Alarge-scale implementation of advanced process control (APC) system has started at the oil refinery of PJSOC Bashneft (included in PJSC NK Rosneft). This system is a multi-parameter regulator functioning on the basis of integrated predictive model of the facility. APC substitutes a process operator by automated control of a single unit or the whole plant, reducing influence of ambient factors (variations of raw material quality, production assignments, actions of operators) on the process. The system includes an optimized set of automatic control algorithms using process data and virtual analyzer data as inputs signals.

Tests and pilot operation of the system were run since 2013 at a catalytic cracking plant of Ufanefteknim. Last year, a similar project was implemented at an electric desalination plant (ELOU-AVT-6) of UNPZ production site. Tests of the innovation showed high efficiency: processing facilities equipped with APC improved stability of their quality indicators, increased output of target products, reduced energy consumption. Payback period of the first project was around one year.

Upon the results of successful pilot project implementation, a decision was made to introduce the system at other process facilities of unified Refinery within 2022. Project replication has started in 2016 from the plants of Ufaneftekhim, Novoil, UNPZ.

Operators of the plants where the new system has been launched have received a course of training and now maintain defined criteria of maximum operation efficiency together with experts of a newly formed APC support division.