Development of an Integrated RBD–FMEA-Based Reliability Optimization Model for Safety Shutdown Instrumentation Systems
DOI:
https://doi.org/10.33387/protk.v13i3.12602Keywords:
Reliability Optimization, Safety Shutdown Instrumentation System, Gas Engine Compressor, Reliability Block Diagram, Failure Mode and Effect AnalysisAbstract
The reliability of Gas Engine Compressors is essential for ensuring production continuity and operational safety in the oil and gas industry, where the performance of the Safety Shutdown Instrumentation System (SSIS) plays a critical role in detecting abnormal conditions and preventing hazardous failures. This study proposes an integrated reliability optimization model for the SSIS by combining Reliability Block Diagram (RBD) and Failure Mode and Effects Analysis (FMEA) to improve system reliability, maintenance effectiveness, and operational safety. A quantitative case study was conducted using operational and maintenance data from a Gas Engine Compressor in an oil and gas production facility. Reliability parameters were evaluated using RBD, while component failure risks were assessed through FMEA based on Severity, Occurrence, and Detection ratings. The initial analysis showed an MTBF of 1,197 h, an MTTR of 730.67 h, a failure rate of 8.35 × 10⁻⁴ h⁻¹, a system reliability of 43.37%, and an availability of 62.10%. Critical components identified were the Vibration Switch (RPN = 64), Temperature Switch (RPN = 54), and Power Supply (Magneto) (RPN = 40). The proposed optimization increased system reliability to 73.82% and availability to 99.64%, while decreasing failures and downtime during the evaluation period. The developed RBD–FMEA model provides a practical decision-support framework for reliability improvement and maintenance prioritization and can be adapted to Safety Instrumented Systems with similar architectures.
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