Abstract

This paper proposes a conceptual framework for process safety and operational reliability in floating production, storage, and offloading (FPSO) energy systems operating under harsh, data-sparse, and cost-constrained conditions. The framework integrates barrier-based safety thinking with reliability-centered maintenance and digital assurance to prevent loss of containment, mitigate escalation, and assure uptime across the asset lifecycle. A systems layer maps hydrocarbon, power, and utility networks, interfaces, and safety-critical elements to expose bow-tie hazards, safety functions, and dependencies. An observability layer fuses condition monitoring, process historians, and marine instrumentation with physics-informed digital twins to estimate unobserved states, detect weak signals, and quantify risk in real time. A decision layer combines risk-based inspection, reliability block diagrams, and Bayesian updating to prioritize interventions by consequence, likelihood, and uncertainty, enabling defensible ALARP demonstrations. An optimization-and-control layer orchestrates start-up, steady-state, and upset responses using model predictive control with constraint handling, supported by flare minimization, gas compression anti-surge, and power management strategies. A human-and-organization layer embeds just culture, competence management, and procedural discipline, aligning control room practices with safety cases and permit-to-work governance. Cyber-physical assurance closes the loop through verification and validation of models, safety instrumented system proof testing, cybersecurity hardening, and anomaly triage workflows. Implementation proceeds through four phases: (1) baseline risk and reliability modeling and data readiness; (2) pilot twin deployment on topsides subsystems (e.g., separators, compressors, cargo handling); (3) integrated optimization with alarm rationalization and barrier health dashboards; and (4) fleet scaling with continuous learning. Key performance indicators include barrier health, loss of containment frequency, safety system demand failure probability, mean time between failures, deferment, flare intensity, and recovery time from upsets. Illustrative use cases show earlier detection of incipient compressor surge, tighter flare compliance during turndown, and reduced SIMOPS conflict via dynamic risk visualization. The framework is standards-aware (ISO 31000, IEC 61511, ISO 14224, and IMO), technology-agnostic, and adaptable to brownfield retrofits, remote operations centers, and hybrid power integrations. By linking hazards, data, decisions, and controls within a governed, human-in-the-loop loop, the framework provides a practical pathway to demonstrably safer operations, higher reliability, and lower environmental footprint for FPSO-based energy systems at industrial scale.