In RN-Komsomolsk Refinery the system of accounting of a status and repairs of technology equipment on the Galaxy EAM platform is implemented

Customer

RN-Komsomolsk Refinery LLC is the largest oil processing enterprise in the territory of the Far Eastern Federal District. The oil products produced by KNPZ are delivered to Seaside and Kamchatka regions, Amur, Sakhalin, Magadan, Jewish autonomous to area and also exported to the countries of Southeast Asia.

Komsomolsk Refinery is located in the city of Komsomolsk-on-Amur (Khabarovsk Krai) and is a part of vertically integrated structure of PJSC Rosneft from the moment of its basis. Construction of the plant began in 1938, and in 1942 it was put into operation.

Power of Refinery is 8.0 million tons (58.5 million barrels) of oil a year. The plant processes the West Siberian oil which is delivered on pipeline system of JSC Transneft to the junction stations Uyar (near Krasnoyarsk) and Zuy (near Angarsk) and further by rail. Besides, the plant processes the oil extracted by the Company on the island of Sakhalin and delivered on the enterprise for Okh's oil pipeline — Komsomolsk-on-Amur. The plant specializes in production of motor fuel and aviation fuel.

History

Cooperation of Komsomolsk Refinery and Galaktika corporation in control automation by economic economic activity of the enterprise lasts since 1998.

For creation of automated information system the Galaktika ERP system was selected and in 1999 forces of specialists of the plant began step-by-step system implementation. Since 2001 implementation continued Northwest regional department of Galaktika corporation.

At the plant the Galaktika ERP system in the automated mode provides the solution of the following tasks:

• Accounting of contract activities;
• Accounting of purchases of material values and their holiday in production;
• Inventory control;
• Accounting and tax accounting;
• Personnel management and payroll;
• Requirements planning in special and a uniform.

On the basis of the Galaktika ERP system it is developed and the management subsystem by shipment of oil products and delivery of oil by rail is successfully operated.

Tasks of automation of accounting of a status and repairs

In oil processing and the chemical industry there is more and more relevant a development of the information systems implementing techniques of assessment of durability, a resource and reliability of vessels of pressure on the basis of specially organized non-destructive testing in use.

Within step-by-step system implementation at Komsomol oil refinery the system of accounting of a status and repairs of technology equipment on the basis of the solution "Galaxy EAM" is implemented.

Implementation of this functionality allowed to provide responsible services with operational and reliable information about all connected with technical operation and repairs of aspects of management of technology equipment. Feature of this project was creation of the integrated guidance loop technical diagnostics and creations of visual interactive schemes of vessels, devices and pipelines. It is important to note the implemented mechanism of the automatic notification about approach or the predicted approach of incidents and failures, failure to follow the instructions and actions set by regulatory authorities.

During the project the following tasks were solved:

• Automation of registration of an operating time and idle times on the equipment from the PCS;
• Automation of input of results of vibration diagnostics and the thickness measuring from the diagnostic systems, calculation of corrosion rate, formation of corrosion cards of pipelines;
• Formation of diagrams of accomplishment of examinations of industrial security, maintenance and repairs of the static and dynamic equipment depending on values of controlled parameters;
• Accounting of hardware failures;
• Automatic calculation of the amount of materials required for carrying out repairs on the basis of consumption rates of materials;
• Automatic state change of objects of repair on the basis of values of controlled parameters, the registered defects and failures, transfers to repair and to operation;
• Maintaining magazines of status monitoring and functioning of technology equipment;
• Possibility of setup of a system of notifications of users on approach of controlled events, approach of values of controlled parameters to extreme values, the recorded defects and failures;
• Import of data on the actual material consumption at accomplishment of repairs in the Galaktika ERP system;
• Setup of the KPI parameters;
• Formation of report forms;
• Import of information on a metering equipment to the Galaktika EAM system;

In the project continuous work on risk management was adjusted, the project team is created and methods are determined by the adjusting and warning actions.

Results

The basic results are: initial certification of engineering devices, transition to paperless document flow, creation of a system of the help of the decision making and common information space necessary for increase in production efficiency. On the basis of the developed software tools costs for formation of production and financial plans are reduced, the objectivity and adequacy of planning of repair work, diagnostics, examinations, surveys and materials requirements increases.

"Galaktika EAM" leads system implementation to reliability augmentation of technology complexes and provides necessary expansion of a system of the Party of Pensioners of Russia to required operation of the equipment in the conditions of the increased interrepair time. It significantly affects cost efficiency of work of the enterprise due to growth of interabnormal and interrepair times of operation of the equipment, increases the employment duration of technology complexes, reduces costs for repairs, leads to growth of production discipline and objectivity of estimates of a contribution of each specialist to result of work of the enterprise.

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