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Risk Assessment for the Expansion of a Refinery

  • Before increasing the operating capacity of a large oil refinery in Java, an Indonesian oil and gas company was looking for an experienced third party to provide comprehensive design review and risk assessment. That’s why they turned to TÜV Rheinland.

    Basic facts

    ClientIndonesian oil and gas company
    Timeframe2012
    Project locationJava Island, Indonesia
    Main services
    • Support for Hazard and Operability Study (HAZOP)
    • Services regarding HAZOP
    Involved regulations/standardsHazard and operability studies (HAZOP Study) — Application guide

    Initial situation and requirements

    Rapidly growing economies in Southeast Asia have increased the demand for energy sources. Indonesia is a major crude oil producer in the region and one of the largest natural gas exporters. Yet the country is still depending on diesel and high-octane gasoline imports because of inadequate domestic refining capacity.

    That is why one of the largest national oil companies of Indonesia decided to raise investment in refineries in order to increase its production capacity and processing intensity.

    Did you know

    Two TÜV Rheinland teams worked on the project, which was completed within twenty days.

    About TÜV Rheinland

    Founded more than 140 years ago, TÜV Rheinland is a global leader in independent inspection services, ensuring quality and safety for people, the environment, and technology in nearly all aspects of life.

    We inspect technical equipment, products and services, oversee projects and help to shape processes for companies around the world. Since 2006, we have been a member of the United Nations Global Compact to promote sustainability and combat corruption.

  • As one of the leading service providers for the energy sector, we can support oil and gas extraction and refinement projects with all certification, inspection, and consulting needs in every phase. We can help reduce risk, prevent material defects and ensure the maximum safety and optimal functions of power plants, pipelines and refineries.

    Solutions, results

    Thanks to extensive experience in risk analysis and risk evaluation services, TÜV Rheinland was the preferred choice to provide consultation for the Hazard and Operability Study of the largest oil refinery on the island of Java.

    The facility was originally designed to operate as a fixed bed (semi-regeneration) unit. To increase the operating capacity of the unit and enable the reformate of octane, as well as convert the unit to the CCR (continuous catalyst regeneration) mode of operation, the company decided to revamp the existing unit.

    The oil refinery's expansion required comprehensive risk assessment services. The main objective of the structured methodology of the Hazard and Operability Study was to identify potential hazards and operational problems in the plant design. Furthermore, it aimed to evaluate plant design intended for the revamping project and the integration of the new system to the existing refinery for safe and reliable operation.

    TÜV Rheinland Indonesia provided support in preparing all the relevant documentation for the HAZOP Study and the final reports.

    Benefits for the client

    TÜV Rheinland Indonesia provided support with:

    • Identifying potential hazards and operational problems in the plant design.
    • Comprehensive technical expertise in risk analysis and risk evaluation services.
    • Preparing detailed HAZOP reports in compliance with applicable standards and regulations.
    • Tailored techniques and services for HAZOP studies, such as special tools and software, monitoring and progress report.

      Need more information? Do not hesitate to contact us!

      TÜV Rheinland Group
      Industrial Services

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