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Life Cycle Cost Analysis

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#1 Pingue2008


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Posted 11 March 2019 - 11:19 AM

Good morning fellow engineers and other in the industry,

I have recently accepted a position of a project manager. And this is the first time I am filling such role. I am currently working on a fairly large project. I am preparing to buy a scrubber to scrub acrylates from my process. we make rubber. I am trying to do a life cycle cost / cost analysis for the project. I have not done such analysis before. I feel very confident about most of my estimates except " Maintenance cost" and "downtime cost".

In this areas I am clueless. I searched online but could not find anything convincing. Then it dawned on me that there is a powerful forum which I used to be active on. I just decided the pose my problem here. if you have done such analysis before please share your knowledge. Or any guidance will be appreciated and this is my first project and I am a bit unease of underestimate. the other costs was a matter of collecting them from different venders/suppliers.


Process units

1- Two (2) packed columns

2- Two (2) recirculation pumps (Mag drive)

3- One (1) air pump to pump spent solution to waste treatment

4- Fifteen (15) horsepower blower

4- Level transmitters, pH transmitter, flow transmitters , a few digital actuated valves. etc..


Thank you,

#2 Dazzler


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Posted 23 March 2019 - 12:39 AM

Hello Pingue,


Some factors here for you to think about in your assessment of maintenance:

  • Maintenance effecting production output. Major maintenance normally needs machine off or open.
  • Maintenance not effecting production output.
  • Cost of parts needed for routine maintenance and calibrations and for major maintenance
  • Cost of labour needed for installing the parts above
  • Risk of equipment major failure or equipment replacement
  • If you have "duty/ standy" pumps are they configured for fast automatic switch over to minimise production disruption.


Some people may simplify the assessment, for example by considering the average annual maintence cost (parts and labour) to be a small percentage of the purchased capital cost, and that % differing depending on the type of equipment complexity (ie rotating machinery needing more TLC than a simple static vessel, and differing based on the quality of what you buy.  


Try and discuss the maintenance costs and strategy with the facility Maintenance and Reliability Manager for some insights or rules of thumb.



Edited by Dazzler, 23 March 2019 - 12:41 AM.

#3 Pingue2008


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Posted 26 March 2019 - 07:52 AM

Thank you Dazzler for you insights.

#4 Zauberberg


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Posted 27 March 2019 - 01:11 AM

Have a look at these:





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