The HPCL Mumbai refinery is one of the most complex refineries in the country, is constructed on an area of 321 acres. This versatile refinery which is the first of India’s modern refineries, symbolizes the country’s industrial strength and progress in the oil industry. Mumbai Refinery has grown over the years as the main hub of petroleum products. The refinery has reached to present level through several upgradation and restructuring processes.
The Mumbai Refinery was commissioned by Esso Standard in 1954, with an installed capacity of 1.25 million tonnes per year. The lube refinery, Lube India Ltd, was commissioned in 1969 with a capacity of 165 million tonnes per year of Lube Oil Base Stock (LOBS) production.
Crude processing capacity increased to 3.5 million tonnes per year during 1969. In 1974, the Government of India took over Esso and Lube India by the Esso (Acquisition of Undertakings in India) Act 1974 and formed HPCL.
Expansion of the fuels block was carried out by installing new 2 million tonnes per year crude units in 1985. A second expansion of Lube Refinery took place to increase the capacity of the refinery to 335 million tonnes per year, so far the largest in India. The installed capacity of the refinery was later enhanced to 6.5 million tonnes per year. The current installed capacity of the refinery is 7.5 million tonnes per year.
The HAZOP study done for following units,
| SR No | DESCRIPTION OF THE UNIT | LOCATION |
| 1 | Lube Oil Upgradation Unit (LOUP) / SCW (LOUP ) | Lube Refinery |
| 2 | Solvent Extraction unit – SEU3 | Lube Refinery |
| 3 | Solvent Extraction unit – SEU1 | Lube Refinery |
| 4 | Solvent Extraction unit – SEU2 | Lube Refinery |
| 5 | Industrial Oil Hydrofiner | Lube Refinery |
| 6 | FRE-Crude Distillation & Vacuum Distillation Units | Fuel refinery Expansion |
| 7 | DHDS -Amine regeneration Unit | Fuels Refinery – DHDS block |
| 8 | DHDS-Sulfur Recovery unit | Fuels Refinery – DHDS block |
| 9 | DHDS-Condensate recovery unit | Fuels Refinery – DHDS block |
| 10 | DHT-Amine Recovery Unit | Fuels refinery – DHT block |
| 11 | DHT-Sour Water stripper unit | Fuels refinery – DHT block |
| 12 | DHT-Sulfur Recovery unit | Fuels refinery – DHT block |
| 13 | GFEC- Sour Water Stripping Unit | Fuels Refinery – GFEC Prime G block |
| 14 | GFEC- Amine Regeneration Unit | Fuels Refinery – GFEC Prime G block |
| 15 | New Boilers SG-10/11, Fuel oil system | Power & Utilities |
| 16 | DHT Boiler | Power & Utilities |
| 17 | Air System | Power & Utilities |
| 18 | N2 plant-DHT Block | Power & Utilities |
| 19 | Integrated Effluent Treatment Plant (IETP) | Lube Refinery-Offsites |
Hindustan Petroleum Corporation Limited (HPCL), has an existing installation of Cyclic HAZOP Phase – II for all Refinery units at HPCL Refinery, Mumbai.
HPCL has awarded iFluids Engineering to carry out Hazard and Operability (HAZOP) study for the Cyclic HAZOP Phase – II for all Refinery units at HPCL Refinery, Mumbai. The project identifies the methodology and results proposed by iFluids Engineering and accepted by HPCL for the completion of the HAZOP study.