Difference between revisions of "Service Life Extension"

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Sukamto, S. 2003. “Plant aging and life extention program at Arun LNG Plant Lhokseumawe, North Aceh, Indonesia.” Paper presented at 22nd Annual World Gas Conference, June 1-5, Tokyo, Japan.
 
Sukamto, S. 2003. “Plant aging and life extention program at Arun LNG Plant Lhokseumawe, North Aceh, Indonesia.” Paper presented at 22nd Annual World Gas Conference, June 1-5, Tokyo, Japan.
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<center>[[Product and Service Life Extension|<- Previous Article]] | [[Product and Service Life Extension|Parent Article]] | [[Capability Updates, Upgrades, and Modernization|Next Article ->]]</center>
  
 
==Signatures==
 
==Signatures==
 
--[[User:Jgercken|Jgercken]] 03:01, 12 September 2011 (UTC)
 
--[[User:Jgercken|Jgercken]] 03:01, 12 September 2011 (UTC)
 
[[Category: Part 3]][[Category:Topic]]
 
[[Category: Part 3]][[Category:Topic]]

Revision as of 19:16, 13 September 2011

Product and service life extension involves continued use of a product and/or service beyond its original design life . Product and service life extension involves assessing the risks and the life cycle cost (lcc) of continuing the use of the product or service versus the cost of a replacement system.

service life extension (sle) emphasizes reliability upgrades and component replacement or rebuilding of the system to delay the system’s entry into wear-out status due to prohibitively expensive sustainment, reliability, safety, and/or performance requirements that can no longer be met. The goal is typically to return the system to as new of a condition as possible while remaining consistent with the economic constraints of the program.

SLE is regarded as an environmentally friendly way to relieve rampant waste by prolonging the use-life of retiring products and preventing them from being discarded too early when they still have unused value. However, challenged by fast-changing technology and physical deterioration, a major concern in planning a product SLE is considering to what degree a product or service is fit to have its life extended.

Topic Overview

Key factors and questions that must be considered by the systems engineer during service life extension include:

  • Current life cycle costs of the system;
  • Design life and expected remaining useful life of the system;
  • Software maintenance;
  • Configuration Management;
  • Warranty policy;
  • Availability of parts, subsystems, and manufacturing sources; and
  • Availability of system documentation to support life extension.

System design life is a major consideration for service life extension. System design life parameters are established early on during the system design phase and include key assumptions involving safety limits and material life. Safety limits and the properties of material aging are critical to defining system life extension. Jackson emphasizes that architecting for system resiliency increases system life. He also points out that a system can be architected to withstand internal and external disruptions (2007, 91-108). Systems that age through use, such as aircraft, bridges, and nuclear power plants, require periodic inspection to ascertain the degree of aging and fatigue. The results of inspections determine the need for actions to extend the product life (Elliot, Chen, and Swanekamp 1998, sec. 6.5).

Software maintenance is a critical aspect of service life extension. The legacy system may include multiple computer resources that have been in operation for a period of many years and have functions that are essential and must not be disrupted during the upgrade or integration process. Typically, legacy systems include a computer resource or application software program that continues to be used because the cost of replacing or redesigning it is prohibitive. The Software Engineering Institute (SEI) has addressed the need for service life extension of software products and services and provides useful guidance in the on-line library for Software Product Lines (SEI 2010, 1).

Systems engineers have found that service life can be extended through the proper selection of materials. For example, transportation system elements such as highway bridges and rail systems are being designed for extended service life by using special epoxy-coated steel (Brown, Weyers, and Spinkel 2006, 13).

Diminishing manufacturing sources and diminishing suppliers need to be addressed early on in the service life extension process. Livingston (2010) in Diminishing Manufacturing Sources and Material Shortages (DMSMS) Management Practices provides a method for addressing product life extension when the sources of supply are an issue. He addresses the product life cycle model and describes a variety of methods that can be applied during system design to minimize the impact of future component obsolescence issues.

During product and service life extension, it is often necessary to revisit and challenge the assumptions behind any previous life cycle cost analysis (and constituent analyses) to evaluate their continued validity and/or applicability early in the service life extension process.

