OQ Sohar Refinery is a major oil and gas processing complex located in Oman.
It is one of the largest and most complex refineries in the Middle East, producing a wide range of refined products, including gasoline, diesel, jet fuel, naphtha, LPG, and petrochemical feedstocks.
Objective
The objective is to identify potential hazards involved in the process/operation, evaluate their likelihood and severity based on cause & consequence identified by the HAZOP study, and propose effective control measures to enhance safety and operational efficiency.The Scope of work awarded to Elixir Engineering is to conduct HAZOP Revalidation study that includes only the SR1 Unit of OQ refinery.
HAZOP revalidation study covers the following facilities:
S.NO
UNITDESCRIPTIONSOHAR REFINER (SR1)
PROCESS UNITS
1.
Crude Distillation Unit (CDU)
2.
CDU LPG Merox Unit
3.
Kerosene Merox Unit
4.
RFCC RX-Regen Section
5.
RFCC Main Frac. Section
6.
RFCC Gas Concentration
7.
RFCC Flue Gas Section
8.
RFCC LPG Merox Section
9.
Propylene Recovery Unit
10.
Fuels Selective Hydrogenation
11.
Indirect Alkylation Unit
12.
Distillate Union fining Unit
13.
Hydrogen Generation Unit
14.
Sour Water Stripping Unit
15.
Amine Regeneration Unit
16.
Sulfur Recovery Unit (SRU-1/2)
17.
Tail Gas Treating Unit
18.
Sulfur Granulation Unit
19.
TAME Selective Hydrogenation
20.
Process (TSHP) & TAME Unit
21.
Gasoline Hydro-desulfurization
UTILITIES AND OFFSITE UNITS
1
Power Plant, Electricity Receiving and Distribution System.
2
Sea Water Intake Station
3
Water system
4
Steam and Condensate system
5
Fuel Gas and Natural Gas System
6
Instrument Air and Plant Air system
7
Nitrogen System
8
Chemical Preparation and Injection Facilities
9
Offsite Common
10
Feedstock and Slop Tankage
11
Product and Component Tankage
12
Truck Loading Facilities
13
Marine Loading Facilities
14
Waste Water Treatment
15
Flare System
16
Flushing Oil System
17
LPG Vaporizer
HAZOP Revalidation Procedure
Team Composition
HAZOP Revalidation study is performed by a multidisciplinary team experienced in Engineering, Operations, and Maintenance. Other relevant Experts should be included as required.
The HAZOP Revalidation study for OQ Refinery SR1 consisted of the following Personnel
Two HAZOP leaders
Two HAZOP scribes
Process Engineers from the respective area
Engineer Operations from the respective area
Instrumentation Engineers from the respective area
Safety Engineers
Corrosion Engineer (if required)
Mechanical Engineer(if required)
Rotary Engineer (if required)
HAZOP Methodology
During HAZOP analysis conducted for OQ Refinery SR1, the initial step involves dissecting the process being examined into manageable sections called Nodes.
These Nodes represent logical segments with clearly defined design objectives.
Each Node is then meticulously examined by applying appropriate Guidewords to design parameters, so as to pinpoint potential hazards and operability issues that may arise as a result.
Various factors, such as Equipment malfunction, Human error, Engineering, and administrative controls, as well as external events, are all taken into account as potential sources of hazards.
By employing a Risk Ranking Matrix, the severity, and likelihood of each hazard are assessed, ultimately leading to the assignment of a numerical risk ranking for each identified hazard.
Checklist Analysis
A detailed list of Questions, written from knowledge and experience is used to assess the acceptability or status of the process, system, or operation compared to standard design and operating practices.
Checklist analysis is done for OQ refinery SR1 considering human factors and fire safety.
During Checklist analysis for Human factors, Questions based on Housekeeping and General Work Environment, Accessibility/Availability of Controls and Equipment, Workload and Stress Factors, Training procedures, etc. were captured.
During checklist analysis for fire safety, Questions based on spacing between Process Components, Location, and Construction of Control rooms, Location of Engineering, Lab, Administration or other occupied buildings, Unit Layout, etc. were captured.
Elixir Engineering
Elixir Engineering is a multi-disciplinary Engineering services company. With our strong technical team, we have proven to be effective for our Clients.
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