Operational Risk Simulation Framework with Process Topology Analysis by EvenSol · Pull Request #1847 · equinor/neqsim

EvenSol · 2026-01-30T16:18:35Z

Summary

This PR introduces a comprehensive Operational Risk Simulation Framework for NeqSim, enabling equipment failure analysis, production impact assessment, degraded operation optimization, Monte Carlo risk simulation, and process topology/dependency analysis with STID (Standard Tag Identification) support.

🎯 Key Features

1. Equipment Failure Modeling (`neqsim.process.equipment.failure`)

Class	Description
`EquipmentFailureMode`	Defines failure types (TRIP, DEGRADED, PARTIAL_FAILURE, FULL_FAILURE, MAINTENANCE, BYPASSED) with capacity reduction factors
`ReliabilityDataSource`	Singleton providing OREDA-based reliability data (MTTF, failure rates, repair times) from CSV files

Example:

EquipmentFailureMode failure = EquipmentFailureMode.trip("Compressor A", "High vibration");
failure.getCapacityReduction();  // Returns 1.0 (100% loss)

ReliabilityDataSource.getInstance().getMTTF("Compressor");  // Returns 8760 hours

2. Production Impact Analysis (`neqsim.process.util.optimizer`)

Class	Description
`ProductionImpactAnalyzer`	Analyzes production loss from equipment failures, compares to plant stop scenarios
`ProductionImpactResult`	Contains production loss %, affected equipment list, revenue impact
`DegradedOperationOptimizer`	Optimizes plant operation during equipment outages
`DegradedOperationResult`	Recovery plans with step-by-step operational changes

Example:

ProductionImpactAnalyzer analyzer = new ProductionImpactAnalyzer(processSystem);
ProductionImpactResult result = analyzer.analyzeFailureImpact(failureMode);

System.out.println("Production loss: " + result.getPercentLoss() + "%");
System.out.println("Revenue impact: $" + result.getRevenueImpact());

3. Monte Carlo Risk Simulation (`neqsim.process.safety.risk`)

Class	Description
`OperationalRiskSimulator`	Monte Carlo simulation of equipment failures over time
`OperationalRiskResult`	Statistical results (P10/P50/P90, expected losses, confidence intervals)
`RiskMatrix`	5×5 graphical risk matrix with probability, consequence, and cost dimensions

Risk Matrix Categories:

Probability	Consequence	Risk Levels
RARE (1)	NEGLIGIBLE (1)	LOW
UNLIKELY (2)	MINOR (2)	MEDIUM
POSSIBLE (3)	MODERATE (3)	HIGH
LIKELY (4)	MAJOR (4)	VERY_HIGH
ALMOST_CERTAIN (5)	CATASTROPHIC (5)	EXTREME

Example:

OperationalRiskSimulator simulator = new OperationalRiskSimulator(process);
simulator.addEquipmentWithReliability("Compressor A", 8760, 24);  // MTTF, MTTR
OperationalRiskResult result = simulator.runSimulation(10000, 365);

System.out.println("Expected production loss: " + result.getExpectedProductionLoss() + "%");
System.out.println("P90 loss: " + result.getP90Loss() + "%");

// Risk Matrix
RiskMatrix matrix = new RiskMatrix();
matrix.addRiskItem("Compressor Trip", ProbabilityCategory.POSSIBLE, 
                   ConsequenceCategory.MAJOR, 500000.0);
System.out.println(matrix.toVisualization());

4. Process Topology Analysis (`neqsim.process.util.topology`)

Class	Description
`ProcessTopologyAnalyzer`	Extracts graph structure from ProcessSystem, identifies parallel equipment
`FunctionalLocation`	STID tag parsing and validation (format: `PPPP-TT-NNNNN[S]`)
`DependencyAnalyzer`	Analyzes cascade failure effects, cross-installation dependencies

STID Format:

PPPP-TT-NNNNN[S]
│    │  │     └─ Train suffix (A, B, C...)
│    │  └─────── Sequence number
│    └────────── Equipment type (KA=compressor, PA=pump, VG=separator)
└─────────────── Installation code (1775=Gullfaks C, 2540=Åsgard A)

Installation Codes:

Code	Installation
1775	Gullfaks C
1776	Gullfaks A
1777	Gullfaks B
2540	Åsgard A
2541	Åsgard B
6608	Troll A

Example:

// Build topology
ProcessTopologyAnalyzer topology = new ProcessTopologyAnalyzer(process);
topology.buildTopology();

// Add STID tags
topology.setFunctionalLocation("Compressor A", "1775-KA-23011A");
topology.setFunctionalLocation("Compressor B", "1775-KA-23011B");

