Successful development of template solution for maintenance and reliabitity management on base of RCM/RBI at OJSC Gazpromneft-Omsk refinery

Successful development of template solution for maintenance and reliabitity management on base of RCM/RBI at OJSC Gazpromneft-Omsk refinery

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30.01.2014 MAINTEX

At the end of December 2013, Maintex successfully completed development of template solution for the enterprise equipment reliability management program at Gazrpomneft refineries. Omsk Refinery (OJSC Gazromnet-Omsk Refinery) was chosen as a pilot site for this enterprise-relevant project.

Gazrpomneft's need in improved asset management solution had been long overdue. Maintenance management approach had been evolving and improving year by year, and finally this had brought understanding that the refinery needed to implement world best practices in refinery equipment reliability management. The head office had realized the urgent need in higher asset availability and reliability, as well as extra profits due to shortened unplanned downtime, while providing safety rules observance and regulatory compliance. The question of optimized maintenance and repair costs was as burning as never before, and it was necessary to achieve and sustain the target equipment reliability level compliant with legislative and regulatory requirements. At that, one of the crucial strategic goals—increasing intervals between minor and capital repairs and maintenance activities—demanded a new approach to statistical data collection and analytical data accumulation.

To run this challenging project, an integrated team of more than 50 people was created, including Omsk Refinery employees and Maintex and ITSC consultants. After five months of the project execution, the following tasks were completed:

  • An enterprise risk matrix developed and limit risks defined for the refinery;
  • Asset criticality analysis procedure developed on the base of assessment of risks in relation to asset failures;
  • A target business process for reliability management and business process regulations developed;
  • Recommendations on modification of organizational structure and job descriptions developed;
  • Functional and technical requirements to IT solution selection developed;
  • Target architecture for maintenance and reliability management template solution for OJSC Gazpromneft Refinery developed.

According to Maintex's experience in project execution, customer's willingness to change plays a crucial role in such innovative approaches as reliability management. Omsk Refinery employees demonstrated high competence and determination to use world best practices in their daily work activities. 

"Omsk Refinery is not only one of the best-performing and advanced refineries in Russia," said Igor Shishkin, Maintex Project Manager. "The plant has a robust, professionally prepared base for reliability management system implementation, qualified personnel, and, equally important, managers who are really interested in process optimization."

The project was completed on time and highly evaluated by the customer. Based on the project results, a decision was made to: Recognize reliability management processes as compliant with best practices and recommend the suggested practices for use at OJSC Gazpromnet-Omsk Refinery.

About ITSC

INFORMATION AND TECHNOLOGY SERVICE COMPANY (ITSC LLC) was established by consolidation of personnel from IT, Communication and Automation Subdivisions of two major Russian companies: OJSC Gazprom Neft and OJSC SIBUR Holding. More than 5,000 specialists provide services for development, implementation and support of high-tech solutions all over Russia. The company has subdivisions in 25 regions of Russia. Over 250 companies are ITSC customers. More: