In the petroleum industry, equipments must be maintained properly to meet the adequate reliability standards in order to achieve the desired business goals in terms of productivity, safety and environmental protection. This article offers a new approach focused on risk analysis to select a better maintenance strategy. The proposed approach consists of three stages. In the first step, we identify the accident scenarios that could lead to the loss of production and damage to the environment. In the second step, we estimate the frequency of occurrence of these scenarios. In the third step, we calculate the economic losses and environmental taxes. Finally, an appropriate maintenance strategy is proposed, taking into account the evaluation results obtained by the previous steps. A case study illustrates the proposed approach and shows that the latter constitutes an important decision support tool to improve the existing maintenance strategy to comply with regulations and standards in term of productivity, reduction of costs and environmental protection.

The Safety Instrumented System (SIS) is an automated system used to implement one or more safety instrumented functions. A SIS, like the Emergency Shutdown (ESD) system, consists of any combination of sensor(s), safety PLC(s) and final element(s) (e.g. ESD valves). ESD valves are the last line of defense against risks, although the ESD valve has high performance, the data (based on expert judgment and OREDA database) indicates that ESD valves failures are the most critical in the ESD systems. In order to improve the reliability and safety of these valves, we applied the FMEDA diagnostic technique. We started with a decomposition of the ESD valve to the subsystems and we identified their functions. Then we described the failure modes, their mechanisms, their sites and their effects. Then we identified the impact of each failure mode according to the criticality classes and identified the failure rates and their class according to the criticality and the detectability by automatic diagnosis of each mode and from the failure rates we calculated the Safe Failure Fraction (SFF) and Safety Integrity Level (SIL) required and we concluded that the actuator subsystem is the most critical system. Finally, we proposed preventive and protective measures to eliminate or reduce the risk of failure.