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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