Hybrid FMEA–OREDA reliability analysis of a Subsea Safety Isolation Valve

Ricardo França Santos; Kauam Vieira; Lara Alvarenga; Maria Eduarda Namba; Maria Fernanda Santos

doi:10.14488/1980-5411.20260043

Research Article

Hybrid FMEA–OREDA reliability analysis of a Subsea Safety Isolation Valve

Ricardo França Santos; Kauam Vieira; Lara Alvarenga; Maria Eduarda Namba; Maria Fernanda Santos

http://dx.doi.org/10.14488/1980-5411.20260043 Production, vol.36, e20260043, 2026

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Abstract

Paper aims: Prioritize failure modes of the Subsea Safety Isolation Valve (SSIV) and identify the most critical risk scenario to support risk-based maintenance and subsea safety-barrier integrity.

Originality: The study advances conventional FMEA by anchoring occurrence scoring in OREDA (2015) failure rate data at the failure-mode level, testing ranking stability through threshold-based sensitivity analysis, and explicitly comparing data-anchored prioritization against a qualitative baseline.

Research method: A hybrid semi-quantitative FMEA was developed using OREDA (2015) data (Taxonomy 5.1.3; 5 installations; calendar time = 0.5334 × 10⁶ h). Severity was assigned per failure mode based on safety and loss-of-containment consequences. Occurrence was normalized by relative failure rate, using the highest observed mode as reference (λ_max = 4.88 per 10⁶ h; INS), and mapped to the 1–10 FMEA scale via a monotonic linear formula. Detection was assigned differentially. RPNs were computed, normalized (RRI), and subjected to threshold-based sensitivity analysis.

Main findings: Control/Signal Failure (INS) is the most critical scenario (RRI = 1.00), driven by the highest failure rate and maximum severity (S = 10). Delayed Operation (DOP) ranks second (RRI = 0.53) and External Leakage (ELP) third (RRI = 0.48); despite ELP's marginally higher failure rate, better detectability (D = 4 vs. 5) places it third. The INS ranking is stable across all detection ranges; the DOP–ELP order is sensitive to detectability assumptions. The data-anchored hierarchy (INS > DOP > ELP) agrees with a severity-led qualitative baseline at position 1 but diverges at positions 2–3.

Implications for theory and practice: INS emerges as top priority — consistent with safety-engineering intuition for control-system failures in emergency isolation valves — with targeted mitigations: redundancy and partial stroke testing (INS), torque/lubrication review (DOP), and sealing-kit replacement (ELP).

Keywords

Risk-Based Maintenance, Subsea Systems, OREDA

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Submitted date:
04/03/2026

Accepted date:
09/21/2026

Hybrid FMEA–OREDA reliability analysis of a Subsea Safety Isolation Valve

Ricardo França Santos; Kauam Vieira; Lara Alvarenga; Maria Eduarda Namba; Maria Fernanda Santos

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