Application to Product Systems

Product life extension requires an analysis of the life cycle cost associated with continued use of the existing product versus the cost of a replacement product. In the INCOSE Systems Engineering Handbook, Chapter 3.3 points out that the support stage includes service life extension. Chapter 7 provides a framework to determine if a product’s life should be extended (INCOSE 2011). In Systems Engineering and Analysis, Chapter 17 provides a Life Cycle Cost (LCC) methodology and emphasizes the analysis of different alternatives before making a decision on product life extension (Blanchard and Fabrycky 2011).

For military systems, service life extension is considered a subset of modification or modernization. Military systems use well developed and detailed guidance for Service life extension programs (SLEP). The Office of the Under Secretary of Defense (AT&L) provides an on-line reference for policies, procedures, planning guidance, and whitepapers for military product service life extension (DAU 2011). Continuous military system modernization is a process by which state of the art technologies are inserted continuously into weapon systems to increase reliability, lower sustainment costs, and increase the war fighting capability of a military system to meet evolving customer requirements throughout an indefinite service life.

Aircraft service life can be extended by reducing the dynamic loads which lead to structural fatigue. The Boeing B-52 military aircraft and the Boeing 737 commercial aircraft are prime examples of system life extension. The B-52 was first fielded in 1955 and the Boeing 737 has been fielded since 1967; both aircraft are still in use today.

For nuclear reactors, system safety is the most important precondition for service life extension. The system safety must be maintained while extending the service life (Paks 2010). Built-in tests, automated fault reporting and prognostics, analysis of failure modes, and the detection of early signs of wear and aging may be applied to predict the time when maintenance actions will be required to extend the service life of the product.

Application to Service Systems

For systems that provide services to a larger consumer base, service life extension involves continued delivery of the service without disrupting consumer use. Service life extension involves capital investment and financial planning, as well as a phased deployment of changes. Examples of these concepts can be seen in transportation systems, water treatment facilities, energy generation and delivery systems, and the health care industry.

As new technologies are introduced, service delivery can be improved while reducing life cycle costs. Service systems have to continuously assess delivery costs based upon the use of newer technologies.

Water handling systems provide a good example of a service system that undergoes life extension. Water handling systems have been in existence since early civilization. Since water handling systems are in use as long as a site is occupied (e.g., the Roman aqueducts), and upgrades are required as the population expands, such systems are a good example of "systems that live forever." For example, there are still U.S. water systems that use a few wooden pipes since there has been no reason to replace them. Water system life extension must deal with the issue of water quality and the capacity for future users (Mays, 2000). Water quality requirements can be further understood from the AWWA Manuals of Water Supply Practices (AWWA 2010).

Application to Enterprises

Service life extension of a large enterprise, such as NASA’s national space transportation system, involves service life extension on the elements of the enterprise, such as the space vehicle (shuttle), ground processing systems for launch operations and mission control, and space-based communication systems that support space vehicle tracking and status monitoring. Service life extension of an enterprise requires a holistic look across the entire enterprise. A balanced approach is required to address the cost of operating older system components versus the cost required to implement service life improvements.

Large enterprise systems, such as oil and natural gas reservoirs, which span broad geographical areas, can use advanced technology to increase their service life. The economic extraction of oil and natural gas resources from previously established reservoirs can extend their system life. One such life extension method is to pump special liquids or gases into the reservoir to push the remaining oil or natural gas to the surface for extraction (Office of Natural Gas & Oil Technology 1999).

Other Topics

Commercial product developers have been required to retain information for extended periods of time after the last operational product or unit leaves active service (for up to twenty years). Regulatory requirements should be considered when extending service life (INCOSE 2011).

Practical Considerations

The cost associated with life extension is one of the main inputs in the decision to extend service life of a product or a service. It is often the case that the funding required for service life extension of large complex systems is spread over several fiscal planning cycles and is therefore subject to changes in attitude by the elected officials that appropriate the funding.

