Fuzzy-FMEA risk assessment approach for pipelines in the oil and gas industry

Purpose The midstream segment of the oil and gas industry is critical, as it operates between the upstream and downstream sectors and handles hazardous materials. Although pipelines are among the safest modes of transportation, their failure can pose significant risks. This paper aims to propose an effective risk assessment approach based on fuzzy-failure mode and effects analysis (FMEA) for the midstream segment of oil and gas pipelines to ensure that associated risks are identified, evaluated and mitigated. Design/methodology/approach An integrated FMEA and fuzzy approach is proposed to prioritize risk variables and analyze pipelines in the oil and gas industry. The risk variables are identified based on work experience and literature review. The model enhances conventional FMEA by addressing uncertainties arising from stakeholder judgment and limited data availability. It systematically identifies and assesses key risk factors and compares the results with those obtained from traditional FMEA. Findings The findings identified key risk factors, including loss of primary containment (leak), corrosion, unauthorized work and excavation damage. By integrating the fuzzy FMEA approach, the study improves risk evaluation, better addresses uncertainties and leads to more accurate prioritization of maintenance activities. Practical implications The integrated approach offers enhanced decision-making in risk prioritization, leading to improved safety, regulatory compliance and cost savings through reduced downtime and emergency repairs. Its flexibility and scalability allow for application across various pipeline systems, ensuring a more robust and reliable risk management framework. Originality/value This work contributes to the body of knowledge by refining the traditional FMEA methodology to better accommodate uncertainties in risk assessment. The proposed model not only identifies critical risk factors but also offers actionable management strategies, enhancing risk management practices within the oil and gas industry.