Technologies such as Internet of Things (IoT), cognitive computing, remote sensing, data combination, etc are developing in global upstream, midstream, and downstream segments.
In the final part of this three part article that has observed how Russian oil and gas giants have implemented Industry 4.0 innovations, the focus has turned to SIBUR Holding.
SIBUR Holding took up automation and digitalisation several years ago. In 2012 it introduced the manufacturing execution system (MES) at its production units. This system automates production collecting of data for analysis and allows it to see and control the process in real-time. It requires a primary level of automation and presence of an automated process control system (APCS) in order to take this data into the MES. APCS uses thousands of sensors around the plant to collect data on temperatures, pressure, flows, etc. This information is stored and analysed so that the MES can develop the most efficient and cost-saving production strategy and ensure the high quality of the product.
SIBUR introduced the manufacturing system, also defined as lean production. Now it uses Six Sigma strategies, allowing it to control and improve the quality of products during the refining. It measures the current state and developing processes to decrease the number of possible failures, it works on improving the production by detecting and eliminating the causes of defects, and also minimising variability in manufacturing and business processes.
Automation is also implemented in the HSE sphere. All the data on accidents, even minor ones, is collected in information systems to be analysed, the origin of the accident detected, and used to prevent such cases in the future.
The Holding is constantly experimenting with new digitalisation solutions. For example, in the field of virtual and augmented reality, in order to make emergency response more effective and immediate by involving distant employees. Automation can also be widely used in logistics and transportation to ensure a continuous supply of raw material and products between more than 20 units of the production structure.
In the frames of digital transformation, SIBUR is also going to implement a wide scale of data collection, storage and processing technologies, drones, and 3D printing. As part of this transformation, facial recognition systems have already replaced pass entry systems at the SIBUR units.
The rapid development of automation and digital transformation causes downstream companies to look for innovative solutions that are competitive in the international market but still adapted to the domestic one, as well as compatible with already existing business and technical processes. In such conditions, it is important to have the opportunity to network with the companies from your industry; to exchange the experience, negotiate, and find reliable partners. PRC Russia & CIS 2018 Congress brings together the whole downstream value chain to cover different aspects of modernisation. Gazprom Neft, SIBUR, TechnipFMC, KBR, Shell, Honeywell and other leading companies will gather to discuss real cases and possible further development. There will also be an exhibition, highlighting the innovations and technologies of tomorrow.
Written by Kristina Sabirova, Managing Partner of BGS Group and Project Director of PRC Russia & CIS 2018.
Read the article online at: https://www.hydrocarbonengineering.com/special-reports/22112018/digitising-russian-downstream-projects--part-three/