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3-1
Atmosphere Fractionator
Bottom
Vacuum Fractionator
Phenol
Asphalt Separator
Asphalt
Propane
Extraction Column
Hydrofining Section
Additive
Lube Base Oil
Lube Oil
3
50(4)
(Lube Base Oil) (Asphalt)
1
1
5
Section Section
Blending Section
3-2
(1) (Distillation)
(2) (Solvent Extraction) (Phenol; C6H5OH)
(3) (Hydrofinning)
(4) (Dewaxing) (Pour Point)
(5) (Asphalt Separation)
By Product (Vacuum Distillation
Column Reactor Asphalt Cement Product
Reactor Reactor Scrubber Oil Scrubber
Scrubber Incinerator
3-3
Heat upSect ion
Coo l DownSect ion Aspha l t
Disti l lat ion FromVacuum Res idual
Vacuum Fract ionator
Oxid izer
W as t eG a s
Scrubber
Wa t e r
S t e am
Ai r
Hot Oi l
Inc inerator
2
(1) (Lube oil) • (Industrial Grade) • (Automotive Grade)
(2) (Grease) • (Industrial Grade) • (Food Grade)
3.1
xxxxx 11/1 . 2
3-4
1. 2. 3.
0-xxxx-yyyy 0-xxxx-abcd
3 1.
(Kerosene) Tank car 12,000 pump Tank car 500 /
17,000-90,000 80% Level indicator Distributed Control System (DCS)
(DCS)
80% High alarm DCS 1 Solvent
Thinner pump Solvent ½ 3 Manhole
2. (Lubrication Oil Processing)
6 bar Header Header (Mixing)
(Additive) Premix-tank Hopper tank
200
6 , 4 , 2 , 1
3-5
3
Lube Base
H e a d e r
P r em i x
Add i t i ve
H o p p e rT a n k
Fi l l ing Unit
3
3. (Grease Processing)
6 bar Header Header Filter
Soap Contactor Contactor Additive
Heat Oil 65-80 Contactor Air Compressor 7 bar Soap
Soap Soap
Contactor soap Contactor (Kettle)
Soap Filter Homogenizer
Homogenizer
3-6
Homogenizer
4
l u b e b a s e f i l t e r
f i l t e rf i l l i n gu n i t
C o n t a c t o r
k e t t l e
A d d i t i v e s
H o m o g i n i z e r
H e a d e r
4
(Utilities Unit) 4
(1) Hot oil (2) Air Compressor (3) (Stand-by Generator) (4)
LPG, Nitrous Oxide Acetylene
1. Tank car
(Kerosene) (Discharge Valve)
3-7
(Kerosene) (Operator) Alarm High DCS
2T (Kerosene)
Explosion proof
(Solvent) (Toluene) Explosion proof
2.
(Mixing tank) -
(Over pressure) (Kerosene)
Mineral oil
(Ground)
2T
3.
Soap Contactor Tank
Safety Valve
3-8
Soap Contactor Tank (Kettle) Soap Contactor
Hot oil
4.
,
5. (Utilities Unit)
(1) (2) Hot oil Unit (3) Air compressor (4) LPG 45 kg Acetylene
Nitrous Oxide
3-9
3.2
3 ( . .2542)
Major Hazard
Major Hazard 2
3-10
15 2545
1. 1
( Kerosene) Tank car
- Tank car -
-
FMEA (1) What if (1)
-
- / - / Base oil Kerosene
- Base oil Kerosene
-
- - ( Kerosene)
2
(Kerosene)
- /
- Kerosene
-
Fault Tree (1) What if (1)
-
-
-
- -
- -
-
3-11
15 2545
3 ( 1
)
- Solvent Thinner
- Solvent
-
What if (3 ) Check list (1)
- -
- -
2. 1
(Kerosene
- /
/
-
-
HAZOP (1) What if (4)
-
- Over pressure
-
- Premix Tank
2 (Additive)
Premix Tank (Mixing Tank)
- Forklift/
- Additive
- Additive Forklift
- Additive
Mineral Oil
-
Additive
3-12
15 2545
3. -
-
- - Hot Oil
- / - /
Hopper Tank
Hopper Tank
-
- (Ground)
-
-
- Hopper
Tank -
What if (5)
4.
