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Cost category:
material costs
Cost categories
Technical structure
Cost element:
Material cost of component A in
the LCC phase operation
Deliverable D6.5.4
Contributions
Glossary
Table of Figures
1. Executive Summary
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• Reliability
• Availability • Availability Migration costs
• Maintainability • Maintainability Costs for new regulations
• … • Tolerance against
conditions Decreasing costs for
Environmental perform.
• … environmental
• Noise
Environmental perform. sustainability
• Ground born vibration
• Noise Decrease maintenance
• …
• Ground born cost
Costs (drivers) vibration Decrease costs
• Investment • … for non availability
• Operation Change in Costs …
• Maintenance • ...
• Non availability Additional income?
Frequencies of service life []
Over designed
Under designed
d
Ba
Availability []
Time [a]
Tech. optimum
Economical
optimum?
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Maintenance
Deferred Immediate
Conceptual Establishing Data Determination Formulating
Formulation the basics assessment of LCC values Recommen-
dation
LCC values
Boundary Product-Breakdown- Determination Evaluation of the (Break-Even,
Conditions Structure (PBS) of data LCC Annuity, key value)
Formulating
Definition Analyse of Sensitivity of a
Cost Matrix
NPV of the Base for
In/Out Frame CBS, PBS, Resilient LCC data
variants decision
Variants
Monitoring, Feedback
Making decision
Implementation Update of LCC data
Developing of LCC contract
Validation Ensuring the circuit of
Tender procedure
knowledge
Definition
Establishment Data RAMS (LCC) Validation, Report Monitoring,
of
of the basics asssessment analyse Output Implementation Feedback
RAMS/LCC task
Output specs preferred variants
RAMS data
analyse results
Implementation
Feedback
To Do
definition of the analyse and update and
combined validation of RAMS
specs, assessement of assessment
Variant study RAMS/LCC and LCC
requirements, data of RAMS data
analyse calculations
key values (verification)
RAMS analysis
System
necessary,feasible?
Requirements
any expecting
Specs (SRS)
benefit?
Chapter, LCC/RAMS
LCC/RAMS task
task In/Out
In/Out Frame
Frame Database
Databse
Database
Databse e.
e. g.
g. D-LCC,
D-LCC, Validation Implementation
Implementation Maintenance
Maintenance
Validation
Temp- RAMSOffice
RAMSOffice database
database
Key
Keyvalues
values
late, Chapter
Chapter4.1,
4.1, 4.2,
4.2, Chapter
Chapter4.6
4.6 –– 4.9,
4.9,
Chapter
Chapter4.3
4.3--4.5
4.5 Chapter
Chapter
Chapter 3.0,
3.0, 4.6
Chapter 4.6 Chapter
Chapter6.0
6.0 Chapter
Chapter7.1,
7.1, 7.3
7.3
Tool 4.6
4.6 5.2
5.2 -- 5.3
5.3 chapter
chapter4.10,
4.10,7.2
7.2
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Development
Construction
(Prototype)
Procurement
(incl. Disposal)
(Test)
Production LCC
Installation
Operation, Maintenance,
Operation
Non-availability
Decommissioning
see Procurement costs
Disposal
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Cost category:
material costs
From EN
From EN 60300-3-3
60300-3-3 the
the Cost categories
shown cost
shown cost matrix
matrix is
is
known.
known.
Basis:
Basis: means
means of
of production.
production.
Technical structure
Component: A
This
This view
view separates
separates the
the Life Cycle Phases Life Cycle Phase: Operation
life
life cycle phases
cycle phases
and
and thethe categories
categories Cost element:
in
in two
two dimensions
dimensions Material cost of component A in
the LCC phase operation
Cost matrix – top level
I. Procurement II. Operation III. Maintenance IV. Non Availability
I.1 Preparation - one-time II.1 Service III.1 Inspection and IV.1 Planned
II.1.2 Energy service (track) IV.1.1 Malfunctions
I.2 Preparation recurrent IV.1.2 Delays
project-specific III.2 Maintenance –preventive IV.1.3 Serviceability
I.10 Other costs II.10 Other costs III.10 Other costs IV.10 Other costs
V. Social Economics
V.1 Energy consumption V.3 Delay
V.2 Environment V.10 Other costs
1 1
C2 · C6 ·
(1+i)2 (1+i)6
Purchase
costs
...
554€
312€
1 1
C2· C6·
(1+i)2 (1+i)6
e.q.:
Current costs in
NPV i=1,08/1,02 -1 1. year 2. year 3. year 4. year 5. year 6. year
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BV 4.0 %
NR 6.5 %
ProRail 4.0 %
P ri
vat
e
Public
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Public
DB
NR
Private
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TLT − TH TH
RV = V Asset = V Asset 1 −
TLT TLT
Calculatory
residual value
t0 t40 t
TLT
Disposal costs
TLT – Technical lifetime
In/Out-frame
to clarify
Inside of the LCC calculation
Outside of calc.
