Decision Framework for Asset Criticality and Maintenance Planning in Complex Systems: An Offshore Corrosion Management Case

Asset maintenance management is critical in industries such as petrochemicals and oil and gas (O&G), where complex, interdependent systems heighten failure risks. Maintenance costs represent a significant portion of operational expenditures, emphasizing the need for effective risk-based strategies. A considerable gap exists in integrating uncertainty modelling into both criticality assessment and maintenance planning. Existing approaches often neglect combining expert-driven assessments with optimization models, limiting their applicability in real-world scenarios where cost-effective and risk-informed decision-making is crucial. Maintenance inefficiencies due to suboptimal asset selection result in substantial financial and safety-related consequences in asset-intensive industries. This study presents a framework integrating Reliability-Centered Maintenance (RCM) principles with fuzzy logic and decision-support methodologies to optimise maintenance portfolios for offshore O&G assets, particularly focusing on corrosion management. The framework evaluates asset criticality through comprehensive FMEA, employing MCDM and fuzzy logic to enhance maintenance planning and extend asset lifespan. A case study on offshore asset corrosion management demonstrates the framework’s effectiveness, selecting 60% of highly critical assets for maintenance, compared to 10% by current industry practices. This highlights the potential risk reduction and prevention of critical failures that might otherwise go unnoticed, providing actionable insights for asset integrity managers in the O&G sector.