- / /
(Hopper Tank)
-
-
What if (6) FMEA (2)
5.
- Forklift/ Hand Lift -
-
-
-
3. 1.
Soap (Contactor Tank
- /
/
-
-
HAZOP (2) What if (7)
3-13
15 2545
- / Contactor
- Over Pressure
- Contactor
-
2. Additive Load Additive Contactor
- Forklift/Hand Lift -
- Additive
-
Contactor
WI Additive
- Additive - - Additive
Contactor 85ºC
-
-
-
3. Soap Contactor
(Kettle)
- - Hot Oil
-
HAZOP (3) Fault Tree (2)
- - Contactor
- -
3-14
15 2545
- / - Soap
Vast
-
-
-
- / -
4. Homoginizer
- / Homoginizer
-
- Guard
- -
Homoginizer
- Homoginizer
-
Homoginizer
-
-
5. /
- -
- /
6. - -
-
- -
3-15
15 2545
7.
- Fork Lift/Hand Lift -
-
4.
1. Hot Oil & Cooling - -
-
FMEA (3) Event Tree (1)
-
-
-
-
2. - Generator -
-
-
-
- Generator
- Generator Interlock
- /
-
Fault Tree (3) FMEA (4)
3. Air Compressor - /
-
- Air
Compressor 4.
- LPG 45 Kg
Acetylene - -
LPG, Acetylene Nitrous Oxide
3-16
15 2545
- Nitrous Oxide
-
-
-
-
5. -
-
-
- -
-
- -
6.
- , , /, ,
, ,
-
Work Instruction
7.
- Forklift
- /
Work Instruction
3-17
3.3
2 Major Hazard
Major Hazard
3-18
Ke
rosene
CL 01
Y N
NA
1.
a
-
2.
a
- So
lvent
3.
(MSD
S)
a
4.
a
5.
a
6.
a
7. No
n Sp
ark To
ol M
anhole
a
-
Non
Spark
Tool
8. Ex
plosio
n Proo
f
a
9.
a
-
5 ..
10.
a
-
11.
a
12.
a
13.
MSD
S
a
-
3-19
Ch
ecklist
Check
list 1
//
//
CL-0
1 15
25
45
Check
list
1.
-
-
-
-
2 4
8 3
( 02
) (
02)
2. No
n Sp
ark To
ol M
anhole
-
-
- No
n Sp
ark To
ol
2 4
8 3
( 02
) (
02)
3.
-
So
lvent
-
-
Manh
ole
5 ..
-
2 4
8 3
( 02
) (
02)
4.
-
-
-
2 4
8 3
( 02
) (
02)
3-20
Tank
Car
LB A
MV
01
MBV
01
MLS
01
PL
B01
MBP
01
SPV
01
Tank
Car
LB
BM
V 0
2M
BV
02M
LS
02
PL
B02
MBP
02
SPV
02
Tank
Car
KR
01M
V 0
3M
BV
03M
LS
03
PKR
02
MBP
03
SPV
03
PL
B01
PRE
MIX
01
FT
MT
K01
MB
K02
MB
K01
TL
01
TL
02
TL
03
PT
L01 PT
L02 P
TL
03
Filt
er
Filt
er
Filt
er
200
L
1.0
L
0.7
L
SPV
04
SPV
05
MBV
04
MLS
04
KL
01
MTK
02
MTK
03
MTK
04
MTK
05
MTK
06
MTK
07
KL
02
MLS
05
KL
03
MLS
06
MBV
05
MBV
06
MBF
01
MBF
02
MBF
03
SPV
06
SPV
07
SPV
08
SPV
09
PI
(B)
(A)
(C)
(D
)
(C)
Wh
at
if A
na
lysi
s (1
) -
(6)
S-E
E-00
1 R
ev. 0
1
5-6-
45 L
UBR
ICAT
ION
PRO
CESS
ION
3-21
W
hat If
Analy
sis
What
If (1)
/
//
/
(kero
sene)
Tank
Car
S-EE
-001A
15
25
45
Wh
at If
1. Ta
nk Ca
r
-.
