elixir-engineering-logo
Register

HAZOP Revalidation Study For Various Area's of Sohar Refinery,Oman

At Elixir Engineering, we specialize in delivering high-quality HAZOP Revalidation Studies to help ensure that your industrial processes continue to meet safety standards. Our expertise extends across various areas of SR1, where we help companies achieve compliance, reduce risks, and improve operational safety. Elixir Engineering  was awarded to perform HAZOP Revalidation Study for SR1 (AREA-100, AREA-200, AREA-300, AREA-400, AREA-500 and utilities for SOHAR REFINERY

What is a HAZOP Revalidation Study?

A HAZOP Revalidation Study (Hazard and Operability Study) is a comprehensive review of your existing process designs and operations to identify potential hazards and operational inefficiencies. This study is essential for industries where safety and reliability are paramount. The revalidation ensures that your previous HAZOP findings remain relevant and that any changes or aging factors in the system are addressed.

Project Summary

  • 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.
  • The OQ Sohar Refinery is located in the industrial area of Sohar, in the northern part of Oman.
  • The refinery was originally built in the 2000s as a joint venture between Oman Oil Company and Aromatics Oman LLC. However, in 2011, Oman Oil Company acquired Aromatics Oman LLC, and the OQ Sohar Refinery became a fully owned subsidiary of Oman Oil Company.
  • The OQ Sohar Refinery has undergone significant expansions and upgrades in recent years to increase its capacity and improve its efficiency.
  • In 2017, the refinery completed its $3.6 billion Sohar Refinery Improvement Project (SRIP), which involved the construction of a new crude oil unit, a new hydrocracker unit, and upgrades to existing units.
  • The OQ Sohar Refinery is a critical component of Oman's economy, providing the country with a reliable source of refined products for domestic consumption and for export to other countries in the region.
  • It also supports Oman's growing petrochemical industry, providing feedstocks for the production of plastics, chemicals, and other products

Hazard & Operability study (HAZOP)

What is Hazard and Operability (HAZOP) Study

Hazard and Operability (HAZOP) Study is a structured and systematic evaluation of a planned and/or existing operation to identify and evaluate potential hazards in design and operation.

  • This study is carried out by a team of engineers from different disciplines.
  • The team looks at each section of a plant or system or operation (node), considers potential deviations from intended operation and analyses their consequences against any existing safeguards.
  • Impact of identified hazards on safety, asset and environment are assessed.

HAZOP is a guideword driven brainstorming technique. Team members contribute based on their collective experience and lessons learnt from past projects.

  • HAZOP study records the identified hazards without proposing any solution, unless a solution is obvious.
  • Proposed solutions may include additional safeguards or operational procedures as necessary. The study record serves as a guide to determine the Health, Safety and Environment (HSE) issues to be resolved during the project.

Purpose of HAZOP:

HAZOP for any project or modification serves many purposes including

  • Identify the hazards inherent to the proposal.
  • Identify the credible equipment instrument failure likely to lead to accident scenarios / hazards / operability problems
  • In addition to these issues, HAZOP occasionally identified items which could improve unit operations and efficiency

Methodology

The HAZOP focuses on the process / utility system and associated interfaces. The basic concept of a HAZOP study is to take full description of the process and question every part of it during brain storming meetings attended by the different specialists involved in the process design to discover firstly what deviations from the intention of design can occur and what their causes and consequences may be.

The main steps involved in a HAZOP study are as follows:

  • Select the node (Line, equipment or a system) on the P&ID;
  • List of the intention & process parameters, guidewords for the nodes;
  • List all deviations an ignore deviations that are not meaningful and apply the deviation;
  • Brainstorm and list various causes of the deviation and ignore causes that are not credible;
  • Determine the consequences of the deviations due to each listed credible cause;
  • Identify safeguards already provided in the system
  • Suggest recommendations / actions, should the safeguards be inadequate;
  • Repeat steps 3 to 7 for each deviation
  • Repeat steps from one (1) to eight (8) on the next node until all the nodes are covered.
The image is a flowchart illustrating the process of conducting a HAZOP Hazard and Operability HAZOP study flowchart detailing step-by-step analysis for identifying and mitigating risks in process design. The process starts with explaining the overall design, followed by selecting a node and agreeing on the design intent. Key elements and characteristics are identified, and guide words are applied to analyze deviations. Each deviation is checked for credibility. The study investigates the causes, consequences, protections, or indications of potential hazards. The process repeats for all elements until every part has been examined, concluding with the documentation of findings

Elements of HAZOP study:

