The HAZOP Revalidation Study for OQ Aromatics Plant in Oman was undertaken by Elixir Engineering to support Oman Oil Company’s (OQ) strong focus on process safety and operational excellence. In the oil and gas industry, conducting regular risk assessments is critical to preventing incidents, maintaining regulatory compliance, and ensuring continuous plant operations.
This study aimed to identify potential hazards, assess operability issues, and validate the adequacy of existing safety systems, ensuring risks remain at ALARP (As Low As Reasonably Practicable) levels throughout the facility
Located in Oman, the OQ Aromatics Plant is an integral part of one of the most sophisticated refinery complexes in the Middle East. The plant processes naphtha to produce high-value products such as benzene, paraxylene, gasoline, diesel, jet fuel, LPG, and petrochemical feedstocks. In the process, valuable by-products like light naphtha, hydrogen, LPG, and heavy aromatics are generated and further circulated within the refinery for downstream use.
The facility is organized into three primary operational areas:
As part of this HAZOP Revalidation Study, Elixir Engineering reviewed and analyzed more than 480 Piping and Instrumentation Diagrams (P&IDs), covering all major process and utility systems. The study also included evaluation of vendor-specific packages such as compressors, dryers, Pressure Swing Adsorption (PSA) units, and refrigeration systems. In addition, a detailed review of Management of Change (MoC) records was carried out, along with verification of the status of previous HAZOP recommendations.
The objective of the revalidation study was to identify new hazards that may have emerged from operational changes or MoCs, assess the effectiveness of existing safeguards, and address open items from the previous HAZOP. Additionally, the team looked for opportunities to enhance safety and improve overall process reliability.
A guideword-driven approach was used to assess deviations from intended design and to evaluate their possible causes and consequences. This structured methodology helped in validating the risk control measures and identifying gaps requiring mitigation.
The HAZOP Revalidation was conducted through multiple structured workshops facilitated by Elixir Engineering. A multidisciplinary team participated in the sessions, including process engineers, operations and maintenance personnel, safety professionals, instrumentation experts, and a certified HAZOP facilitator.
Each section of the plant was reviewed using standard guidewords such as No Flow, High Pressure, and Reverse. For every deviation, the team assessed its potential causes and consequences and discussed the effectiveness of current safeguards.
A two-tier risk ranking method was applied:
Risk was evaluated using the formula:
Risk = Probability × Severity, following the OQ Risk Matrix. All findings and discussions were documented using OQ’s standardized HAZOP worksheet.
The HAZOP Revalidation Study was successfully completed with active engagement from OQ’s operations and engineering teams. Key outcomes included:
The study delivered several tangible benefits for the client:
Through the HAZOP Revalidation Study for the OQ Aromatics Plant in Oman, operational risks were thoroughly assessed and brought under control, ensuring continued compliance with international safety standards.
By applying a systematic, collaborative, and expertise-driven approach, the team successfully enhanced process safety and supported the plant’s long-term reliability and performance.
Partner with Elixir Engineering to enhance safety, reduce operational risk, and ensure compliance with international standards.
Contact Us to schedule your HAZOP consultation.
