Failure Mode and Effect Analysis using an integrated approach of clustering and MCDM under pythagorean fuzzy environment

Failure Mode and Effect Analysis (FMEA) is an effective risk analysis and failure avoidance approach in the design, process, services, and system. With all its benefits, FMEA has three limitations: failure mode risk assessment and prioritization, complex FMEA worksheets, and difficult application of FMEA tables. This paper seeks to overcome the shortcomings of FMEA using an integrated approach based on a developed Pythagorean fuzzy (PF) k-means clustering algorithm and a popular MCDM method called PF-VIKOR. In the first step, Pythagorean fuzzy numbers (PFNs) were used to collect Severity (S), Occurrence (O), and Detection (D) factors for failure modes to incorporate uncertainty and fuzziness into subjective judgments. Afterward, failure modes were clustered by developing a novel k-means clustering algorithm that accepts PFNs as input. Finally, the PF-VIKOR approach was used to analyze the ordering of cluster risks. The proposed approach was implemented in the dehydration unit of an Iranian gas refinery and the results were compared with the traditional FMEA. The findings showed the flexibility and applicability of the proposed approach in addressing real-world problems. This research provides two key contributions: (1) designing a PFN-based k-means clustering algorithm that tackles FMEA limitations and (2) using the PF-VIKOR method for prioritizing and evaluating failure mode clusters.     

矿井安全评价中的几个问题的初步研究

研究了矿井灾害系统危险评价中的几个关键问题，分析了煤矿灾害系统的结构特点，针对矿井灾害系统这样一个过程性本质模糊的灾害发生环境，提出了危险程度的模糊风险度量理论和基于此理论的定量表示方法，以及对不同灾害事故后果相关性计算方法。还论述了全矿与其各组成部分的危险程度之间的相互关系。     

A new simple methodology for evaluation of explosion risk in underground coal mines

The key objective of this paper is the presentation of a new risk assessment tool for underground coal mines based on a simplified semi-quantitative estimation and assessment method.In order to determine the risk of explosion of any work process or activity in underground coal mines it is necessary to assess the risk. The proposed method is based on a Risk Index obtained as a product of three factors: frequency of each individual scenario P_ucm, associated severity consequences C_ucm and exposure time to explosive atmospheres E_ucm. The influence of exposure time is usually not taken into account up to now. Moreover, the exposure to explosive atmospheres may affect factors of hazardous event probability as much as its consequences. There are many definitions of exposure to explosive atmospheres but in the case of underground coal mines the exposure is defined as frequency risk of firedamp and coal dust. The risk estimation and risk assessment are based on the developed of a risk matrix.The proposed methodology allows not only the estimation of the explosion risk but also gives an approach to decide if the proposal investment is well-justified or not in order to improve safety.     

Does the potential safety risk affect whether particular construction hazards are recognized or not?

Introduction: Evidence from the global construction industry suggests that an unacceptable number of safety hazards remain unrecognized in construction workplaces. Unfortunately, there isn’t a sufficient understanding of why particular safety hazards remain unrecognized. Such an understanding is important to address the issue of poor hazard recognition and develop remedial interventions. A recent exploratory effort provided anecdotal evidence that workers often fail to recognize safety hazards that are expected to impose relatively lower levels of safety risk. In other words, the research demonstrated that the underlying risk imposed by a safety hazard can affect whether a hazard will be recognized or not. Method: The presented research focused on empirically testing this preliminary finding. More specifically, the study tested the proposition that Construction workers are more likely to recognize safety hazards that impose higher levels of safety risk than those that impose relatively lower levels of safety risk. The research goals were accomplished through a number of steps. First, a set of 16 construction case images depicting a variety of construction operations that included a number of known safety hazards was presented to a panel of four construction safety experts. The experts were tasked with examining each of the known safety hazards and providing a rating of the relative safety risk that the individual hazards impose. Having obtained an estimate of the underlying safety risk, a hazard recognition activity was administered to 287 workers recruited from 57 construction workplaces in the United States. The hazard recognition activity involved the examination of a random sample of two construction case images that were previously examined by the expert panel and reporting relevant safety hazards. Results: The results of the study provided support for the proposition that workers are more likely to recognize hazards that impose relatively higher levels of safety risk. Practical Applications: The findings of the study can be leveraged to improve existing hazard recognition methods and develop more robust interventions to address the issue of poor hazard recognition levels.     

基于毕达哥拉斯模糊贝叶斯网络的海底管道泄漏风险分析*

为分析海底管道运行中存在的泄漏风险,提出1种基于毕达哥拉斯模糊数与贝叶斯网络的风险评估模型。首先,通过毕达哥拉斯模糊数转换专家定性评价,拓展专家意见模糊范围;然后,结合主客观组合赋权法,利用毕达哥拉斯梯形爱因斯坦混合几何算子（PTFEHG）实现专家意见的聚合;最后,通过贝叶斯网络的推理与敏感性分析,计算海底管道泄漏风险的失效概率,并辨识关键风险因素。研究结果表明:该方法可以结合专家意见对海底管道泄漏风险进行定量分析,并识别导致泄漏事故的关键风险因素,对海底管道安全管理具有指导意义。     

Confidence-based quantitative risk analysis for offshore accidental hydrocarbon release events

Quantitative risk analysis (QRA) has been widely used to conduct the assessment of offshore accidental risks. However, the accuracy and validity of QRA is significantly affected by uncertainties when subjective judgments are involved. Therefore, it is unrealistic to determine the probability of a hazardous event by using one single explicit value when safety experts have a relatively low confidence level in their judgments. This paper proposes a new methodology for incorporating uncertainties into conventional QRA using the concept of confidence level. Offshore hydrocarbon release hazards are focused on and a barrier and operational risk analysis (BORA-Release) method is selected as the basic model to illustrate the proposed methodology. A left–right (L–R) bell-shaped fuzzy number is employed and its membership curve is able to control its shape to represent different confidence levels. As to the complex geometry of the bell-shaped fuzzy number, an α-cut operation is introduced to conduct the arithmetic operations of the fuzzy number, and a defuzzification method with total integral value is chosen to match the α-cut operations and acquire complete information for the fuzzy numbers. In the meantime, an optimism index is used to describe the attitude of the decision-maker. One case study is provided in this paper to demonstrate the implementation of this method.     

Fuzzy logic for piping risk assessment (pfLOPA)

This paper explores the application of the fuzzy logic for risk assessment of major hazards connected with transportation of flammable substances in long pipelines. As a basis for risk assessment, the framework of the fuzzy Layer of Protection Analysis (fLOPA) was used. fLOPA presents a new approach to risk assessment based on two assumptions: 1. different effects of the layer of protection functions on particular elements of the risks (frequency and severity of consequence), and 2. the application of fuzzy logic system (FLS) composed of three elements: fuzzification, inference process and defuzzification. A further calculation follows LOPA methodology with the use of fuzzy logic system where fuzzy risk matrix is used for risk assessment. A typical case study comprising section of a long pipeline failure is performed and a comparison between the classical LOPA approach and fuzzy approach is made.     

Safety in the mining industry and the unfinished legacy of mining accidents: Safety levers and defense-in-depth for addressing mining hazards

Mining remains one of the most hazardous occupations worldwide and underground coal mines are especially notorious for their high accident rates. In this work, we provide an overview of the broad and multi-faceted topic of safety in the mining industry. After reviewing some statistics of mining accidents in the United States, we focus on one pervasive and deadly failure mode in mines, namely explosions. The repeated occurrence of mine explosions, often in similar manner, is the loud unfinished legacy of mining accidents and their occurrence in the 21st century is inexcusable and should constitute a strong call for action for all stakeholders in this industry to settle this problem. We analyze one such recent mine disaster in which deficiencies in various safety barriers failed to prevent the accident initiating event from occurring, then subsequent lines of defense failed to block this accident scenario from unfolding and to mitigate its consequences. We identify the technical, organizational, and regulatory deficiencies that failed to prevent the escalation of the mine hazards into an accident, and the accident into a “disaster”. This case study provides an opportunity to illustrate several concepts that help describe the phenomenology of accidents, such as initiating events, precursor or lead indicator, and accident pathogen. Next, we introduce the safety principle of defense-in-depth, which is the basis for regulations and risk-informed decisions by the US Nuclear Regulatory Commission, and we examine its relevance and applicability to the mining system in support of accident prevention and coordinating actions on all the safety levers, technical, organizational, and regulatory to improve mining safety. The mining system includes the physical confines and characteristics of the mine, the equipment in the mine, the individuals and the organization that operate the mine, as well as the processes and regulatory constraints under which the mine operates. We conclude this article with the proposition for the establishment of defense-in-depth as the guiding safety principle for the mining industry and we indicate possible benefits for adopting this structured hazard-centric system approach to mining safety.     