// Check parallel equipment
FunctionalLocation locA = new FunctionalLocation("1775-KA-23011A");
FunctionalLocation locB = new FunctionalLocation("1775-KA-23011B");
locA.isParallelTo(locB);  // Returns true

// Analyze dependencies
DependencyAnalyzer deps = new DependencyAnalyzer(process, topology);
FailureImpactResult result = deps.analyzeFailure("Compressor A");

// What equipment needs extra monitoring?
Map<String, String> toMonitor = deps.getEquipmentToMonitor("Compressor A");

5. Cross-Installation Dependency Analysis

Supports tracking dependencies between installations (e.g., Gullfaks → Åsgard gas export):

// Define cross-installation dependency
deps.addCrossInstallationDependency(
    "Export Gas",              // Source equipment
    "Åsgard Inlet Separator",  // Target equipment
    "Åsgard A",                // Target installation
    "gas_export"               // Dependency type
);

// Or using STID tags
FunctionalLocation source = new FunctionalLocation("1775-KA-23011A");  // Gullfaks
FunctionalLocation target = new FunctionalLocation("2540-VG-30001");   // Åsgard
deps.addCrossInstallationDependency(source, target, "gas_export", 0.6);

// Analyze cross-installation effects
FailureImpactResult result = deps.analyzeFailure("Export Gas");
for (CrossInstallationEffect effect : result.getCrossInstallationEffects()) {
    System.out.println("Affects: " + effect.getTargetInstallation());
    System.out.println("Impact: " + effect.getImpactFactor() * 100 + "%");
}

📁 Files Added

Java Source Files (14 files)

Package	File	Description
`failure`	`EquipmentFailureMode.java`	Failure type definitions with builder pattern
`failure`	`ReliabilityDataSource.java`	OREDA reliability data singleton
`failure`	`package-info.java`	Package documentation
`risk`	`OperationalRiskSimulator.java`	Monte Carlo simulation engine
`risk`	`OperationalRiskResult.java`	Simulation results with statistics
`risk`	`RiskMatrix.java`	5×5 risk matrix with visualization
`optimizer`	`ProductionImpactAnalyzer.java`	Failure impact analysis
`optimizer`	`ProductionImpactResult.java`	Impact analysis results
`optimizer`	`DegradedOperationOptimizer.java`	Degraded operation optimization
`optimizer`	`DegradedOperationResult.java`	Optimization results
`topology`	`ProcessTopologyAnalyzer.java`	Graph extraction from ProcessSystem
`topology`	`FunctionalLocation.java`	STID tag parsing
`topology`	`DependencyAnalyzer.java`	Cascade failure analysis
`topology`	`package-info.java`	Package documentation

Data Files (2 files)

File	Description
`reliabilitydata/equipment_reliability.csv`	OREDA-based MTTF/MTTR data
`reliabilitydata/failure_modes.csv`	Failure mode definitions

Test Files (9 files)

File	Tests
`EquipmentFailureModeTest.java`	Failure mode creation, capacity reduction
`ReliabilityDataSourceTest.java`	OREDA data loading, lookups
`ProductionImpactAnalyzerTest.java`	Impact analysis, equipment ranking
`DegradedOperationOptimizerTest.java`	Optimization, recovery plans
`OperationalRiskSimulatorTest.java`	Monte Carlo simulation
`RiskMatrixTest.java`	Risk matrix operations, visualization
`ProcessTopologyAnalyzerTest.java`	Topology extraction, parallel detection
`FunctionalLocationTest.java`	STID parsing, validation
`DependencyAnalyzerTest.java`	Failure cascade, cross-installation

Jupyter Notebooks (4 files)

Notebook	Description
`RiskSimulationDemo.ipynb`	Monte Carlo risk simulation demo
`ProductionImpactAnalysis.ipynb`	Production loss analysis
`DegradedOperationDemo.ipynb`	Degraded operation optimization
`TopologyDependencyAnalysis.ipynb`	Topology and STID tagging demo

🧪 Test Coverage

All new functionality includes comprehensive unit tests:

neqsim.process.equipment.failure - 12 tests
neqsim.process.util.optimizer    - 18 tests  
neqsim.process.safety.risk       - 15 tests
neqsim.process.util.topology     - 27 tests
────────────────────────────────────────────
Total: 72 new tests

