Gazprom Neft’s Omsk Refinery has completed its installation of a vibration monitoring system for equipment at key technological facilities. Developed by Russian specialists, the system is integrated with the Omsk Refinery’s general diagnostic network, and helps prevent any potential deviation from standard operations. System installation remains ongoing, with 60% of equipment having been fitted with diagnostic units thus far. The deployment of cutting-edge monitoring and control systems at the Omsk Refinery forms part of Gazprom Neft’s production-asset reliability management programme, directed at improving process facilities’ operational readiness and safety, as well as improving efficiency in maintenance and repairs.
Sensors installed directly on equipment detect even the slightest change in performance, highlighting a problem before any malfunction even occurs. One of the key tasks that this new system addresses is managing equipment repairs not according to schedule, but in line with equipment’s actual condition. Online diagnostics of this kind make it possible to automate the process of assessing equipment status and taking a decision on maintenance scheduling, while reducing the time spent on repairs. The information collected forms the basis for determining the optimum number of consumer and expendable (C&E) materials required, and making the necessary specialists and equipment available.
Developed by the Dynamics Scientific and Production Centre, Omsk, this technology is highly rated by international specialists, with the Expert Committee at the USA’s “Hydrocarbon Processing Awards” citing its deployment at the Omsk Refinery as the best AI technology developed for use in the oil and gas refining industry. The system’s effectiveness has been confirmed by higher equipment reliability at the Omsk Refinery, and by facilities’ planned-repair lead-times increasing from two to four years.
“A refinery’s quality and output is directly dependent on the state and condition of its key technological equipment. Digitising diagnostics processes at the Omsk Refinery means we can eliminate malfunctions in units’ operations before they happen, extend technological complexes’ overhaul runs, and prevent unscheduled production downtime. The Omsk Refinery’s work, in conjunction with Russian developers, is giving new impetus to the entire industry, allowing us to keep moving forward, and become ever more efficient.”Oleg Belyavsky CEO, Gazprom Neft Omsk Refinery
“This system makes it possible to eliminate accidents and unplanned downtime caused by sudden equipment failure at technological complexes completely. It reduces planned shutdown repairs by 30%, improves employees’ discipline and sense of responsibility, and cuts servicing and repair costs six- to eight-fold in comparison with planned repair and maintenance systems.”Andrey Kostyukov CEO, Dynamics Scientific and Production Centre
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 plants moving over to the exclusive production of modern, environmentally friendly Euro−5 fuels. 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.