Proving the Business Case for the Internet of Things

ABB modernises Kazakhstan refinery with data analytics

Steve Rogerson
August 7, 2019

Swiss engineering giant ABB has won a multi-million-dollar order to modernise a major oil refinery in Kazakhstan using sensors, data and analytics to monitor the plant.
This is part of the republic’s Digital Kazakhstan programme, which seeks to elevate economic sectors including the oil, gas and chemicals industry and accelerate growth nationally with digital technology.
ABB will leverage ABB Ability, the company’s unified, cross digital offering, in modernising the Shymkent oil refinery in Kazakhstan. Sensors, data and analytics will monitor and assess the real-time health of the plant’s assets, with operator Petro Kazakhstan Oil Products (PKOP) to gain critical, real-time insights into assets and production processes.
The order win is against a wider backdrop, as the government-led Digital Kazakhstan programme focuses on accelerating growth and elevating economic sectors including the oil, gas and chemicals industry throughout the republic through digitalisation, with a goal of creating a future digital economy by 2022.
At Shymkent oil refinery, digital transformation enabled by ABB is expected to increase productivity and lower operational costs, with operators empowered to make better-informed decisions based on accurate and live data and reporting.
“With our leading technologies and deep-domain knowledge, we can help operators across the energy industry move forward confidently towards digital transformation,” said Kevin Kosisko, managing director of ABB Energy Industries. “ABB is uniquely positioned to drive and support the digital transformation of the chemical and refining industry in Kazakhstan, and it is exciting to contribute to the modernisation of Shymkent oil refinery.”
Using ABB Ability asset performance management features, the company’s maintenance strategy will progress from an hourly-based maintenance system to prescriptive-based maintenance. ABB will extend the current maintenance annual turnaround intervals at the refinery to a three-year plan. This will be achieved through early identification of when assets might need repair or replacement well ahead of potential failure, supporting operators to prioritise maintenance based on actionable insights.
ABB will also provide a business consultancy service to PKOP to support the lifecycle of the project and promote culture change in adopting digital practices at the plant. This will include assessing current work processes, leveraging opportunities to increase efficiency and resilience, recommending improvements, and providing training.
The Shymkent project site was first commissioned in 1970 and is in the Sayramskiy region of Kazakhstan. It is operated by PKOP as a joint venture between China National Petroleum and Kaz Munay Gas, the national oil and gas company of Kazakhstan.
ABB Ability delivers integrated and secure digital services that can create value for users with increasing autonomy, sustainability and optimised performance. The company brings domain knowledge and technical expertise in energy and water, oil and gas, specialty chemicals, and primary pharmaceutical industries.
ABB’s power grids business will be divested to Hitachi in 2020. ABB operates in more than 100 countries with about 147,000 employees.