Exploring the relationships between safety and maintenance in the cold generation process: insights from the functional resonance analysis method

Industrial refrigeration systems typically use ammonia as a refrigerant gas, which is a toxic gas so leaks can be catastrophic. This study aimed to identify how to improve robustness in a cold generation process using the functional resonance analysis method (FRAM). A case study was conducted through interviews and direct observations to develop three FRAM models: one focusing on operation and maintenance functions; another focusing on functions related to the provision of occupational health and safety (OHS) measures; and a third overlapping the first two models. Results revealed that the management of OHS is restricted to the legislation applied to piping under pressure, and the company did not consider a more comprehensive safety approach for the ammonia storage stage. This study also highlighted the need for action, such as non-destructive and penetrating liquid tests, in one of the process steps considered critical for operation and maintenance, but not for OHS.