Safety Improvement of engineering processes, especially Oil & Gas operations, has gained a lot of attention during the last decades. This fundamental vision results in risk remediation programs, minimizing the risks of failure, and reducing the associated costs for operation and maintenance. As failures may represent serious threats for both humans and the environment, a comprehensive tool is required to employ maintenance and avoid immoderate dangerous consequences. Traditional risk frameworks mainly include estimation approaches, such as Fault Tree (FT) and Event Tree (ET), producing more simplified models than other tools, such as Bayesian inference. The present work aimed at developing an advanced Risk-Based Maintenance (RBM) methodology for prioritizing maintenance operations, by addressing associated uncertainties through the accident modelling of the process. For this purpose, a Hierarchical Bayesian Approach (HBA) is applied to estimate the failure probabilities of each component while a Failure Mode, Effects and Criticality Analysis is performed to assess the severity. With Markov Chain Monte Carlo simulation from likelihood function and prior distribution, the HBA is capable of incorporating the fluctuations and uncertainties associated with operational data including the variability between the source of data and the correlation of observations. Lastly, to make a meaningful difference between different kinds of risk consequences, whether the risk has a direct or indirect loss, the cost of failures of components is accounted for. To demonstrate the application of the methodology, a Natural Gas Reduction and Measuring Station (NGRMS) is taken into account as a case study. The outcome of the case study proofed that PTG and pump are the most failures sensitive components among other if they being left unattended in the operation with an average number of failure occurrences of 67 and 45; While the THT pipelines and THT tank are less sensitive for being considered for major maintenance request with almost average of 5 times in their lifetime. The proposed method can be exploited by maintenance engineers, asset managers, and policymakers to reduce the downtime periods as well as the risks of on-going operations.

The probabilistic analysis on condition monitoring data has been widely established through the energy supply process to specify the optimum risk remediation program. In such studies, the fluctuations and uncertainties of the operational data including the variability between source of data and the correlation of observations, have to be incorporated if the efficiency is of importance. This study presents a novel probabilistic methodology based on observation data for signifying the impact of risk factors on safety indicators when consideration is given to uncertainty quantification. It provides designers, risk managers and operators a framework for risk mitigation planning within the energy supply processes, whilst also assessing the online reliability. These calculations address the involved and, most of the time, unconsidered risk to make a prediction of safety conditions of the operation in future. To this end, the generalized linear model (GLM) is applied to offer the explanatory model as a regression function for risk factors and safety indicators. Hierarchical Bayesian approach (HBA) is then inferred for the calculations of regression function including interpretation of the intercept and coefficient factors. With Markov Chain Monte Carlo simulation from likelihood function and prior distribution, the HBA is capable of capturing the aforementioned fluctuations and uncertainties in the process of obtaining the posterior values of the intercept and coefficient factors. To illustrate the capabilities of the developed framework, an autonomous operation of Natural Gas Regulating and Metering Station in Italy has been considered as case study.