Optimization of safety instrumented system performance and maintenance costs in Algerian oil and gas facilities

Gas processing industry is associated with high risks which have the potential to cause catastrophic accidents. Safety Instrumented Systems (SISs) are considered the most effective safety barriers in this sector aiming to prevent undesired events and mitigate their consequences. However, several factors can affect their performance including maintenance strategy in place. In this paper, a Stochastic Petri Net (SPN) model is proposed for evaluating maintenance strategies related to SIS. The model is applied to analyze the performance of an Emergency Shutdown System (ESD) in a Flared Gases Recovery Unit located at south Algerian field. Furthermore, the paper investigates the financial impact of proof tests, including direct costs (such as manpower, equipment, and transportation) and indirect costs (such as production losses and gas flaring tax). These costs can be effectively managed and reduced by optimizing proof test intervals and scheduling tests during planned plant shutdowns. The results demonstrate that the proposed Stochastic Petri Net (SPN) model successfully analyzes the impact of imperfect full and partial proof tests on PFD average values of Safety Instrumented Functions (SIFs). In addition, it has been shown through reliability analysis that the proposed model is able to minimize spare parts expenses leading to significant cost savings while maintaining the required safety integrity levels (SILs), about 60% benefit achieved within two years compared to the actual procurement process over same period.