- St
opper
-
Bund
2
3 6
2 (
06)
2. M
V-01,
02
03
-.
Keros
ene
-
Tank
Car
-
Start P
ump
-
Bund
1
3 3
2 (
06)
3.
(Grou
nd)
(K
erosen
e )
-.
ke
rosene
-
Tank
Car
- Gr
ound
- Gr
ound
2
3 6
2 (
06)
4. 12
,000
-.
- Ta
nk Ca
r -
Bund
1
3 3
2 (
06)
3-22
W
hat If
Analy
sis
What
If (1)
//
//
Tank
Car
S-EE
-001 (
A)
15
2545
What I
f
5.
-.
-
-
Bund
2
3 6
2 (
06)
6.
-.
- Ta
nk Ca
r -
1
2 2
1
7. Ta
nk Ca
r (K
erosen
e)
-. ,
Pu
mp
Ke
rosene
-
1.
2.
Tank
Car
2
3 6
2 (
06)
8.
(Drai
n)
-.
(Drai
n)
- Ta
nk Ca
r
1
2 2
1
3-23
W
hat If
Analy
sis
What
If (1)
//
//
Tank
Car
S-EE
-001 (
A)
15
2545
Wh
at If
9. (V
ent)
-.
- Bu
nd
-
Pump
Ta
nk Ca
r
1
3 3
2 (
06)
10.
-.
-
3
1 3
2 (
06)
11.
Strai
ner
-.
- St
rainer
2
3 6
2 (
06)
3-24
What
If An
alysis
Wh
at If (
2) /
//
/
(Kero
sene)
S-EE-0
01 (B)
15
2545
What I
f
1.
-
-
(U
nconfi
ned Va
por)
1. ,
2.
3.
4.
(Bund
) /
Bu
nd 5.
(Prev
entive
Ma
intena
nce)
1.
2.
3.
2
4
8
3 (
01) 01
)
2.
,
1.
2.
3.
- 1
3 3
2 (
01)
3-25
What
If An
alysis
Wh
at If (
2) /
//
/
(Kero
sene)
S-E
E-001
(B)
15
25
45
Wh
at If
3.
-
/
-
-
1.
2.
3. ,
4.
5.
(P
revent
ive
Maint
enance
)
1.
2.
3.
1
4
4
2 (
01)
4. /
(H2S)
,
1.
2. No
n-De
structiv
e Test
/X-Ra
y 3.
1.
2.
3.
1 4
4 2
( 01
)
3-26
What
If An
alysis
What
If (2)
/
//
/
(Kero
sene)
S-E
E-001
(B)
15
25
45
Wh
at If
5.
(In
sulatio
n)
1.
2.
Non-D
estruc
tive T
est/X-
Ray
3.
4.
1.
2.
3.
4.
1
4
4
2 (
01)
3-27
What
If An
alysis
What
If (2)
/
//
/
(Kero
sene)
S-E
E-001
(B)
15
25
45
Wh
at If
6.
/
1.
2. Ta
nk Ca
librat
ion
3.
Reliab
ility
-
2
3
6
2 (
01)
7.
1.
1.
2. (
)
3.
4.
5.
2 4
8 3
( 01
) (
01)
3-28
What
If An
alysis
What
If (2)
/
//
/
(Kero
sene)
S-E
E-001
(B)
15
25
45
Wh
at If
8.
-
1.
2.
1.
1
4
4
2 (
01)
9.
-
-
1.
1.
2 4
8 3 01
) (
01)
10.
Ho
t Work
, ,
-
-
1.
(Hot
Work
Permi
t) 2.
(Rest
ricted
Area)
3.
1.
2.
