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Anticipating asset problems through failure analysis![]() *Statistical modelling can be used to forestall network asset failures in the most financially efficient way possible, says Tim Watson.* It might be thought that using statistical models to predict the number of fish in the ocean or holes in roads is a far cry from predicting when a pipe might fail in the Scottish Highlands, but the beauty of data and statistics is that they do not know, or care, whether the subject is a fish, road or pipe: the same techniques can be applied to all. The problem common to all such work is trying to manage resources in the most efficient and sustainable way. To do this you need some kind of statistical model of the resource, or asset, to help develop management and investment strategies. Once a statistical model is built, it can be used to predict the future state of a resource given a particular management strategy. This is called scenario building, and it allows you to assess the effects that decisions may have now and in the future. Alternatively, a statistical model can be used to determine the optimal strategy given a set of constraints. To work properly, the model must be robust and applicable to a range of uses in a repeatable and transparent manner. Then quality and unbiased data must be obtained to fit the model. Failure to achieve either of these will result in inefficient investment and management decisions, possibly with disastrous results - the decline of the Atlantic cod fishery is a classic example. *Infrastructure Risk Management* MWH such statistical models to develop infrastructure risk management (IRM), a decision support system and framework for Scottish Water for the management of every individual sewer and water pipe in Scotland. This involved using pipe-level statistical models to determine optimal investment requirements given specified levels of serviceability and budget. The project was divided into four areas: data collection and processing; estimation of failure probabilities; quantification of the consequences of failure; and optimisation of benefits and costs. Data was a problem because many asset records were incomplete. Several statistically-based "imputation" techniques were used to overcome this - for example, statistical models were used to impute a missing age of a pipe based on other known attributes, such as the age of surrounding properties and the material type itself. *Every pipe in Scotland* Once we had an unbiased data set, failure models were built and tested to provide the expected failure rates of every pipe in Scotland, now and in the future. The expected failure rate of a pipe after intervention - for example, replacement, cleaning or relining - was also predicted and an associated cost assigned to each action. The consequence of pipe failure was measured in both monetary and non-monetary terms (reactive costs, number of events, water quality, flooding, environmental, loss of service, customers affected, type of customer, reputation and so on). The key to calculating the consequence of failure is the direct link, spatial and temporal, between cause and effect. For example, a key performance indicator for the water supply network is the number of customers who experience an unplanned outage. To calculate this, the network is traced to determine the number of customers that would be isolated if a pipe burst. These consequences were also judged against the "overall performance assessment" framework, which monitors the performance water companies provide to their customers. *Cost/benefit analysis* By benchmarking and quantifying the effect of an intervention, probability, cost, and consequence, against a do-nothing strategy, we determined the most cost beneficial strategy, under certain constraints. Of particular interest was the calculation of the minimal investment required to achieve yearly serviceability targets. For example, what is the investment needed to reduce bursts by 20 per cent over five years? Multiple constraints were also considered and resulted in considerable synergies between programmes. Overall, IRM provided a defensible calculation of the sum of investment required to achieve fixed serviceability levels. At the same time, the method earmarked the specific pipe assets needing intervention during each year of the investment period and beyond. From the water company's point of view, the method provided confidence that the major sums of money being spent on capital maintenance were being spent in the best possible way. Tim Watson is senior principal consultant with MWH Business Solutions. For more information, visit the Water Statistics User Group *The next big thing? Life cycle failure analysis* *By Rohit Banerji, business consultant, Tata Consultancy Services>* Infrastructure assets can be very long lived. Sewers, for instance, can survive for more than two centuries. Gas pipelines can last for 30 years. Planning horizons extending over decades are necessary but need the support of fancy analysis. After all, it is not easy to trace the impact of every asset's performance on that of the network, and by extension on corporate performance. For more than six decades, a procedure known as failure modes, effects and criticality analysis (FMECA) has been used to assess the impact of failures on a system. Originally invented by Nasa, the system has been successfully used in manufacturing. It offers a method of identifying the root cause of failure by analysing the ways assets can fail, the effects on the system, and the severity and frequency with which those failures occur. Using this analysis, companies can find and rank (in order of effectiveness, ease, or whatever) options to manage the risk of failure. However, as it stands, it is unsuitable for utility requirements. It can analyse only specific problems rather than an entire asset base and does not support the whole lifecycle of an asset. Moreover, the consequences of asset failure are not shown, and cost-benefit analyses are not included. *Crystal ball-gazing* However, looking into a crystal ball for a moment, some well-guided alterations might allow FMECA to meet utilities' needs. Employees in the utilities industry analyse risk every day as part of their jobs. Were these analyses carried out in a single, integrated process, FMECA could be applied through all corporate systems. That being the case, we can envisage an enhanced version - a "lifecycle FMECA" - that would: * define the consequences of asset failure in terms of risk, thereby capturing the effects on consumers, the environment, the network and on its own future (such as the possible dangers of employing a quick fix); * map consequences to options and cost, affording economic analyses; * project future failures, allowing development of lifecycle profiles; * be automated and fully integrated with the company's corporate systems. Such lifecycle FMECA would offer mind-boggling potential for asset management. It would provide a long-term view, particularly important when the list of jobs to do is huge and the capital to cover them insufficient. It would compare lifetime trade-offs, making it easy to assess things such as which options offer more value for money, how to reach the lowest whole-lifecycle cost for the asset, and how future risk is affected by exercising any particular option at any given time, or indeed exercising none. More importantly, it could show which high risk problems are just waiting to happen. In short, and when properly-deployed, lifecycle FMECA would provide a way to balance and optimise the needs of short and long-term investment. Source: Karma Ockenden © Faversham House Group Ltd 2009. News articles may be copied or forwarded
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