📊 API Summary

Risk Simulation Flow

┌─────────────────┐     ┌──────────────────────┐     ┌────────────────────┐
│ EquipmentFailure│────►│ ProductionImpact     │────►│ DegradedOperation  │
│ Mode            │     │ Analyzer             │     │ Optimizer          │
└─────────────────┘     └──────────────────────┘     └────────────────────┘
        │                        │                            │
        ▼                        ▼                            ▼
┌─────────────────┐     ┌──────────────────────┐     ┌────────────────────┐
│ Reliability     │     │ OperationalRisk      │     │ RiskMatrix         │
│ DataSource      │     │ Simulator (MC)       │     │ (5×5 Visualization)│
└─────────────────┘     └──────────────────────┘     └────────────────────┘

Topology Analysis Flow

┌─────────────────┐     ┌──────────────────────┐     ┌────────────────────┐
│ ProcessSystem   │────►│ ProcessTopology      │────►│ DependencyAnalyzer │
│                 │     │ Analyzer             │     │                    │
└─────────────────┘     └──────────────────────┘     └────────────────────┘
                                 │                            │
                                 ▼                            ▼
                        ┌──────────────────────┐     ┌────────────────────┐
                        │ FunctionalLocation   │     │ CrossInstallation  │
                        │ (STID Tags)          │     │ Dependencies       │
                        └──────────────────────┘     └────────────────────┘

🔧 Usage from Python (neqsim-python)

import jpype
import neqsim

from neqsim.process.util.topology import ProcessTopologyAnalyzer, FunctionalLocation
from neqsim.process.safety.risk import RiskMatrix, OperationalRiskSimulator

# Topology analysis
topology = ProcessTopologyAnalyzer(process)
topology.buildTopology()
topology.setFunctionalLocation("Compressor A", "1775-KA-23011A")

# Risk matrix
matrix = RiskMatrix()
matrix.addRiskItem("Compressor Trip", 
                   RiskMatrix.ProbabilityCategory.POSSIBLE,
                   RiskMatrix.ConsequenceCategory.MAJOR, 
                   500000.0)
print(matrix.toVisualization())

✅ Checklist

All tests passing
Java 8 compatible (no var, List.of(), etc.)
Complete JavaDoc documentation
OREDA-based reliability data included
Jupyter notebook examples
Cross-installation support (Gullfaks ↔ Åsgard)
STID tag parsing and validation
JSON and DOT graph export

🔗 Related Issues

Equipment reliability analysis for production optimization
Process topology extraction for dependency mapping
STID/SAP integration for functional location tagging
Cross-field dependency analysis (multi-installation)

📝 Notes

All reliability data is based on OREDA (Offshore Reliability Data) handbook values
STID installation codes follow Norwegian Continental Shelf standards
Risk matrix follows ISO 31000 / NORSOK Z-013 guidelines
Topology export supports Graphviz DOT format for visualization

EvenSol added 5 commits January 30, 2026 12:04

update

4950903

a nuer of updates

fc8160e

update

636cf56

update

b109213

update

7e49def

EvenSol merged commit 46e2098 into master Jan 30, 2026
7 checks passed

EvenSol deleted the streaming-processes branch January 30, 2026 16:43

Provide feedback

Saved searches

Use saved searches to filter your results more quickly

Operational Risk Simulation Framework with Process Topology Analysis#1847

Operational Risk Simulation Framework with Process Topology Analysis#1847
EvenSol merged 5 commits intomasterfrom
streaming-processes

EvenSol commented Jan 30, 2026

Uh oh!

Uh oh!

Reviewers

Assignees

Labels

Projects

Milestone

Development

Uh oh!

1 participant

Conversation

EvenSol commented Jan 30, 2026

Summary

🎯 Key Features

1. Equipment Failure Modeling (neqsim.process.equipment.failure)

2. Production Impact Analysis (neqsim.process.util.optimizer)

3. Monte Carlo Risk Simulation (neqsim.process.safety.risk)

4. Process Topology Analysis (neqsim.process.util.topology)

5. Cross-Installation Dependency Analysis

📁 Files Added

Java Source Files (14 files)

Data Files (2 files)

Test Files (9 files)

Jupyter Notebooks (4 files)

🧪 Test Coverage

📊 API Summary

Risk Simulation Flow

Topology Analysis Flow

🔧 Usage from Python (neqsim-python)

✅ Checklist

🔗 Related Issues

📝 Notes

Uh oh!

Uh oh!

Reviewers

Assignees

Labels

Projects

Milestone

Development

Uh oh!

1 participant

1. Equipment Failure Modeling (`neqsim.process.equipment.failure`)

2. Production Impact Analysis (`neqsim.process.util.optimizer`)

3. Monte Carlo Risk Simulation (`neqsim.process.safety.risk`)

4. Process Topology Analysis (`neqsim.process.util.topology`)