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COST BENEFIT ANALYSIS            
             
PLANT OR LOAD FUNCTION:   Transformer (T3) Supply of electricity to the Resin Plant        
             
COST OF PLANT DOWNTIME            
             
No of production days / annum     320      
Cost of product / ton     15000      
Production rate / ton     40      
    Total R21,917.81 p/hr    
             
PREDOMINANT FAILURE MECHANISM:     Failure of TC switch contacts      
Failure effects:            
a) Plant shutdown            
b) Damage to equipment            
c) Loss of product (raw material)            
d) Operations staff – idle            
             
             
MEAN TIME BETWEEN FAILURE WITHOUT MAINT:     8 years    
             
PRICE OF NON CONFORMANCE            
             
Cost of failure:            
Description   Qty Unit Cost / Unit Total  
Plant shutdown   8 hr R 21,918 R 175,342  
Operations staff standing time   0 hr R 0 R 0  
Damage to equipment   0   R 0 R 0  
Isolate and disconnect transformer   2 hr R 80 R 160  
Rigging to remove transformer   0 hr R 300 R 0  
Repairs by service company   1 pc R 60,000 R 60,000  
Rigging to replace transformer   0 hr R 300 R 0  
Connect and energise transformer   3 hr R 80 R 240  
          R 235,742  
PRICE OF CONFORMANCE            
             
Description   Qty Unit Cost / Unit Total  
Tasks:            
Oil Analysis A 1 serv 353 R 353  
Check General condition of transformer K 6 hr 80 R 480  
Painting K 0.2 serv 1200 R 240  
Oil Purification M 0.25 serv 4000 R 1,000  
K=Keep A=Add: M=Modify: D=Delete         R 2,073  
             
MEANTIME BETWEEN FAILURE WITH MAINTENANCE:     30 years    
             
ANALYSIS            
             
Annual cost without PM   R29,467.81 (Total PONC / MTBF wo PM)      
             
Annual cost with PM   R9,931.08 (Total PONC /MTBF w PM) + Annual      
      (POC)      
Annual saving   R19,536.73 Approved: Y