I. Procurement II. Operation III. Maintenance IV. Non Availability
I.1 Preparation - one-time II.1 Service III.1 Inspection and IV.1 Planned
II.1.2 Energy service (track) IV.1.1 Malfunctions
I.2 Preparation recurrent IV.1.2 Delays
project-specific III.2 Maintenance –preventive IV.1.3 Serviceability
I.10 Other costs II.10 Other costs III.10 Other costs IV.10 Other costs
V. Social Economics
V.1 Energy consumption V.3 Delay
V.2 Environment V.10 Other costs
Parameter Reference case Innovation A
Technical Parameter 1
Technical Parameter 2
Technical Parameter 3
Technical Parameter …
Technical Parameter n
Remarks
Nom. discount rate: __ % The nominal discount rate should based on asset life
Mean inflation rate: __ % The inflation rate should be estimated from the last years
Effective rate: __ %
Time horizon __ years:
Data
Cost block structure Reference case Innovation A
Euro
Cycle
Investment Source
Quality
Euro
Cycle
Operation Source
Quality
Euro
Maintenance Cycle
Activity A Source
Quality
Euro
Maintenance Cycle
Activity B Source
Quality
Euro
Maintenance Cycle
Activity C Source
Quality
•Tender
procedure &
placing
•Developing a •Monitoring /
LCC-contract Verification
•Making a
•Formulating decision
of
recommenda
tion
•Determination
of LCC-data
End
•Processing of •Ensuring
data the circuit of
knowledge
•Establishing the
basics •Conceptual
formulation
Start
1
• Investment - material
• Life time
High
• Long-term behaviour
Influence on LCC
• Investment - installation
• Quality • Maintenance
• Time to market
Low
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0
Development,
manufacturing Operation
installation
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Innovation
Reference
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4 10 14
System System Integration & Decommissioning &
Requirements Acceptance Disposal
5 9
Apportionment of
System Validation
System
system Requirements
requirements
Project 6 8
Definition Design & Project Test and
Installation
Implementation Integration
7
Manufacturing
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Control loop of Reliability Management:
Description of object
Definition of Modelling
Definition of event
the targets
Description of environment Amount
Allocation of data,
Homogeneity
Quality of data Plausibility
Consistency
Analysis, Prediction
and Optimisation
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Definition of specifications regarding operation and maintenance quality
Description of quality specifications through RAMS values Technical
specifications
R A M S
Reliability Availability Maintainability Safety
Operation &
Maintenance
LCC
Cost / Benefit
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Conceptual phase Engineering phase Realisation phase Operational phase
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Tα
MTBF =
λ
αλ
Χ
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2A Varianten 2B Preferred
Analyse 1 Investigation Variant Study 3 Realisation
Study
RA
S question
RAMS
LCC input New Infra output
phase 1 / 2A / 2B / 3
RAMS / LCC
method
Social Cost and
Benefit analyses
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1
Costs of Corrective Maintenance as part of the life cycle costs relate not only to the disrup-
tions caused by timetable affecting errors, but also to the errors that do not directly affect the
train service.
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R LCC
M
+
A
# trains
Cost for # passengers
Value of Time
unavailability
S
+
Σ (€)
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2
The list of tools shows only a small extract of possible tools
Cost Breakdown Structure
Cost Breakdown Structure
1 LCC
1.1 INVESTMENT
1.1.1 Investment (Renewal)
1.1.1.1 Ballast
1.1.1.2 Sleeper incl. Fastening/ Freight
1.1.1.3 USP/ UBP
Product Tree 1.1.1.4 Rail incl. Freight
Product Tree
1.1.1.5 Substructure Measure
1 TRACK 1.1.1.6 Installation
1.1 Rail 1.1.2 Rail Renewal
1.1.3 Disposal
1.1.1 UIC 60
1.1.3.1 Residual Value
1.2 Rail Pad ZW700
1.1.3.2 Recycling
1.3 Sleeper 1.2 MAINTENANCE
1.3.1 B 70 W 1.2.1 Inspection Vehicle
1.4 Under Sleeper Pad 1.2.2 Visual Inspection
1.5 Ballast 1.2.3 Day-To-Day Track Maintenance
1.6 Subsoil 1.2.4 Ballast Tamping
1.2.5 Rail Grinding
1.2.6 Control of the Vegetation
1.2.7 Change ZW/ZWP
1.3 NON-AVAILABILITY
1.3.1 Planned
1.3.1.1 Day-To-Day Track Maintenance
1.3.1.2 Ballast Tamping
1.3.1.3 Rail Grinding
1.3.1.4 Rail Relying
1.3.1.5 Track Stoppage Reinvestment
1.3.2 Not-Planned
1.3.2.1 Track Stoppage
1.3.2.2 Speed Restriction
6. Compilation of results
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Asset management
Innovations
Maintenance
Track/network
Optimisation
Investment Innovation
strategies
management
Actual & further and
requirements Assessment and
Organisation implementation
risk management
Annex I Examples
function
Number Average func- Average
Performance level crossing: timetable af- repair
of er- tion repair number of
fecting errors time
rors time [hour] errors
[hour]
For underpasses in comparable situations (12 found) no timetable affecting errors are regis-
tered in the last 3 years. For non-timetable affecting errors no reliable data was found.
