Application of STPA for Comprehensive Risk Analysis of Naphtha Explosion Hazards

Chemical accidents always result in significant losses due to the flammable, explosive, and toxic characteristics of hazardous chemicals. Analysis of process safety parameters is an effective way to prevent hazardous chemical accidents and reduce losses. System-theoretic process analysis (STPA) is a newer hazard analysis technique that is based on systems theory. It has been shown to be effective in identifying hazards in other industries, but its application in oil and gas plants is still rare and limited due to systems complexities and other challenges. This paper aims to apply the STPA method to a complex system “column C-63” at the Skikda RA1K refinery to prevent the explosion scenario of naphtha. The results show that STPA was able to identify the root causes of the explosion scenario, which is important for preventing chemical risks.