References

Citations

AWWA. 2010. AWWA manuals of water supply practices. In American Water Works Association (AWWA). Denver, CO, USA, accessed August 5, 2010. http://www.awwa.org/Resources/standards.cfm?ItemNumber=47829&navItemNumber=47834

Blanchard, B. S., and W. J. Fabrycky. 2011. Systems Engineering and Analysis, 5th ed. Prentice-Hall International series in Industrial and Systems Engineering. Englewood Cliffs, NJ, USA: Prentice-Hall.

Brown, M., R. Weyers, and M. Sprinkel. 2006. “Service life extension of Virginia bridge decks afforded by epoxy-coated reinforcement.” Journal of ASTM International (JAI) 3 (2): 13.

DAU. 2010. “Acquisition community connection (ACC): Where the DoD AT&L workforce meets to share knowledge.” In Defense Acquisition University (DAU)/US Department of Defense (DoD). Ft. Belvoir, VA, USA, accessed August 5, 2010. https://acc.dau.mil/.

Elliot, T., K. Chen, and R. C. Swanekamp. 1998. Standard handbook of powerplant engineering. New York, NY, USA: McGraw Hill, section 6.5.

INCOSE. 2011. Systems Engineering Handbook A Guide for System Life Cycle Processes and Activities. v3.2.1.2011. San Diego, CA, USA: International Council on Systems Engineering (INCOSE), INCOSE-TP-2003-002-03.2.1

Jackson. 2007. “A Multidisciplinary Framework for Resilience to Disasters and Disruptions.” Journal of Integrated Design and Process Science. 11 (2): PAGE NUMBERS NEEDED.

Livingston, H. 2010. GEB1: Diminishing manufacturing sources and material shortages (DMSMS) management practices. McClellan, CA, USA: Defense MicroElectronics Activity (DMEA)and U.S. Department of Defense (DoD).

Mays, L., ed. 2000. Water distribution systems handbook. New York, NY, USA: McGraw-Hill Book Company, chapter 3.

Office of Natural Gas and Oil Technology. 1999. Reservoir LIFE extension program: Encouraging production of remaining oil and gas. Washington, DC: U.S. Department of Engery (DoE),

Paks Nuclear Power Plant. 2010. “Paks nuclear power plant: Service life extension.” In Paks Nuclear Power Plant Ltd., Hungary, accessed August 5, 2010. http://paksnuclearpowerplant.com/service-life-extension.

SEI. 2010. “Software engineering institute.” In Software Engineering Institute (SEI) and Carnegie-Mellon University (CMU). Pittsburgh, PA, USA, accessed August 5, 2010. http://www.sei.cmu.edu.

Primary References

Blanchard and Fabrycky. 2006. Systems Engineering and Analysis, 4th ed. Upper Saddle River, NJ, USA: Prentice Hall International Series.

Caltrans and USDOT. 2005. Systems Engineering Guidebook for Intelligent Transportation Systems (ITS). Sacramento, CA, USA: California Department of Transportation (Caltrans) Division of Research and Innovation and U.S. Department of Defense (USDOT), SEG for ITS 1.1.

INCOSE. 2011. Systems Engineering Handbook: A Guide for System Life Cycle Processes and Activities, version 3.2.1. San Diego, CA, USA: International Council on Systems Engineering (INCOSE), INCOSE-TP-2003-002-03.2.1.

Jackson. 2007. “A Multidisciplinary Framework for Resilience to Disasters and Disruptions.” Journal of Integrated Design and Process Science, 11 (2).

OUSD(AT&L). 2010. “Logistics and Materiel Readiness. On-line policies, procedures, and planning references.” Arlington, VA, USA: Office of the Under Secretary of Defense for Aquisition, Transportation and Logistics (OUSD(AT&L)). http://www.acq.osd.mil/log.

Seacord R.C., D. Plakosh, and G.A. Lewis. 2003. Modernizing Legacy Systems. Boston, MA, USA: Pearson Education Inc.