2 4
8 3 01
) (
01)
3-29
W
hat If
Analy
sis
What
If (3)
/
//
/
S-EE
-001 (
B)
15
25
45
What I
f
1.
(K
erosen
e)
- So
lvent
Th
inner
- W
I
2 3
6 2
( 02
)
2.
Non
Spark
Tool
Ma
nhole
-
So
lvent
-
- No
n Sp
ark To
ol
2 4
8 3
( 02
) (
02)
3-30
W
hat If
Analy
sis
What
If (3)
/
//
/
S-EE
-001 (
B)
15
25
45
What I
f
3.
-
Solve
nt
-
-
M
anhole
5
..
-
2 4
8 3
( 02
) (
02)
-
-
-
1
3
3
2 (
02)
4.
-
Ex
plosio
n Proo
f
-
-
2 4
8 3
( 02
) (
02)
3-31
W
hat If
Analy
sis
What
If (4)
/
//
/
(K
erosen
e)
.
S-EE
-001 (
C)
15
2545
What I
f
1. Va
lve M
TK01
, 02,
03,04,
05,06,
07 MB
P01,
02-03
- Hi
gh Pre
ssure
- Ov
er Pre
ssure
Contr
ol
-
-
Pump
-
2 3
6 2
( 07
)
2 .
Valve
MTK
(M
TK-01
-07)
-
- Hi
gh Pre
ssure
- 1
-
Over
Pressu
re Co
ntrol
-
-
Pu
mp
- 2
3 6
2 (
07)
3.
Manua
l
- Hi
gh Pre
ssure
- 1
-
Over
Pressu
re Co
ntrol
-
-
Pu
mp
- 2
3 6
2 (
07)
3-32
W
hat If
Analy
sis
What
If (4)
/
//
/
(K
erosen
e)
.
S-EE
-001 (
C)
15
2545
What I
f
4.
(Disc
harge)
Pu
mp
-
-
-
-
Pu
mp
- 2
3 6
2 (
07)
5.
MBV
01,02
,03
Strain
er
- Pum
p Rund
ry
-
- Re
circul
ation L
ine
-
- St
rainer
- 2
1 2
1
6. M
BV
01,02,
03 M
LS
01,02,
03 St
rainer
- Ov
erheat
Pu
mp
Pu
mp
-
-
- Re
circul
ation L
ine
- St
rainer
- 2
1 2
1
7. Fl
ow Tr
ansmi
tter
-
-
(Flow
Tra
nsmitte
r: FT)
-
- 2
3 6
2 (
07)
3-33
W
hat If
Analy
sis
What
If (4)
/
//
/
(K
erosen
e)
.
S-EE
-001 (
C)
15
2545
What I
f
- (
)
-
- 1
3
3
2 (
07)
8.
Valve
MTK
(M
TK01
07)
- ( )
-
- 1
1 1
1
9. He
ader
-
-
- He
ader
- 1
3 3
2 (
07)
3-34
W
hat If
Analy
sis
What
If (5)
/
//
/
.
S
-EE-00
1 (D)
15
2545
What I
f
1.
(Ex
plosio
n Proo
f)
-
-
-
2
3 6
2 (
08)
2.
-
-
-
-
2
3 6
2 (
08)
3. M
LS-04
-06
TL-01
-03
- TL
-01-03
-
-
TL
2
2 4
2 (
08)
3-35
W
hat If
Analy
sis
What
If (6)
/
//
/
S-
EE-00
1 (E)
15
2545
What I
f
1. M
BV 04
, 05,06
-
- Pu
mp
Pump
-
- Ov
erload
Trip
2
1
2
1 2.
