Estimating the Reliability and Predicting Damage to Ship Engine Fuel Systems Using Statistics and Artificial Intelligence

The reliability of ocean-going ship engine fuel systems is crucial for the safety and continuous operation of vessels. Failure of this system can lead to serious operational and economic consequences; therefore, effective diagnostics and failure prediction are essential elements of modern fleet management. This paper presents an analysis of the reliability of fuel systems based on operational data from ten bulk carriers operated by Polska Żegluga Morska in Szczecin. The analysis combined classical statistical methods with artificial intelligence algorithms to develop a hybrid diagnostic and forecasting framework. The Weibull lifetime distribution was applied to estimate time-to-failure parameters, revealing mixed failure mechanisms—random failures (k < 1) and aging-related processes (k > 1). Using the k-means algorithm, ships were automatically classified into two reliability groups: high-failure-rate units and stable operational vessels. Individual linear regression models were then developed for each ship to forecast the time to the next failure, achieving satisfactory predictive performance (R2 > 0.75 for most vessels). Sensitivity analysis quantified model robustness under different disturbance scenarios, yielding mean Relative Prediction Deviation (RPD) values of approximately 65% for Missing Data, 60% for False Failure, and 26% for Data Noise. These results confirm that the proposed hybrid reliability–AI framework is resistant to random noise but sensitive to incomplete or erroneous historical data. The developed approach provides an interpretable and effective tool for predictive maintenance, supporting reliability management and operational decision-making in marine engine systems. The article presents a hybrid model that has been developed to enable the detailed characterization of emergency processes and the identification of the most important factors that influence damage forecasting. For systems with variable failure risk, it was found that both classical probabilistic models and machine learning methods must be considered to interpret damage patterns correctly. Implementing data filtration and validation procedures before using data in artificial intelligence models has been shown to improve forecast stability and increase the usefulness of forecasts for planning repairs.