Additional References

AWWA. 2010. “AWWA manuals of water supply practices.” In American Water Works Association (AWWA). Denver, CO, USA, accessed August 5, 2010. http://www.awwa.org/Resources/standards.cfm?ItemNumber=47829&navItemNumber=47834.

Blanchard, B. S. 2010. Logistics engineering and management, 5th ed. Englewood Cliffs, NJ, USA: Prentice Hall, 341-342.

Braunstein, A. 2007. Balancing hardware end-of-life costs and responsibilities. Westport, CT, USA: Experture Group, ETS 07-12-18.

Brown, M., R. Weyers, and M. Sprinkel. 2006. “Service life extension of virginia bridge decks afforded by epoxy-coated reinforcement.” Journal of ASTM International (JAI) 3 (2): 13.

Caltrans and USDOT. 2005. Systems engineering guidebook for ITS, version 1.1. Sacramento, CA, USA: California Department of Transportation (Caltrans) Division of Research & Innovation/U.S. Department of Transportation (USDOT), SEG for ITS 1.1: 278, 101-103, 107.

Casetta, E. 2001. Transportation systems engineering: Theory and methods. New York: Kluwer Publishers Academic, Springer.

DAU. 2010. “Acquisition community connection (ACC): Where the DoD AT&L workforce meets to share knowledge.” In Defense Acquisition University (DAU)/US Department of Defense (DoD). Ft. Belvoir, VA, USA accessed August 5, 2010. https://acc.dau.mil/.

DLA. 2010. “Defense logistics agency disposition services.” In Defense Logistics Agency (DLA)/U.S. Department of Defense. Battle Creek, MI, accessed June 19 2010: 5. http://www.dtc.dla.mil.

Elliot, T., K. Chen, and R. C. Swanekamp. 1998. Standard handbook of powerplant engineering. New York, NY, USA: McGraw Hill, section 6.5.

FAA. 2006. “Systems engineering manual.” Washington, D.C.: U.S. Federal Aviation Administration (FAA), section 4.1.

FCC. 2009. “Radio and television broadcast rules.” Washington, D.C.: U.S. Federal Communications Commission (FCC), 47 CFR Part 73, FCC Rule 09-19: 11299-11318.

Finlayson, B., and B. Herdlick. 2008. Systems engineering of deployed systems. Baltimore, MD, USA: Johns Hopkins University: 28.

Gehring, G., D. Lindemuth, and W. T. Young. 2004. “Break Reduction/Life extension program for CAST and ductile iron water mains.” Paper presented at NO-DIG, Conference of the North American Society for Trenchless Technology (NASTT), March 22-24, New Orleans, LA, USA.

Hovinga, M. N., and G. J. Nakoneczny. 2000. “Standard recommendations for pressure part inspection during a boiler life extension program.” Paper presented at ICOLM (International Conference on Life Management and Life Extension of Power Plant), May, Xi’an, P.R. China.

IEC. 2007. “Obsolescence management - application guide,” ed 1.0. Geneva, Switzerland: International Electrotechnical Commission, IEC 62302.

IEEE. 1998. IEEE Standard Reliability Program for the Development and Production of Electronic Systems and Equipment. New York, NY, USA: Institute of Electrical and Electronics Engineers (IEEE), IEEE STD 1332.

IEEE 2005. IEEE Standard for Software Configuration Management Plans. New York, NY, USA: Institute of Electrical and Electronics Engineers (IEEE), IEEE STD 828.

IEEE. 2008. IEEE Recommended practice on Software Reliability. New York, NY, USA: Institute of Electrical and Electronics Engineers (IEEE), IEEE STD 1633.

---. 2008. ISO/IEC/IEEE Systems and Software Engineering – System Life Cycle Processes. Geneva, Switzerland: International Organization for Standardization, ISO 15288.

IEEE. 2010. IEEE Standard Framework for Reliability Prediction of Hardware. New York, NY, USA: Institute of Electrical and Electronics Engineers (IEEE), IEEE STD 1413.

Ihii, K., C. F. Eubanks, and P. Di Marco. 1994. “Design for product retirement and material life-cycle.” Materials & Design 15 (4): 225-33.