  • Node definition
    • The HAZOP study progresses through the plant node by node.
    • The selection of the node sizes and the route through the plant is made before the study by the facilitator.
    • The node should be described in terms of: -
      • Brief description of the node
      • Typical operating and design conditions
      • Method of operation and maintenance, and requirement for operator intervention
  • Parameters
    • Flow, Pressure & temperature are usually regarded as the main parameters/elements.
    • Additional parameters relate to general considerations like maintenance, safety, relief, corrosion/ erosion, instrumentation, start-up & shutdown, etc.
    • Some of these may be selected for nodes in a study as appropriate based on relevance and concerns expressed by team members.
  • Guidewords
    • Guide words are simple words or phrases used to qualify or quantify the intention and associated parameters in order to suggest deviations.
    • Standard guide words; No/less, more/Less, As Well As/Part of, Reverse/Other Than, Early/Late, Before/After are applicable to each parameter. ‘Other Than’ is a very popular ‘catch all’ guide word at the end of each parameter.
The image shows a table of HAZOP study parameters and corresponding guidewords used to identify potential deviations in process systems. The parameters include Flow, Pressure, Temperature, Level, and Others. Each parameter is associated with guidewords such as No/Less, More, Reverse Flow for Flow; Low and High for Pressure, Temperature, and Level; and Exchanger Leak and Composition under Others. This table helps guide systematic analysis of potential hazards in a process by examining deviations from normal operating conditions.
  • Causes
    • All credible/ plausible scenarios leading to the deviations, should be considered when determining causes.
    • The Causes should be “Local” to the node being studied. The consequences are deliberated only after listing all the Causes.
    • Two events happening simultaneously without any correlation should not be considered.
  • Consequence
    • Global effects should be considered for the consequences i.e., Keep researching the resulting reactions till you reach the Ultimate Consequence of a deviation.
  • Safeguards
    • Risk is a function of both Probability and Consequence.
    • Safeguards reduce either Probability or Consequence.
    • These could be either related to hardware or operator practices & intervention., While selecting safeguards, you may consider engineering or administrative safeguards, but it is necessary to check whether these are existing & functional for the operating plant
  • Risk matrix
    • Risk assessments should be carried out to quantify the risks associated with deviations and their potential consequences, and to assist in determining the adequacy of planned safeguards and the possible need for further action.
    • An initial informal risk assessment should be carried out on each case – Consequence scenario based on the inherent risk in the unprotected state.
    • The risk matrix included in the below table should be used as a guide.
    • The risk should then be reassessed taking into consideration the planned safeguards and risk reduction measures.
    • For less important risks, the need for further action can be based on the experience and judgement of the HAZOP study team.
The image is a risk matrix used to assess risks based on five categories of consequences: Health & Safety, Environmental, Stakeholder Impact, and Financial Impact, and five likelihood levels, ranging from Practically Impossible to Possibility of Repeated Incidents. Consequences are rated from I, most severe, to V, least severe, and risks are color-coded as red for high, yellow for medium, or green for low based on the combination of severity and likelihood. This tool helps prioritize risks for effective management.
The image is a simple risk impact table that categorizes risks into four levels based on their impact. The table uses color coding: black represents extreme risk, red indicates high risk, yellow signifies moderate risk, and green represents low risk. This table helps quickly assess and classify the severity of different risks for decision-making and management purposes.
  • Once the reasonable consequence and likelihood of each potential unwanted event is determined, the risk can be ranked using the above “Risk Assessment Matrix” and recorded on the HAZOP study Worksheet.

Recommendations

  • Recommendations should be reported using action-based words (such as Check, Provide, Consider, Ensure, Review etc.), and assigned to specific work groups.
  • It should be verified whether three chief questions have been explained, viz.
    • What is to be done?
    • Where is it to be done?
    • Why is it to be done?

Key Benefits of HAZOP Revalidation

  • Risk Identification and Mitigation: Our team thoroughly reviews your processes to identify new risks and recommend the best strategies to mitigate them.
  • Regulatory Compliance: Stay compliant with the latest industry safety regulations and avoid penalties.
  • Enhanced Operational Safety: Safeguard your workforce and equipment by addressing potential hazards before they become critical.
  • Optimized Performance: By identifying inefficiencies, we help streamline operations and improve performance.

Why Choose Elixir Engineering for Your HAZOP Revalidation Study?

At Elixir Engineering, we bring a wealth of experience in conducting HAZOP studies for various industries. Our team of experts uses the latest methodologies and advanced tools to deliver precise and actionable insights. We work closely with your team to ensure that the HAZOP revalidation process is smooth, efficient, and tailored to your operational needs.

  • Proven Expertise: Years of experience working with diverse industries.
  • Tailored Solutions: We adapt our approach to your specific operational challenges.
  • Cost-Effective: Competitive pricing without compromising on quality.

Explore More Engineering Insights CLICK HERE

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.
Contact Form
Use this form to contact our team. We usually respond within 24 hours but it can take longer on weekends and around public holidays.
Contact Form
crossmenu