Based on every hour four passenger trains and one freight train per direction this leads to
delay and cancellation of trains. Knowing it is not correct we simplified the model by assuming
for this study that a timetable affecting error only leads to cancellation of trains.
All Level
Comparable
crossings Comparable
Performance data Level cross-
average Tunnel
ing
Netherlands
Number of hours not available (due to errors) 0.535 1.496 0
Number of cancelled passenger trains 4.280 11.964 0
Number of delayed freight trains 0.535 1.496 0
Safety:
Like performance also safety on a level crossing near a station has its own specific key fig-
ures. We searched for safety figures for comparable level crossings, see next table:
Seriously Slightly
Deaths /
Safety data injured / injured /
year
year year
Cost data:
For the two variants the cost data is shown in the next table:
Based on the performance, safety and cost data it is possible to make a complete RAMS /
LCC analyses using the methodology shown in this guideline.
LCC:
Next table shows the LCC costs using Net Present Value (interest + inflation = 4 %),:
Level
LCC Tunnel
crossing
Including all the social cost – benefits the total costs during the lifetime using Net Present
Value (interest + inflation = 4 %) are:
Level
LCC + social cost – benefits Tunnel
crossing
So based on all these data the decision for a variant can be made. But be aware that RAMS /
LCC is not the only parameter the project managers uses to choose for a variant!
Boundary conditions
Load
- Track category
LCC Model
Wear (vertical)
- Rail type
- Steel grade
- Radius class
Load
- Actual Load [MGT/a]
Process parameters
wear (side)
700
600
500
NPV [€/Tm]
400 R260
300 R350HT
200
100
0
10 20 30 40 50 60 70 80 100
Load [MGT]
relevant for
to clarify
Inside of the LCC calculation
R 260 Cost for Same grinding
Regulations of
and investment and performance for
each country
R350HT non-availability HT grade
Maintenance –
Interactions with Grinding Wear and RCF
fault clearance
other SPs
Mixed traffic
Load dependent Reference to
Radius 700–
maintenance test sites and
1500 m
costs experiments
20-30 MGT/a
Outside of
calculation Same grinding
welding quality
performance for
and costs
HT grade?
Used cost elements
I. Procurement II. Operation III. Maintenance IV. Non Availability
I.1 Preparation - one-time II.1 Service III.1 Inspection and IV.1 Planned
II.1.2 Energy service (track) IV.1.1 Malfunctions
I.2 Preparation recurrent IV.1.2 Delays
project-specific III.2 Maintenance –preventive IV.1.3 Serviceability
I.10 Other costs II.10 Other costs III.10 Other costs IV.10 Other costs
V. Social Economics
V.1 Energy consumption V.3 Delay
V.2 Environment V.10 Other costs
Discount rate: 8%
Inflation rate: 2%
Effective rate : 5.8 %
LCC What change in life What life cycle What life cycle What life cycle
cycle costs is asso- costs are asso- costs are associ- costs are ex-
ciated with the im- ciated with the ated with the dif- pected after im-
plementation of the different vari- ferent options? plementation?
function change? ants?
RAMS / What reliability, What level of What option has What technical
LCC availability and reliability, avail- the highest level of solution pro-
safety can be ability and reliability, availabil- vides the high-
achieved at what safety can be ity and safety at est level of
life cycle costs? achieved per the lowest life cy- reliability, avail-
variant at what cle costs? ability and
life cycle costs? safety at the
lowest life cycle
costs?
Social What expected What expected What expected What costs and
cost – costs and benefits costs and bene- costs and benefits benefits are ex-
benefit relate to the func- fits relate to relate to every op- pected after the
analysis tion change? every variant? tion? implementation?
RAMS / What RAMS re- What RAMS What RAMS re- What RAMS
LCC quirements can we requirements quirements can we performance is
specifica- specify, and at what can we specify specify and at expected in the
tion maximum life costs and at what what maximum life operational
should it be possi- maximum life cycle costs should phase and what
ble to implement cycle costs it be possible to are the maxi-
the function should it be achieve the infra mum life cycle
change? possible to im- change? costs for the
plement the in- selected techni-
fra change? cal solution?