowledge of the consumed life along a survivor curve or degradation curve.
  • Assign a Consequence of Failure (CoF) ranking to each asset based on knowledge of the significance of the failure effects.
  • Assign any weightings to reflect the owners operating standards.
  • Rank all the assets based on their criticality index (PoF x CoF x weighting).
  • Map all the assets onto a criticality matrix.
  • Identify the critical assets and the non-critical assets
  • Determine the intervention practices to manage the risk through an appropriate maintenance mix – time-based maintenance (TbM) and condition-based maintenance (CbM).
  • Criticality ranking factors that reflect the business drivers of the organization
  • Reports and export options that quickly and clearly illustrate answer distributions and criticality rankings, both individual and overall
  • Group consensus on the relative criticality ranking for all systems and machines
  • Support and justification for work management decisions going forward