基于二元语义和AHP法的矿山职业危害综合评价方法

为科学评价矿山企业职业危害风险,提出一种基于二元语义和层次分析法(AHP)的矿山职业危害风险综合评价方法。首先,在分析企业生产活动的过程和相关文献的基础上,应用相关性分析方法,优化建立地下矿山职业危害风险评价体系;其次,在分析二元语义理论的基础上,给出原始数据标准化处理方法和详细的建模步骤;最后,通过实例进行应用。实例分析结果表明:利用语言短语处理定性信息的准确性高;职业危害风险的负面因素主要为粉尘等致灾因子,通过提高作业者素质和安全管理水平可大大降低其风险。     

A methodology for evaluation and monitoring of recurring hazards in underground coal mining

This study provides a methodology for evaluation and monitoring of recurring hazards in underground coal mining. An important measure in this regard may be the ‘time between occurrences’ (TBO) of hazards that can be modeled in the similar fashion of ‘time between failures’ (TBF) data modeling which is practiced in reliability study. Typically, time between accidents is modeled in safety study. This study is therefore new in two counts: (i) statistically modeling hazard occurrences based on inspection reports and (ii) monitoring of safety status based on control charting of hazard occurrences. The methodology includes Weibull-distribution based hazard rate functions, Poisson-distribution based cumulative risk functions, and Weibull-distribution based control charts. The new methodology is applied to an underground coal mining worksystem and the results are discussed. The case study results show that hazards related to machinery, ground-fall, housekeeping, roadways, and materials are more frequently occurring. It is recommended that in addition to planned inspections for identification of hazards, a control chart based hazard mitigation scheme should be employed at the mine sections for better monitoring and control of hazards.     

A hybrid decision-making approach based on FCM and MOORA for occupational health and safety risk analysis

IntroductionWith the development of industries and increased diversity of their associated hazards, the importance of identifying these hazards and controlling the Occupational Health and Safety (OHS) risks has also dramatically augmented. Currently, there is a serious need for a risk management system to identify and prioritize risks with the aim of providing corrective/preventive measures to minimize the negative consequences of OHS risks. In fact, this system can help the protection of employees’ health and reduction of organizational costs. Method: The present study proposes a hybrid decision-making approach based on the Failure Mode and Effect Analysis (FMEA), Fuzzy Cognitive Map (FCM), and Multi-Objective Optimization on the basis of Ratio Analysis (MOORA) for assessing and prioritizing OHS risks. After identifying the risks and determining the values of the risk assessment criteria via the FMEA technique, the attempt is made to determine the weights of criteria based on their causal relationships through FCM and the hybrid learning algorithm. Then, the risk prioritization is carried out using the MOORA method based on the decision matrix (the output of the FMEA) and the weights of the criteria (the output of the FCM). Results: The results from the implementation of the proposed approach in a manufacturing company reveal that the score at issue can overcome some of the drawbacks of the traditional Risk Priority Number (RPN) in the conventional FMEA, including lack of assignment the different relative importance to the assessment criteria, inability to take into account other important management criteria, lack of consideration of causal relationships among criteria, and high dependence of the prioritization on the experts’ opinions, which finally provides a full and distinct risk prioritization.     