INCOSE. 2010. In-service systems working group. San Diego, CA, USA: International Council on Systems Engineering (INCOSE).

INCOSE UK Chapter. 2010. Applying systems engineering to in-service systems: Supplementary guidance to the INCOSE systems engineering handbook, version 3.2, issue 1.0. Foresgate, UK: International Council on Systems Engineering (INCOSE) UK Chapter:10, 13, 23.

Institute of Engineers Singapore. 2009. Systems engineering body of knowledge, provisional version 2.0. Singapore.

ISO/IEC. 2003. “Industrial automation systems integration-integration of life-cycle data for process plants including oil, gas production factilies.” Geneva, Switzerland: International Organization for Standardization (ISO)/International Electro technical Commission (IEC).

———. 1997. “Systems engineering for commercial aircraft.” Surrey, UK: Ashgate Publishing Ltd.

Koopman, P. 1999. “Life cycle considerations.” In Carnegie-Mellon University (CMU). Pittsburgh, PA, USA, accessed August 5, 2010. http://www.ece.cmu.edu/~koopman/des_s99/life_cycle/index.html.

L3 Communications. 2010. “Service life extension program (SLEP).” Newport News, VA, USA: L3 Communications, Flight International Aviation LLC.

Livingston, H. 2010. GEB1: “Diminishing manufacturing sources and material shortages (DMSMS) management practices.” McClellan, CA: Defense MicroElectronics Activity (DMEA)/U.S. Department of Defense (DoD).

Mays, L., ed. 2000. Water distribution systems handbook. New York, NY, USA: McGraw-Hill Book Company, chapter 3.

MDIT. 2008. System maintenance guidebook (SMG), version 1.1: A companion to the systems engineering methdology (SEM) of the state unified information technology environment (SUITE). MI: Michigan Department of Information Technology (MDIT), DOE G 200: 38.

NAS. 2006. Natioanl airspace system (NAS) system engineering manual, version 3.1 (volumes 1-3). Washington, D.C.: Air Traffic Organization (ATO)/U.S. Federal Aviation Administration (FAA), NAS SEM 3.1.

NASA. 2007. Systems engineering handbook. Washington, D.C.: National Aeronautics and Space Administration (NASA), NASA/SP-2007-6105, December.

Office of Natural Gas and Oil Technology. 1999. “Reservoir LIFE extension program: Encouraging production of remaining oil and gas.” Washington, D.C.: U.S. Department of Engery (DoE).

Paks Nuclear Power Plant. 2010. “Paks nuclear power plant: Service life extension.” In Paks Nuclear Power Plant, Ltd. Hungary, accessed August 5, 2010. http://paksnuclearpowerplant.com/service-life-extension.

Reason, J. 1997. Managing the risks of organizational accident. Aldershot, UK: Ashgate.

Ryen, E. 2008. Overview of the systems engineering process. Bismarck, ND, USA: North Dakota Department of Transpofration (NDDOT).

SAE International. 2010. Standards: Automotive--maintenance and aftermarket. Warrendale, PA, USA: Society of Automotive Engineers (SAE) International.

Schafer, D.L. 2003. “Keeping Pace With Technology Advances When Funding Resources Are Diminished.” Paper presented at Auto Test Con. IEEE Systems Readiness Technology Conference, Anaheim, CA, USA: 584.

SEI. 2010. “Software engineering institute.” In Software Engineering Institute (SEI)/Carnegie-Mellon University (CMU). Pittsburgh, PA, USA, accessed August 5, 2010. http://www.sei.cmu.edu.

SOLE. 2009. “Applications divisons.” In The International Society of Logistics (SOLE). Hyattsville, MD, USA accessed August 5, 2010. http://www.sole.org/appdiv.asp.

Sukamto, S. 2003. “Plant aging and life extention program at Arun LNG Plant Lhokseumawe, North Aceh, Indonesia.” Paper presented at 22nd Annual World Gas Conference, June 1-5, Tokyo, Japan.



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Signatures

--Jgercken 03:01, 12 September 2011 (UTC)