Melios was pleased to present its work on “Predictive Safety Critical Element Management: Integrating Cumulative Risk Assessment, Maintenance Optimisation and Artificial Intelligence” at the recently concluded CCPS/EPSC Global Conference on Process Safety and Big Data in Frankfurt.

The presentation introduced a predictive approach to Safety Critical Element (SCE) management. It combines cumulative risk assessment, maintenance optimisation and artificial intelligence to show where residual risk is really building up across a facility's barriers. A key insight was that conventional backlog metrics can hide uneven risk exposure. By linking maintenance backlog directly to barrier degradation, operators can see which barriers are eroding fastest and act before cumulative risk becomes unacceptable.

This work draws on Melios' experience in safety cases, HAZOP, bowtie analysis and HSSE audits. It also reflects the thinking behind REVaRS, our Risk Exposure Visualisation and Reporting Solution, which helps operators turn barrier and maintenance data into clear, decision-ready risk insight.

Our thanks go to CCPS, EPSC and the organising committee, and to the delegates who engaged with the work. If you would like to explore how predictive SCE management could support your operations, we would be glad to talk.