Single asset

The Gazprom Neft Downstream Division continues its digital transformation under the Single Asset management framework, based on digital solutions covering the entire value chain and aiming to improve production process flexibility and the performance of key business processes, optimise resources and minimise deviations.

In 2020, the hydrocarbon feedstock supply segment started to roll out a digital oil supply management system. The solution optimises the distribution and sale of all produced crude, as well as feedstock delivery to own and customers’ refineries according to the market situation, as well as internal and external demand.

All data on crude supplies and changes in demand for petroleum products are collated by the Gazprom Neft Efficiency Control Centre, where a cross-functional team uses advanced big data analysis, predictive analytics and state-of-the-art digital tools in a shared digital environment to manage the whole chain from refinery to sales. The centre creates an optimum production plan with due regard for production and logistic constraints, while monitoring inventories and managing the quality and quantities of petroleum products.

These plans are being executed by the Gazprom Neft Refinery Production Control Centre, which has, at its core, IT tools built into a digital continuous production platform. The platform, developed jointly by Gazprom Neft and Zyfra Group, will integrate these refinery facilities and key production control systems. With accurate mathematical models of process facilities (digital twins), the production control centre will ensure a safe and optimum production flow that factors in the energy mix and the economic impacts of production chains at company refineries.

Stemming from a high level of digitisation, this degree of process flexibility along with the company’s value chain results in maximum efficiency; for example, being able to offer the right product slate and quantities for the market demand, anticipate changes in market demand, and achieve maximum operational efficiency in all segments of the chain.

The Neftekontrol (oil control) system is deployed in all Downstream Division assets

Gazprom Neft has now fully rolled out the Neftekontrol digital system. The system monitors all terminals and refuelling complexes, as well as the company’s own refineries and filling stations. A higher availability and quality of data led to a fivefold decrease in the time needed to resolve critical deviations impacting on the performance of the entire value chain.

The Neftekontrol system processes over 15 million data points every day to create a single digital model of crude and product flows. The system more than halved the number of critical and system-wide deviations in the value chain year-on-year.

The next step in the system’s development would be to implement intelligent ML-based decision support. Taking the human factor out of the equation through an AI module will significantly improve accuracy and speed in managing the value chain.

Lean Six Sigma projects at company refineries

Operational efficiency management is a key element of the Etalon operations management system. One method to eliminate waste in this element is the LeanLean is a management concept based on continuous improvement and commitment to eliminating all types of waste. Six SigmaSix Sigma is a manufacturing management concept introduced by Motorola in 1986. The concept uses quality management tools and requires measurable goals and results, with special teams launched at enterprises to eliminate problems and improve processes (Black Belts and Green Belts). methodology. Pilot team training in this methodology was launched back in 2018.

In 2020, the company started to operationalise the programme at a pilot unit, the Oil and Gas Refining Directorate. Plans are in place to establish a Lean Six Sigma competency centre at the Omsk and Moscow Refineries. In December 2020, despite the pandemic, the first IALSSIALSS — International Association for Lean Six Sigma, an acknowledged international certification body. certificates were officially awarded: Green Belts (successful completion of one project) and Black Belts (successful completion of two projects). Driving a higher raffinate yield at the oil solvent extraction unit, a higher drilling rate and an optimised well construction time are just a handful of examples of projects.

We plan to certify at least 1% of employees at the company’s production assets and subsidiaries in Lean Six Sigma by 2030, with potential benefits from projects hitting more than ₽2 billion.

37
employees trained
10
projects completed
190 million
in total impact

Company refineries: 2020 highlights

Refinery Installed capacity, mt Refining throughput, mt Conversion rate, % Light product yield, % Upgrade and technological development
Key projects implemented in 2020 Plans for 2021

Gazprom Neft Omsk Refinery

22.23
19.77
93.9
71.2
  • Second phase of the refinery modernisation programme
  • Second phase of the aromatics complex revamp completed, with advanced processing of benzene concentrate from Unit L-35–11–600 now commissioned
  • Crude storage tanks converted for winter diesel fuel as part of the second phase of the modernisation programme
  • Oily waste processing, recycling and treatment site commissioned
  • TSU-0.5 (hybrid) bunker fuel production line onstream
  • Deep conversion complex now ready for start-up, with commissioning activities and ramp-up underway
  • Deep conversion complex commissioning and ramp up to full production
  • Complete the revamp and commissioning of a number of process units, including the catalytic reformer, diesel hydrotreater, delayed coker, refinery flare system, etc.

Gazprom Neft Moscow Refinery

12.76
10.02
84.1
62.3
  • Construction of Euro+ combined oil refining unit completed
  • First phase of a multifunctional office and production complex construction project completed
  • Commission the revamped visbreaker (AT-VB)
  • Active implementation of the second phase of the refinery modernisation programme, including sulphur unit, hydrocracker and delayed coker construction

NIS

4.6
3.32
91.4
78.5
  • Deep conversion complex, based on delayed vacuum residue coking technology, commissioned
  • Engineering and design under the Fluid Catalytic Cracking Units (FCCU) Revamp and ethyl tertiary butyl ether (ETBE) Unit Construction project

Slavneft-YANOS

15.0
7.28
66.7
55.6
  • Wet Catalysis–2 hydrogen sulphide removal unit achieved guaranteed performance
  • First phase of the sulphur unit revamp completed
  • Continue construction of the deep conversion complex
  • Continue the upgrade of the VT-6 unit
  • Complete the upgrade of the gas-loading rack
  • Complete the upgrade of the sealed bitumen loading rack

Mozyr Refinery

14.03
0.00 Gazprom Neft’s share in the Mozyr Refinery’s refining volumes is subject to the oil supply schedule to the refinery, as approved by the Ministry of Energy of the Russian Federation. The company may process up to 50% of oil supplied to the refinery. Actual refining volumes will depend on the refinery’s economic efficiency. The company did not process any of its oil at the Mozyr Refinery under tolling arrangements in 2020.
84.4
65.2
  • Construction of the heavy residue hydrocracker
  • Complete the construction and installation of the heavy residue hydrocracker and start commissioning