Tobolsk, 23 November 2018. As at the beginning of November, off-site facilities at ZapSibNeftekhim, a deep hydrocarbon conversion plant under construction, were 91% complete. Overseen by NIPIgaspererabotka, the construction of the facilities is approaching its end, with testing and pre-commissioning preparations already in progress.
“On the plant’s way towards completion, off-site facilities are used to support activities ranging from timely deployment of resources, arrival of large-size equipment, and accommodation of builders and administrative personnel to arranging power and heat supply for the site and the future complex and preparing for the pre-commissioning of the entire project,” says Alexei Vereshchagin, Deputy CEO of ZapSibNeftekhim. “The offsites include more than 320 temporary buildings and structures, occupying most of the area allocated to the complex.”
Since the project launch, ZapSibNeftekhim has entered into 3,460 contracts with Russian suppliers and contractors to source building materials and equipment for its off-site facilities. Over 700 contracts have also been signed with domestic construction companies.
By far, Russian suppliers and contractors have implemented the greatest part of the off-site project. At its peak in July 2018, a total of 4,267 workers were mobilised by contractors. Today, the headcount stands at 3,540.
Off-site facilities construction progress
The 500 kV ZapSib substation has been commissioned, comprising four 250 MVA autotransformers 356 tonnes each. A rare technology is used in the central distribution substation: the gas-insulated switchgear (GIS-110) has helped to reduce the area and space occupied by the substation, eliminating the need to build an additional open switchgear, which would require over 5,000 sq m.
The on-site piperack has been completed. One of the key facilities, it is designed to provide a reliable connection between existing operations in Tobolsk and ZapSibNeftekhim’s main piperack. Its overall length is about 5,000 metres.
The boiler house has been commissioned. An element of the energy infrastructure, it will serve as an independent source of heat and hot water for the off-site facilities. Equipped with five water boilers and two steam boilers, the house has a working capacity of 100 MWt (expandable to 120 MWt) and 3 tonnes of steam per hour.
Sourced from the Epanchinsky intake, water will be piped into the treatment system through the piperack and supplied to ZapSibNeftekhim via a dual pipeline. The treatment station, where the water will be filtered and prepared for industrial and non-industrial use at the plant, is in the pre-commissioning stage, which is close to completion.
Fit-out is in progress in the central control room, which will be used to control and manage ZapSibNeftekhim’s processes.
The administrative and service facilities have come on stream. Now a workplace for 350 members of ZapSibNeftekhim’s operating team, the 26 metres-high administrative facility occupies over 5,000 sq m and will accommodate the plant’s offices.
The first floor is connected via a heated passage to the service facility, where off-site engineers and technical staff have their offices. Its other features include welfare facilities, a canteen, and auxiliary and storage rooms.
Twelve spherical storage tanks for natural gas liquids (NGL) have been constructed (aggregate volume – 7,200 cu m).
The use of advanced hydrocarbon conversion and logistics technologies will help make the entire investment project safer, more reliable and efficient.
As part of SIBUR's digital transformation, SIBUR Tobolsk has started pilot testing an array of digital solutions that will be subsequently used by ZapSibNeftekhim in its core activities. For example, predictive maintenance of the extrusion machine piloted at a polypropylene facility has shown the ability to foresee 85% of equipment failures, while the predictive analytics tools tested at a butadiene facility boosted its output by 1,000 tonnes. Thanks to an augmented reality technology (AR glasses), it is now possible to obtain advice from a remote maintenance expert in one hour instead of two days. Digital work permits have allowed maintenance crews to extend their useful working time by 16%.
“Over the recent years, SIBUR has implemented a range of technologies across its Tobolsk facilities to introduce them to digital transformation, including a manufacturing execution system (MES) to collect and process data for process management, a comprehensive laboratory information management system (LIMS) for supervision and analytical control, and an EPC system providing operational prompts,” says Gennady Savin, Head of Digital Technology at SIBUR Tobolsk. “Now, we are implementing an integrated digital solution that will bring our operations to the next level.“
At ZapSibNeftekhim, a hardware and software information support package is being developed by NIPIgaspererabotka to help project staff achieve a 15% reduction in labour input across its audit, monitoring and supervision activities. The equipment that will be used to operate the package includes AR glasses, tablets and attachable cameras. Thanks to the system’s integration capabilities, the results can be uploaded to such office and professional software as Excel and 1C, respectively.