As part of the Digital Transformation Program of NC KazMunayGas JSC, a production optimization system based on Spiral software was introduced at Atyrau Refinery in 2018.
Thanks to the system, Atyrau Refinery reduced operating costs by 67 million tenge. These results were achieved by optimizing the consumption of additives, catalysts and reagents. In addition, during the operation of the new planning system, the burned fuel and losses at the plant were reduced by 1.5%.
Before the introduction of Spiral, production plans at the plant were calculated in Excel without taking into account all market and technological factors, and they were not flexible. This system provides high planning accuracy: Spiral Plan takes into account the volumes of loads, oil product yields, consumption of additives, catalysts and reagents at any given time. It analyzes a large amount of constantly updated data and calculates the best plan option. Thanks to this, it is possible to avoid overusing the materials required for the processes. At the same time, the system provides access to plans for KazMunayGas specialists, which allows KMG and the plant to respond to the state of the market more efficiently.
Within the framework of automation and digitalization of processes, Atyrau Refinery also introduced MES production process control systems, the IBM MAXIMO maintenance and repair management system, and the Meridium APM inspection and reliability management system. In addition, Atyrau Refinery is implementing the Bailanys telecommunication network modernization project. It includes creating a unified information space at the plant, which will optimize data transmission and voice traffic, distribute resources and organize joint access to various enterprise resources.