Risk analysis for oil & gas pipelines: A sustainability assessment approach using fuzzy based bow-tie analysis

Vast amounts of oil & gas (O&G) are consumed around the world everyday that are mainly transported and distributed through pipelines. Only in Canada, the total length of O&G pipelines is approximately 100,000 km, which is the third largest in the world. Integrity of these pipelines is of primary interest to O&G companies, consultants, governmental agencies, consumers and other stakeholder due to adverse consequences and heavy financial losses in case of system failure. Fault tree analysis (FTA) and event tree analysis (ETA) are two graphical techniques used to perform risk analysis, where FTA represents causes (likelihood) and ETA represents consequences of a failure event. ‘Bow-tie’ is an approach that integrates a fault tree (on the left side) and an event tree (on the right side) to represent causes, threat (hazards) and consequences in a common platform. Traditional ‘bow-tie’ approach is not able to characterize model uncertainty that arises due to assumption of independence among different risk events. In this paper, in order to deal with vagueness of the data, the fuzzy logic is employed to derive fuzzy probabilities (likelihood) of basic events in fault tree and to estimate fuzzy probabilities (likelihood) of output event consequences. The study also explores how interdependencies among various factors might influence analysis results and introduces fuzzy utility value (FUV) to perform risk assessment for natural gas pipelines using triple bottom line (TBL) sustainability criteria, namely, social, environmental and economical consequences. The present study aims to help owners of transmission and distribution pipeline companies in risk management and decision-making to consider multi-dimensional consequences that may arise from pipeline failures. The research results can help professionals to decide whether and where to take preventive or corrective actions and help informed decision-making in the risk management process. A simple example is used to demonstrate the proposed approach.     

An extension of the fuzzy improved risk graph and fuzzy analytical hierarchy process for determination of chemical complex safety integrity levels

The risk graph (RG) is widely used to evaluate the safety integrity level (SIL) of safety instrument systems (SIS). However, subjective opinion-based conventional RGs cannot provide successful results for the problems of risk parameters, such as shortages or lack of data; hence, the output of a conventional approach lacks sufficient reliability. We introduced the fuzzy improved risk graph (FIRG), an extension of fuzzy set theory, to deal with possible ambiguities during SIL study and increase the reliability of conventional RGs. In the present study, the levels of consequences defined as linguistic terms were converted into qualitative intervals; therefore, by correlating the proposed approach with experts’ opinions and attributing weight factors, a desired SIL value was obtained. The output of this new approach can be compared directly with quantitative risk assessment techniques to improve the safety performance of industrial systems.     

A new practical approach to risk management for underground mining project in Quebec

The mining industry worldwide is currently experiencing an economic boom that is contributing to economic recovery and social progress in many countries. For this to continue, the mining industry must meet several challenges associated with the start-up of new projects. In a highly complex and uncertain environment, rigorous management of risks remains indispensable in order to repel threats to the success of mining.In this article, a new practical approach to risk management in mining projects is presented. This approach is based on a novel concept called “hazard concentration” and on the multi-criteria analysis method known as the Analytic Hierarchy Process (AHP). The aim of the study is to extend the use of this approach to goldmines throughout Quebec. The work is part of a larger research project of which the aim is to propose a method suitable for managing practically all risks inherent in mining projects.This study shows the importance of taking occupational health and safety (OHS) into account in all operational activities of the mine. All project risks identified by the team can be evaluated. An adaptable database cataloguing about 250 potential hazards in an underground goldmine was constructed. In spite of limitations, the results obtained in this study are potentially applicable throughout the Quebec mining sector.     

Risk assessment: an approach to control hazards in mines

Accidents and injuries related to work are major occupational health problems in most of the industrialized countries.Traditional approaches to manage workplace safety in mines have mainly focused on job redesign and technical aspects of engineering systems.It is being realized that compliance to rules and regulations of mines is a prerequisite;however,it is not sufficient to achieve further reduction in accident and injury rates in mines.Proactive approaches are necessary to further improve the safety standards in mines.Unsafe conditions and practices in mines lead to a number of accidents,which in turn may cause loss and injury to human lives,damages to property,and loss of production.Hazard identification and risk assessment is an important task for the mining industry which needs to consider all the risk factors at workplaces.Applications of risk management approaches in mines are necessary to identify and quantify potential hazards and to suggest effective solutions.In this paper,the following risk estimation techniques were discussed:(i)DGMS(Directorate General of Mines Safety,India)risk rating criterion,and(ii)a matrix based approach.The proposed tools were demonstrated through an application in an opencast coal mine in India.It was inferred that the risk assessment approach can be used as an effective tool to indentify and control hazards in mines.     

