Modernization of the control system
The initial phase of the planned five consecutive stages of modernization of the production process control system at the polymerization plant for low-density polyethylene production at Gazprom neftekhim Salavat (workshop No. 23) has been completed. Process unit “A” was the first to be equipped with an automated control system based on modern microprocessor technology produced in Russia.
The polymerization plant in workshop No.23 consists of several technological systems (A, B, C, D, E) operating under pressure up to 1,500 kgf/cm2 and performing identical functions, with the overall outcome being the production of low-density polyethylene. The technological process was developed by the company “Salzgitter” (Germany). The first products were obtained in 1962.
The existing control system of the plant, based on relay circuits, has become outdated both morally and physically, significantly reducing its maintainability. The vector for modernization of the plant was set by a special development program, which is continuously developed and updated by specialists from the Chief Instrumentation Engineer Department in accordance with the strategic course for the complete automation of the company’s technological processes. The ultimate goal of this initiative is to implement a modern automation system for all technological units of the “Polymerization” plant. The advantages of modernization are obvious. This is not only enhances the reliability of the technological plant and the overall production culture, but also represents a tangible step towards achieving import substitution and transitioning to domestic equipment and software in the field of automation.
Employees who took an active part in the implementation of the project — Vitaly Boyarchuk, Head of the “Polymerization” plant in workshop No. 23, Aleksandr Grubov, Leading Specialist of the Engineering Group, Chief Instrumentation Engineer Department, Nail Agliullin, Chief Specialist of the Automated Control System Department, Monomer plant, Andrey Kormshchikov, Head of Instrumentation Area No. 4, Automation Workshop, Monomer plant
The equipment was selected specifically for this aim. It was important to find a reliable automation system. The choice was made in favor of the domestic manufacturer of the equipment — INCOMSYSTEM, REC, JSC (Kazan). At the stage of equipment selection, Gazprom neftekhim Salavat specialists visited the industrial site of the automation system manufacturer, where they witnessed the entire manufacturing process of equipment firsthand.
To this date, the plant's production process control system is fully operational. The “project implementation schedule” of the program includes the subsequent transfer of the positive experience of implementing the automation system to other technological facilities of the “Polymerization” plant. A significant amount of work remains to be done to analyze the accumulated experience and implement automation systems on technological systems B, C, D and E.
For reference:
Gazprom neftekhim Salavat is one of the largest oil refining and petrochemical complexes in Russia. The Complex was founded in 1948.
The Company is integrated into the Gazprom system. It has the basic advantage: consolidating on a single site a full cycle of crude hydrocarbons processing, petrochemistry and mineral fertilizers production. The Company comprises the Oil Refinery, Gas & Chemical Plant and the Monomer Plant.
Gazprom neftekhim Salavat produces more than 150 items, over 50% of which are bulk products including motor gasoline, diesel fuel, fuel oil, styrene, polystyrene, low density polyethylene, high density polyethylene, DOP plasticizer, butyl alcohols, sulphur, ammonia, urea, acrylic acid, butyl acrylate etc.
The products are shipped to all federal subjects of the country. Export supplies of oil products are mainly directed to European and CIS countries. Petro- and gas chemicals are exported to over 30 CIS and non-CIS countries.
High quality of Gazprom neftekhim Salavat output is confirmed by certificates of conformity to ISO 9001 and 14001, the international standards of quality and environmental safety.