Calculator Inputs
Example Data Table
Illustrative scenarios for comparing resilience strategies. Adjust to your context.
| Scenario | N | Unit cost | Redundancy | Hardening % | Outage hrs | Reduction % | Downtime/hr |
|---|---|---|---|---|---|---|---|
| Small facility controls | 8 | 2,500 | 1.15 | 6 | 10 | 45 | 700 |
| Industrial process line | 22 | 6,000 | 1.30 | 9 | 18 | 60 | 1,800 |
| Critical power system | 14 | 9,500 | 1.40 | 12 | 12 | 65 | 2,500 |
| Water pumping network | 30 | 3,200 | 1.20 | 7 | 22 | 50 | 900 |
| Data room cooling | 10 | 4,800 | 1.25 | 8 | 14 | 55 | 1,200 |
Formula Used
- Asset base:
AssetBase = N × UnitCost - Redundancy capital:
CapexRed = AssetBase × (RedundancyMultiplier − 1) - Hardening capital:
CapexHard = AssetBase × (Hardening% ÷ 100) - Total capital:
CapexTotal = CapexRed + CapexHard + Implementation - Residual outage hours:
H1 = H0 × (1 − Reduction% ÷ 100) - Downtime cost:
DowntimeCost = Hours × CostPerHour - Capital recovery factor:
CRF = i(1+i)^L / ((1+i)^L − 1) - Annualized capital:
AnnualCapex = CapexTotal × CRF - Total annual after:
AnnualAfter = AnnualCapex + AnnualOpex + ResidualDowntime - Net annual benefit:
Benefit = (BaselineDowntime − ResidualDowntime) − (AnnualOpex − BaselineOpex)
How to Use This Calculator
- Enter the asset count and realistic unit replacement cost.
- Set redundancy and hardening based on your design approach.
- Fill annual monitoring, training, maintenance, and testing costs.
- Estimate baseline outage hours and expected reduction percentage.
- Provide downtime cost per hour for your process or facility.
- Select life years and discount rate for annualized comparisons.
- Click Calculate and review summary and breakdown tables.
- Use CSV or PDF export to share the report.
Resilience spending drivers in engineered assets
Resilience cost begins with the asset base: component count multiplied by unit replacement cost. Redundancy raises capacity by a multiplier, while hardening adds a percentage for protection measures, spares, and improved materials. Implementation captures design effort, commissioning, permits, and integration labor. Together these inputs form the upfront investment used throughout the evaluation. Map N to pumps, feeders, servers, or bays, and include installation and commissioning inside unit cost.
Annualized capital comparison using CRF
Engineers often compare options on an annual basis. The calculator uses a capital recovery factor derived from the discount rate and useful life to convert upfront capital into an equivalent yearly cost. This allows a five year retrofit to be compared against a ten year redesign on a common scale, without ignoring the time value of money. If the rate is zero, CRF equals 1 divided by life, supporting straight-line annualization.
Quantifying downtime risk and residual exposure
Downtime risk is modeled as baseline outage hours per year times cost per hour. Expected outage reduction lowers hours to a residual level, producing a residual downtime cost. The difference is the risk reduction value. If baseline outage is 14 hours and reduction is 55%, residual hours become 6.3, cutting annual loss proportionally. Run sensitivity with low, expected, and high costs per hour to avoid underestimating exposure.
Operating discipline: monitoring, testing, and training
Resilience is sustained through operating costs. Monitoring supports early detection, training improves response quality, and maintenance preserves protective performance. Testing costs scale with test count and unit test cost, encouraging realistic drill programs. These recurring expenses are combined into annual operating cost and compared against any existing baseline operating spend you enter. Align test frequency with standards and record outcomes to validate reductions annually.
Decision signals: payback, ROI, and NPV
Net annual benefit equals downtime savings minus the change in operating cost. Simple payback divides total capital by net annual benefit when positive. ROI expresses the same ratio as a percentage. NPV discounts annual benefits over life and subtracts capital, highlighting long term value when payback alone appears slow. Use NPV to compare alternatives when payback horizons differ across designs materially.
FAQs
1) What does the redundancy multiplier represent?
It models added capacity or duplication. A multiplier of 1.25 means you are investing for roughly 25% additional redundant capability compared with the base asset set.
2) How should I estimate downtime cost per hour?
Use the value of lost production, penalties, labor idle time, and recovery waste per hour. For service systems, include customer churn, SLA credits, and emergency response costs.
3) Why does the discount rate change annualized capital?
Annualized capital uses the capital recovery factor, which increases as the discount rate rises. Higher rates weight near term costs more heavily, making long-lived investments appear more expensive each year.
4) Can I model phased upgrades?
Approximate phases by running the calculator for each phase and summing capital, operating, and downtime effects. Use a weighted average life and discount rate if the phases are similar.
5) What is included in net annual benefit?
It includes downtime savings after risk reduction minus the change in operating costs relative to your baseline operating spend. It does not include strategic benefits like reputation or compliance unless you monetize them.
6) What is the difference between CSV and PDF exports?
CSV exports structured numbers for analysis in spreadsheets and dashboards. PDF captures a formatted snapshot of the results summary card for reporting and approvals.