Optimizing emergency shutdown system inspection, testing, and maintenance through the tool design and validation

Emergency Shutdown (ESD) systems serve as reliable control mechanisms within the petrochemical industry. These systems enhance safety by automatically shutting down processes during emergencies, mitigating hazards. The effectiveness of ESD systems is closely linked to robust practices in inspection, testing, and maintenance (ITM). This study aims to optimize the ITM of ESD systems through an asset integrity management (AIM) approach in the petrochemical industry located in the Assaluyeh region of Iran, focusing on the analysis of individual and organizational factors as well as the design and validation of a specialized assessment tool. The research follows a structured methodology. The first step involves identifying, screening, and validating the individual and organizational factors that influence the effectiveness of ITM for ESD systems. This is achieved through a literature review and expert opinions gathered via the Fuzzy Delphi method. The second step entails the development of tool items based on the literature review and expert feedback, along with verifying reliability and validity. By concentrating on aspects such as planning, supervision and support, documentation, communication, training, safety, and the integration of new technologies and artificial intelligence, organizations can significantly enhance their ITM practices. The tool designed for assessing individual and organizational factors in the ITM of ESD systems demonstrated strong validity and reliability. The validation of this tool underscores the importance of having accurate instruments to evaluate current conditions and future requirements, ultimately leading to the optimization of ESD systems.