The production control system at the Gazprom Neft Omsk Oil Refinery is being modernised. This reorganisation mainly affects the in-line analysis system, which controls the entire production chain — from feedstocks to finished products. The system’s digital circuit monitors the operation of control devices continuously and, in the event of any deviation from norm, reports any disparities instantly. All facilities at the Omsk Refinery are expected to be connected to this automated in-line quality-analysis data-verification system by 2021. Monitoring the quality of products manufactured, and the efficiency of how they are produced, is a major element in the Omsk Refinery’s full-scale development programme, being pursued by Gazprom Neft since 2008.
More than 250 in-line quality analysers are currently in operation at the Omsk Refinery, monitoring key oil-product metrics, in real time — the accuracy of these being confirmed through regular inspections by specialists. The new system will monitor the stability of a whole range of analysers, automatically, lightening workloads on personnel. A digital model means the system will be able to identify potential deviations from norm while operations are ongoing, and generate recommendations for servicing and maintenance — allowing the Omsk Refinery to improve the efficiency of quality-control processes.
Information on product quality at the Omsk Refinery is forwarded to the Gazprom Neft Efficiency Control Centre in St Petersburg, online: from where the entire value chain — from refinery to company sales departments — is managed in a single, cohesive digital environment.
“The Omsk Refinery is continuing its path of full-scale digital transformation, part of which involves ongoing improvements to and fine-tuning of the plant’s product-quality control system. Automatic verification of data from in-line quality analysers, alongside other high-tech solutions at the Omsk Refinery, will deliver improvements in key performance indicators (KPIs) in oil refining to match those of global industry leaders.”Oleg Belyavsky Director General, Gazprom Neft Omsk Refinery
* In-line quality analysers are devices used in determining metrics for facilities’ production flows at various stages of a technological process. Virtual analysers are mathematical models that calculate quality indicators on the basis of archived production data and data from laboratory analysis. Determining a facility’s in-flow quality is of major importance since most of the commercial goods produced through oil refining comprise multicomponent mixtures consisting of a specific set of semi-finished products (facility in-flows).
Gazprom Neft is currently involved in a full-scale modernisation programme at its Omsk and Moscow refineries, involving cumulative investment of more than RUB550 billion. The first stage of this programme has involved the construction and modernisation of key technological facilities, allowing plants to move over to the exclusive production of Euro−5 fuels, significantly improving energy efficiency and environmental friendliness in production. The implementation of the second phase of this modernisation programme is now ongoing, as a result of which the refining depth (“conversion factor”) and light product yield are expected to exceed those of leading global producers.
Specialists at the Gazprom Neft Downstream Efficiency Control Centre are responsible for controlling all technological stages involved in the value chain. The Centre’s work is directed at improving business efficiency through cutting-edge data-analysis technologies, predictive analysis and work with Big Data, to create a single and cohesive digital platform for managing efficiency.