Strai
ner
-
Pump
Pu
mp
Pu
mp
- St
rainer
2
1 2
1
3. M
BF
01,02,
03
Filter
-
- Re
circul
ation L
ine
- Oi
l Filte
r -
WI
2
3 6
2 (
09)
4. SP
V 06,
07,08,
09
-
- Re
circul
ation L
ine
-
2
3 6
2 (
09)
3-36
MV
007
TP 04 TP 05 TP 06
ML
S04
ML
S05 M
LS
06
SPV
20 SPV
19
SPV
18
PI00
3
Fil
ter
TW
-3
MV
-03
6
GK
A-1
1
GK
A-1
2
GK
A-1
0G
KA
-13
GK
A-1
5
GK
A-1
4
MV
-01
9
MV
-02
0
MV
-02
1M
V-0
22
MV
-02
3
MV
-02
4
MV
-02
5M
V-0
26
MV
-01
6
MV
-01
7M
V-0
18M
V-0
27
GK
A-1
6
GK
A-1
7
GK
A-1
8
SV
-01
SV
-02
SV
-03
SV
-04
SV
-05
SV
-06
PD
V-0
1
PD
V-0
2
PD
V-0
4
PD
V-0
3
MV
-01
2
MV
-01
3M
V-0
14
MV
-01
5
MV
-02
8
MV
-01
1
MV
-03
0
MV
-02
9
MV
-01
0
PI0
04
TI0
11
GK
A-0
6
PI0
05
TI0
12
GK
A-0
9
PI0
06
TI0
19
GK
A-0
3
TW
-4
TW
-5 TW
-6
TW
-7
TW
-8
FT
00
3
Inle
t
GK
A-2
1
GK
A-1
9
MV
-00
9 MV
-00
8
: G
reas
e Pr
oces
sing
S-E
E-00
2 Re
v. 0
1
5-6-
2545
Wh
at
if A
na
lysi
s (7
)
3-37
W
hat If
Analy
sis
W
hat If
(7)
//
//
So
ap (Co
ntacto
r)
S-E
E-002
15
2545
Wh
at If
1. M
LS-
04,05,
06 Pu
mp
- Pum
p Rund
ry Pu
mp
-
Conta
ctor T
ank
- So
ap -
Recir
culatio
n Line
- 2
1 2
1
2. SP
V-018
,019,0
20
-
Cont
actor
Tank
-
SPV
1
- 2
1 2
1
3. Fi
lter
M
V-007
Pump
-
- Pu
mp
Pump
- PT
He
ader
- Ov
er Pre
ssure
Contr
ol -
Pu
mp
- 2
3 6
2 (
10)
4. M
V-036
Pu
mp
-
-
WI
-
2 1
2 1
3-38
W
hat If
Analy
sis
What
If (7)
/
//
/
Soap
(Conta
ctor)
S-EE
-002
15
2545
What I
f
5. PC
V-1
Pump
Vent
- Co
ntacto
r Tank
-
Pump
- PT
He
ader
- Ov
er Pre
ssure
Contr
ol -
Pu
mp
2
3 6
2 (
10)
6. He
ader
-
- So
ap -
Heade
r
1
3 3
2 (
10)
3-39
Tank
Car
LB A
MV
01
MBV
01
MLS
01
PL
B01
MBP
01
SPV
01
Tank
Car
LB
BM
V 0
2M
BV
02M
LS
02
PL
B02
MBP
02
SPV
02
Tank
Car
KR
01M
V 0
3M
BV
03M
LS
03
PKR
02
MBP
03
SPV
03
PL
B01
PRE
MIX
01
FT
MT
K01
MB
K02
MB
K01
TL
01
TL
02
TL
03
PT
L01 PT
L02 P
TL
03
Filt
er
Filt
er
Filt
er
200
L
1.0
L
0.7
L
SPV
04
SPV
05
MBV
04
MLS
04
KL
01
MTK
02
MTK
03
MTK
04
MTK
05
MTK
06
MTK
07
KL
02
MLS
05
KL
03
MLS
06
MBV
05
MBV
06
MBF
01
MBF
02
MBF
03
SPV
06
SPV
07
SPV
08
SPV
09
PI
HA
ZO
P (
1)
S-E
E-00
1 R
ev. 0
1
5-6-
45 L
UBR
ICAT
ION
PRO
CESS
ION