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Shymkent oil refinery adopts predictive maintenance with ABB technologies

A leading Central Asian oil refinery has chosen ABB’s digital solutions to reduce the interval of turnaround maintenance to enhance productivity and reduce operational costs.

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Photo credit: PetroKazakhstan Oil Products (PKOP)

The PetroKazakhstan Oil Products (PKOP)-operated Shymkent oil refinery will progress its maintenance strategy with ABB’s state-of-the-art digital technologies to modernize the site, which was commissioned nearly 50 years ago. 

The multimillion-dollar order comes at a time when Kazakhstan is actively seeking to boost its economy by investing in energy industries through programs such as Digital Kazakhstan. With a rich digital background, deep domain expertise and highly skilled engineers, ABB is the ideal partner to enable digital transformation for oil, gas and chemicals operators. 

PKOP aims to progress the maintenance strategy at Shymkent from the current hourly-based reactive maintenance to a more proactive maintenance, also known as predictive maintenance, to ensure early identification of potential asset failure, supporting operators to prioritize maintenance based on actionable insights. 

Solutions based on ABB Ability™ – the company’s unified, cross-industry digital platform – will allow real-time monitoring of assets, equipment and processes at the Shymkent oil refinery. Sensors, data and advanced analytics will provide valuable insights, enabling PKOP to make better-informed decisions. 

ABB technologies and solutions will enable PKOP to extend the current maintenance annual turnaround intervals at the refinery to a three-year plan. 
 
PKOP, which is a joint venture between China National Petroleum Corporation (CNPC) and Kazakhstan’s national oil and gas company KazMunayGas (KMG), will upgrade its maintenance cycle to help the operator reduce costs and increase uptime.

Shymkent will employ ABB Ability™ Asset Performance Management solutions to adopt predictive maintenance, where maintenance is carried out based on the actual condition of assets and equipment. 
 
Additionally, ABB’s business consultancy service will support the lifecycle of this digital transformation project at the refinery, helping PKOP to promote digital practices, assess work processes, identify areas of improvement and provide expert training to plant personnel. 
 
At ABB, the customer is always the main focus, offering end-to-end solutions and services for energy industries to stay competitive in the fourth industrial revolution. 

Main Data

 Customer: 

PetroKazakhstan Oil Products (PKOP)  

 Site: 

Kazakhstan 

 Customer need:    

Update maintenance strategy from an hourly-based maintenance system to prescriptive- based maintenance 

 Scope: 

 

  • ABB Ability™ platform 

  • Asset performance management including condition monitoring and  diagnostics 

  • Reliability management for criticality analysis using Risk Based Inspection (RBI) and Reliability Centered Maintenance techniques to suggest new maintenance strategies 

  • Interfacing with existing ERP for management of maintenance, assets, and work orders 

  • Consulting: criticality analysis and change management 

 Commissioning year 

 2020 

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