PurposeThe aim of this study is to employ the failure mode and effect analysis (FMEA) for risk management in cross-country pipelines, coupled with the utilization of Geographic Information System (GIS). The objective is to enhance the significance of the project, considering the potential severe consequences of pipeline failures. These consequences encompass environmental damages, loss of life and disruptions to critical services like energy and water supply. By identifying the most frequent causes of pipeline failures and developing a predictive model, the intention is to contribute toward the prevention of such incidents and minimize their impact.Design/methodology/approachA total quality management (TQM) technique for risk management; FMEA, was employed in this study integrated with GIS. Eight specific failures were identified and analyzed, exploring their effects and severity, causes and likelihood of occurrence as well as control and detection value. To find the likelihood of occurrence along the pipeline, the GIS was utilized to survey a 10 km wide area along the pipeline of 180 km long. Occurrence spatial mapping for each individual failure was generated. Subsequently, the risk priority number (RPN) was calculated for each failure, presenting the values as separate maps. By overlaying the RPN maps, a final map was generated, illustrating the areas with the highest risk along the pipeline.FindingsA modified risk management model has been developed to detect potential pipeline failures before they escalate into catastrophic events. The results provide a visual representation of the average failure modes along the pipeline, clearly highlighting regions with varying probabilities of failure based on RPN values. The RPN has been meticulously calculated across the entire pipeline, with results presented through both 2D spatial mapping and a comprehensive line graph. This comprehensive approach sets our study apart from others in the field. Our emphasis on a thorough and inclusive risk assessment methodology represents a key novelty in this research. The findings underscore the paramount importance of proactive maintenance and regular inspection practices, with these measures emerging as critical strategies for enhancing the reliability and safety of pipeline infrastructure.Research limitations/implicationsThis research study aims to enhance the safety and quality of cross-country pipelines. The main limitations of the study include the inability to consider the risks associated with the flow characteristics inside the pipeline and the exclusion of the future master plan from our analysis.Practical implicationsThe current integrated model is significant for pipeline operative companies and the oil and gas industries. These pipelines are susceptible to failures that can have alarming negative impacts on the environment, human safety and public health. It can improve the quality of risk management and elevate the safety integrity level of their pipelines. Focusing on the high-risk areas, taking action and implementing proactive measures can reduce the risk of failure and improve the safety and reliability of the pipeline system. It utilizes GIS-detailed surveying of the areas along the pipeline without the necessity of making on-site visits.Originality/valueThis study introduces a novel framework incorporating FMEA for quality risk management with advanced spatial mapping GIS software. This approach stands out as a unique contribution to the field, as prior studies have not undertaken the comprehensive task of highlighting risks along the entire pipeline using such a sophisticated methodology. This research makes a significant contribution to the field of crude oil transportation through pipelines, ultimately mitigating the risk of undesirable events.
