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Ordinary and Challenging at the Same Time

The section will be a part of the Catalytic reformer block designed for the production of high-octane gasoline components of environmental class Euro-5, the Press-center "Gazprom Neft" writes. MNPZ is a refinery giant which provides more than 34% of the Metropolitan fuel market and produces 30 kinds of oil products. The program on complex reconstruction and modernization of the enterprises to the value of more than 250 billion rubles was started by the company "Gazprom Neft" 6 years ago. Now, the plant gradually gets rid of outdated production facilities and actively introduces modern industrial complexes in order to achieve European production standards and absolute environmental safety. Besides the major oil company, the project involves the Design Institute “NIPIGASpererabotka” forming a part of SIBUR Holding and the Italian engineering company Tecnimont.

According to the latest data, in 2017 MNPZ is going to put into operation the most modern biological sewage treatment plants (“Biosphere”), and next year a combined oil refining unit ("Euro+") will begin operations.

It bears reminding that for this reputation project NTZMK undertook to fabricate about 6 thousand tons of metal structures. It will be technical buildings which are planned then to fill with equipment and other engineering ʺstuffingʺ. Let's try to trace the current status of the order 3074 at several workings stages.

«Designing on a napkin»

Practically the whole wall behind the NTZMK chief designer in his office is filled with the drawings for MNPZ. The Engineering Department has been developing drawings since the end of July 2016.

"And there’s more, – D. V. Lezhnev explains. – Three orders are already finished, the rest of 14 orders are in progress. Actually the work is familiar to us but the requirements specified to us starting from the documentation to already fabricated structures are rather high. We were not quite ready for them. For example, there are the requirements for execution of KMD drawings which have been constantly changed. But all the same we’ve achieved the approval of the Italian auditor. Construct, drawing, content, accuracy, volume – all this didn’t raise questions. Frequently it is the need to put a point somewhere or some small details that contribute to artificial delays in the process. Some of the drawings were submitted by us for approval 24 times. Because of this we’ve received the first feedback and the status ʺAʺ not so long ago, that means there are no comments.

There are some questions on the erection drawings. For usual and ordinary orders we develop the drawings and immediately transfer them to the shop for fabrication. So, from the start of production and until construction on-site it takes at least a month. While the programs are formed, metal is obtained; cut, welded, cleaned, painted, and etc. the designers have time for making of erection drawings. Today in order to hand in a drawing to the shop, we have to make both erection drawings and all keys and material specifications. Of course, everything should be completed not just according to GOST but in compliance with the request of a specific customer. 

After procedure of approval with the auditor, the documentation is uploaded to the server and is waited for approval in Milan. In the process of developing of KMD drawings technical issues that require immediate response are arisen, but quite often it happens so that after 15 days a check mark appears on the server, "offer your solution of the issue" i.e. we are asked to eliminate any error or deficiency. We put forward our proposal, for that it can be said that they need a few more alternate solutions. So, you understand because of such communication we have a delay of at least a month, and the work has to be done.

In addition, the Chief Designer Department faced with the problem of metal replacement. In ten structures (numbers) of the project the beams 14 B2, 16 B2, 18 B2 were designed in. They aren’t rolled in Russia. As for typical order we could replace them with 16B1, 20 B1 (they are of larger cross-section, but similar in mass and you can buy them in Russia) and make structures from them of the required quality without any loss of strength. As for MNPZ it's not all as easy as it sounds. Initially they approved this variant, but in the drawings we need to put the weight of the element which was originally used. Let me remind that we design all using Tekla Structures software, in it there is a library with characteristics of the elements. So if we take another beam, respectively, the weight will be different unless you make changes to the program itself.

- The main cause is haste and projecting on a napkin, – the chief designer is sure. If the project was ready from the beginning and done properly, this would not have happened.

As remembered by the experienced designers, earlier there used to be the state plan. The multiple purchase order came for the nearest 5 years. Everybody knew in advance what and when would be built. The drawings were of 100 tons, not 100 kilos. They were taken in work gradually, then the metal was ordered which would come within a year, and the KMD drawings were already finished and checked. Now there are no such long-lasting plans therefore, we used to work at a different pace and with different requirements.

Production Reworking

In the metal structures shop we have seen several structures for the Order 30742. After shot blasting in the 8th-bay, TCD inspection of grinding and welds quality the column is waiting to go back to shot blasting unit.

And as for the cross-bar, it was already twice shot blasted, returned for reworking. After that it will be transferred to the paint-dispatching shop. "At the moment there are approximately 20 such large structures in production and as for small ones, of course, they are more, - the Head of the 8th-bay area of the metal structures shop E. S. Nikolaev says. - The production process for this order is complex. Here we collect the structures, weld, grind and transfer to shot blasting unit and rework again."

A multistep process is waiting for the structures in the next shop. "First we paint them by one layer of conductive primer "HEMPADUR ZINC". The thickness of dry layer is 80 microns, and the drying time is at least 5 hours on each side until complete drying out. After that we prepare the structure for the next step of anticorrosive protection, closing separate parts with masking tape. There are many such closings: all friction joints and the areas coated with Zinc. Then the first layer of HEMPADUR MASTIC can be applied. The second layer is applied after 4 hours so as the previous layer is completely dried. The whole process of anticorrosive protection of metal structures against this order is 2 days at average without considering the pre-stage of air shot blasting and repeated grinding, – the foreman of the paint-dispatching shop T. G. Pastukhova tells about nuances of the process. - To prevent mistakes before you begin to paint with zinc, the foreman should raise all the drawings and mark what to paint for the painters. When the part dries, the foreman again takes the drawings and indicates the distances to cover as per technology. Milled surfaces are covered with film and masking tape, they are not painted".

And finally, on the finished structures the markings is embossed, lots and other information are specified with a special scanner, then they are handed over to the representatives of AKZ  (anticorrosive  protection) customer, collected in packages carefully insulating the structures to prevent damage. The shipment for one truck is up to 20 tons of packaged structures but more often we focus on the volume of metal structures.

According to the data from the specialists of Commercial Department, last year about 800 tons were shipped for MNPZ, and for the first month of 2017 half a thousand tons were already shipped.