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<p>The increasing complexity of petrochemical systems demands innovative hazard analysis methods capable of capturing both component and systemic failures. In this paper, we propose a new hazard analysis framework that integrates System-Theoretic Process Analysis (STPA) with traditional Fault Tree Analysis (FTA). Initially, STPA is applied to identify Unsafe Control Actions (UCAs) and associated loss scenarios. Subsequently, FTA is employed to model dysfunctional component behaviors and quantify critical risk metrics, including the Probability of Failure on Demand (PFDavg), Minimal Cut Sets (MCSs), and Safety Integrity Level (SIL) using GRIF software. Finally, STPA outputs are incorporated into the traditional FTA by treating UCAs as basic developed events. The framework is applied to a High Integrity Pressure Protection System (HIPPS 2351) safeguarding the C-63 distillation column at the Skikda RA1K refinery. The results revealed additional MCSs that were not discovered by the traditional FTA, which increased the number of MCSs from 8 to 39. Furthermore, the Birnbaum Importance Factor is applied to rank and prioritize UCAs, identifying the most critical UCAs (UCA 1 through UCA-15) that have a significant impact on the HIPPS 2351 reliability. Overall, the proposed framework provides a comprehensive hazard analysis covering both qualitative and quantitative aspects.</p>

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STPA-FTA hybrid hazard analysis framework applied to a high integrity pressure protection system

  • 期刊论文

  • 发表日期：

    2026年3月26日

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  • Yasser Rehail,
  • Noureddine Tchouar,
  • Youcef Zennir,
  • Andrei Carniel

摘要

The increasing complexity of petrochemical systems demands innovative hazard analysis methods capable of capturing both component and systemic failures. In this paper, we propose a new hazard analysis framework that integrates System-Theoretic Process Analysis (STPA) with traditional Fault Tree Analysis (FTA). Initially, STPA is applied to identify Unsafe Control Actions (UCAs) and associated loss scenarios. Subsequently, FTA is employed to model dysfunctional component behaviors and quantify critical risk metrics, including the Probability of Failure on Demand (PFDavg), Minimal Cut Sets (MCSs), and Safety Integrity Level (SIL) using GRIF software. Finally, STPA outputs are incorporated into the traditional FTA by treating UCAs as basic developed events. The framework is applied to a High Integrity Pressure Protection System (HIPPS 2351) safeguarding the C-63 distillation column at the Skikda RA1K refinery. The results revealed additional MCSs that were not discovered by the traditional FTA, which increased the number of MCSs from 8 to 39. Furthermore, the Birnbaum Importance Factor is applied to rank and prioritize UCAs, identifying the most critical UCAs (UCA 1 through UCA-15) that have a significant impact on the HIPPS 2351 reliability. Overall, the proposed framework provides a comprehensive hazard analysis covering both qualitative and quantitative aspects.