Modeling and application of risk assessment considering veto factors using fuzzy Petri nets

Risk assessment is important for plant safety, and fuzzy set theory is useful for such assessment because many risk factors have fuzzy characteristics. In this study, veto factors for risk assessment are taken into account. Weighted fuzzy Petri nets (WFPN) with inhibitor arcs are proposed to model relationships between risk factors and establish the risk assessment structure considering veto factors. Definitions of WFPNs as well as the enabling rule and execution rule are provided. The modeling approach for the assessment combining normal factors with veto items is discussed. The proposed fuzzy risk assessment approach is illustrated by an example of the assessment of production installations and process technology of plants that deal with hazardous chemicals. Veto factors and non-veto factors are presented and the assessment structure based on WFPNs is established. Using the factor data of a plant, an assessment value is obtained through the operation of WFPNs and the verification of the approach is discussed.     

基于三角模糊理论的尾矿库风险评价研究

根据尾矿库的特点和我国现行的尾矿库安全生产监督管理法律法规及标准规范的要求,构建了尾矿库风险评价指标体系。综合考虑评价指标对风险发生可能性及后果严重程度的不同影响来确定指标权重,同时考虑到权重确定和指标赋值中的模糊性和不确定性等问题,选用三角模糊理论建立了尾矿库风险评价模型,并以本溪某尾矿库为例进行说明。理论分析和实例计算表明,该方法对尾矿库风险评价有很好的适用性。     

A fuzzy risk assessment approach for occupational hazards in the construction industry

The techniques in the construction industry have been improved due to the rapid development of science and technology. However, the constructional hazards are not decreased as expected. To reduce or prevent occupational hazards in the construction industry, a fuzzy risk assessment method was proposed to provide a prevention and improvement technique against occupational hazards. This method used two-stage quality function deployment (QFD) tables to represent the relationships among construction items, hazard types and hazard causes. A fuzzy analytic network process (ANP) method was developed to identify important hazard types and hazard causes. Failure modes and effect analysis (FMEA) was performed to assess the risk value of hazard causes based on the fuzzy inference approach. The proposed method was applied to a telecom engineering company in southern Taiwan. The performance evaluation result indicated that this method can provide satisfactory risk assessment values of hazard causes and relevant improvement strategies.     

The role of behavioral factors on safety management in underground mines

Traditional approaches on the prevention of accidents/injuries in mines reached its limit of effectiveness in improving safety performance and a fresh approach is utmost required. Behavioral safety analysis has been identified as an effective alternative in many industries. This paper is therefore sought to examine the role of behavioral factors on the occurrence of mine accidents and injuries through a case study. Data were collected from two neighboring underground coalmines operating under a large public sector organization of India. High–low plots and t-test were done to explore the differences between behavioral characteristics of accident involved (case) and non-involved (control) workers. How these differences could cause accidents/injuries in mines was estimated through structural equation modeling. The case study results show that accident group of workers (cases) are more job dissatisfied, negatively affected, and highly risk taking compared to the non-accident group of workers (controls). The accident model path analysis shows that negative affectivity, job dissatisfaction, and risk taking behaviors predict an increased number of injuries in mines. Apart from direct influences to work injuries, negative affectivity and job dissatisfaction make workers to take more risks and behave unsafely. These findings contribute to the design of safety programs including safety training, which should be behaviorally motivated. Mine safety management of the case study mines should outskirt their age old belief that accidents/injuries are due to hazardous nature of mining and only engineering control and regulatory monitoring are sufficient for improving safety of the mines. The multivariate analysis also shows that experience bears no relationships with work injury indicating that a less experienced worker is equally likely to be injured as an experienced worker. It implies that experience though helps workers in understanding the physical hazards, however, avoiding the imminent danger is much more behavioral. The variables negative affectivity, job dissatisfaction, and risk taking behaviors are therefore crucial in avoiding accident/injuries in mines.