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Purpose The purpose of this paper is to validate a fuzzy risk graph model through a case study results carried out on a safety instrumented system (SIS). Design/methodology/approach The proposed model is based on an inference fuzzy system and deals with uncertainty data used as inputs of the conventional risk graph method. The coherence and redundancy of the developed fuzzy rules base are first verified in the case study. A new fuzzy model is suggested for a multi-criteria characterization of the avoidance possibility parameter. The fuzzy safety integrity level (SIL) is determined for two potential accident scenarios. Findings The applicability of the proposed fuzzy model on SIS shows the importance and pertinence of the proposed fuzzy model as decision-making tools in preventing industrial hazards while taking into consideration uncertain aspects of the data used on the conventional risk graph method. The obtained results show that the use of continuous fuzzy scales solves the problem of interpreting results and provides a more flexible structure to combine risk graph parameters. Therefore, a decision is taken on the basis of precise integrity level values and protective actions in the real world are suggested. Originality/value Fuzzy logic-based safety integrity assessment allows assessment of the SIL in a more realistic way by using the notion of the linguistic variable for representing information that is qualitative and imprecise and, therefore, ensures better decision making on risk prevention.

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An important issue faced by risk analysts is how to deal with uncertainties associated with accident scenarios. In industry, one often uses single values derived fro m historical data or literature to estimate events probability or their frequency. However, both dynamic environments of systems and the need to consider rare component failures may make unrealistic this kind of data. In this paper, uncertainty encountered in Layers Of Protection Analysis (LOPA) is considered in the framework of possibility theory. Data provided by reliability databases and/or experts judgments are represented by fuzzy quantities (possibilit ies). The fu zzy outcome frequency is calculated by extended mu ltip licat ion using αcuts method. The fu zzy outcome is co mpared to a scenario risk tolerance criteria and the required reduction is obtained by resolving a possibilistic decision-making problem under necessity constraint. In order to validate the proposed model, a case study concerning the protection layers of an operational heater is carried out.

PurposeThe main objective of safety instrumented systems (SISs) is to maintain a safe condition of a facility if hazardous events occur. However, in some cases, SIS's can be activated prematurely, these activations are characterized in terms of frequency by a Spurious Trip Rate (STR) and their occurrence leads to significant technical, economic and even environmental losses. This work aims to propose an approach to optimize the performances of the SIS by a multi-objective genetic algorithm. The optimization of SIS performances is performed using the multi-objective genetic algorithm by minimizing their probability of failure on demand PFDavg, Spurious Trip Rate (STR) and Life Cycle Costs (LCCavg). A set of constraints related to maintenance costs have been established. These constraints imply specific maintenance strategies which improve the SIS performances and minimize the technical, economic and environmental risks related to spurious shutdowns. Validation of such an approach is applied to an Emergency Shutdown (ESD) of the blower section of an industrial facility (RGTE- In Amenas).Design/methodology/approachThe optimization of SIS performances is performed using the multi-objective genetic algorithm by minimizing their probability of failure on demand PFDavg, Spurious Trip Rate (STR) and Life Cycle Costs (LCCavg). A set of constraints related to maintenance costs have been established. These constraints imply specific maintenance strategies which improve the SIS performances and minimize the technical, economic and environmental risks related to spurious shutdowns. Validation of such an approach is applied to an Emergency Shutdown (ESD) of the blower section of an industrial facility (RGTE- In Amenas).FindingsA case study concerning a safety instrumented system implemented in the RGTE facility has shown the great applicability of the proposed approach and the results are encouraging. The results show that the selection of a good maintenance strategy allows a very significant minimization of the PFDavg, the frequency of spurious trips and Life Cycle Costs of SIS.Originality/valueThe maintenance strategy defined by the system designer can be modified and improved during the operational phase, in particular safety systems. It constitutes one of the least expensive investment strategies for improving SIS performances. It has allowed a considerable minimization of the SIS life cycle costs; PFDavg and the frequency of spurious trips.

Summary Industrial systems are becoming more sophisticated, and their failure can result in significant losses for the company in terms of production loss, maintenance costs, fines, image loss, etc. Conventional approaches to modeling and evaluating the failure mechanisms of these systems do not consider certain important aspects, such as the interdependencies between failure modes (FMs) with information and data containing uncertainties as they are generally collected from experts’ judgments. These restrictions may lead to improper decision-making. The use of more advanced techniques to model and assess the interdependencies among components’ failures under uncertainties seems to be more than necessary to overcome these deficiencies. It is in this context that the proposed approach fits. It consists of proposing a hybrid multicriteria decision-aking (MCDM) approach that combines several techniques for a better selection of maintenance strategies. Using the failure mode and effects analysis (FMEA) technique, the potential FMs of components, along with their causes and effects, are identified. The relative importance (or weight) of these FMs is determined using the fuzzy simple additive weighing (FSAW) method based on how they affect the system’s goals. The causal relationships between FMs and their final weights are determined by the fuzzy cognitive maps (FCM) method and the nonlinear Hebbian learning and differential evolution (NHL-DE) algorithm. Finally, based on the final FM weights provided by the FCM, the simple additive weighing (SAW) method is used to select the optimal maintenance strategies. The results of applying the proposed approach to an operating compressor lubrication and sealing oil system demonstrate its importance and usefulness in assisting system operators to efficiently allocate the optimal maintenance strategies, considering the strong correlation between FMs and their effects on system performance while accounting for the uncertainties associated with experts’ judgments. These correlation effects have led to changes in the assigned weights of the selected FMs. Specifically, the FM related to the low output of the lube/seal oil pump, which was initially assigned a lower priority, and with the correlation effects has become the first critical FM. This shift in prioritization emphasizes the need to address this particular FM promptly. By focusing on addressing these high-priority FMs, maintenance efforts can be optimized to prevent or mitigate more severe consequences. Among the various maintenance strategies evaluated, it was determined that the combination of condition-based maintenance (CBM) and precision maintenance (PrM) yields the most favorable outcome in terms of mitigating the impact of accidental failures and undesired events on the selected system.

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