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Redundancy and system availability

Enter each unit’s MTBF and MTTR, the current and proposed arrangements and the downtime cost to see system availability, downtime hours per year and the payback of installing a standby unit.

Pre-sizing and estimating tool: results do not replace design, calculations or reports signed by a licensed professional, nor verification against the applicable codes and standards.

Preliminary estimate
Unit (pump, compressor, fan)

Include waiting for parts and labor in the MTTR: it is the real time the unit is unavailable.

Arrangements
Costs
Economic analysis
—Downtime hours per year, proposed arrangement
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Expected downtime by arrangement

Hours per year with the system down, on a log scale, for each possible arrangement.

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Effect of repair time

Downtime hours per year versus MTTR, for the current and proposed arrangements.

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Arrangement comparison

Project payback

Cash flow of the improvement: investment in year 0 and annual savings escalated at the rate entered, discounted at the MARR.

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The report gathers this page's inputs, results, equations, assumptions and references, with fields for project, engineer and revision. In the print dialog, choose Save as PDF.

Method, assumptions and references

Equations used

Unit availability: A = MTBF ÷ (MTBF + MTTR); u = 1 − A
Independent k-out-of-n: As = Σ (j = k..n) C(n, j) · Aᵢʲ · (1 − Aᵢ)ⁿ⁻ʲ
Common cause (β factor): Aᵢ = 1 − (1 − β)·u; As,total = As · (1 − β·u)
Series (n-out-of-n): As = Aⁿ; downtime hours = (1 − As) × hours per year
Annual gain = Δdowntime hours × downtime cost − Δunits × annual maintenance

Assumptions and limits

  • Identical units, running or hot standby, independent repair (one crew per unit) and perfect switchover.
  • The system stops completely when fewer than k units are available; reduced-capacity operation is not considered.
  • A cold spare can fail on demand; include that risk in the β factor or test the spare periodically.

Standards and technical documents

  • IEC 61078:2016: Reliability block diagrams
  • IEC 61703:2016: Mathematical expressions for reliability, availability, maintainability and maintenance support terms
  • IEC 61508-6:2010, anexo D: modelo do fator β para falhas de causa comum
  • IEC 60300-3-1:2003: Dependability management — Analysis techniques for dependability

U.S. regulations

  • NFPA 20: installation of stationary fire pumps, including redundancy and reliability of power supply
  • ASME BPVC Section I, PG-61: boilers over 500 ft² of heating surface need two means of feeding water

Frequently asked questions

How much does a standby pump raise availability?

With an MTBF of 2,000 h and an MTTR of 24 h, one unit is unavailable about 1.2% of the time, more than 100 h per year. With one spare and 5% common cause, the system is down only a few hours per year.

What is a common cause failure?

It is a failure that hits all units together, such as loss of the power supply or a repeated maintenance error. It limits the benefit of redundancy, so reduce it with physical and electrical separation.

Hot or cold standby?

Hot standby runs alongside and takes over instantly, but wears. Cold standby sits idle and preserved, but can fail to start. Test the cold spare periodically and rotate units.