An Integrated Risk-Based Decision-Making Framework for Enhancing Industrial Steam Boiler Safety: Hybridizing HAZOP-FMEA-LOPA with AHP-TOPSIS Analysis

Industrial steam boilers, serving as the core of thermal processes, represent a focal point for catastrophic operational risks. This research aims to transition from reactive safety management to a predictive paradigm by developing an integrated engineering decision-making framework for risk management across 12 livestock feed factories in Isfahan province. The methodology employs a five-stage algorithm comprising deviation identification via HAZOP, root cause analysis and risk quantification using integrated FMEA and FTA, safety gap assessment of protection layers via LOPA methodology, and finally, strategic prioritization of corrective actions using the AHP-TOPSIS multi-criteria decision-making approach. Findings from the analysis of 245 failure modes revealed that 48.2% of scenarios fell within the unacceptable risk range ( ), while only 22.9% of Independent Protection Layers (IPLs) fully complied with ASME and NFPA standards. Final prioritization results indicate that implementing an IoT-based smart monitoring platform, retrofitting critical mechanical connections, and competency-based personnel training—as the top strategies—offer the potential to reduce the operational risk index by 55.3% and lower the frequency of critical incidents to less than one per year, achieving a payback period of 3.5 years.