Nizhnekamsk, December 6, 2024 – Production capacity is set to increase significantly as a repair hub for the entire SIBUR group is being established in Nizhnekamsk.
By 2026, SIBUR will complete the modernization of the "Nizhnekamskneftekhim" Repair and Mechanical Plant (RMP). The plant will undergo a full reconstruction. The new workshops and production facilities of the plant will be capable of supporting both current and future NKNK production needs. Additionally, synergies with other SIBUR enterprises, such as "Kazanorgsintez," "ZapSibNeftekhim," and "Tomskneftekhim," are being explored. Replacing analog machines with CNC equipment will enable the creation of new technological chains.
Rebuilt from the Ground Up
The modernization of the RMP at NKNK is part of SIBUR’s broader strategy for technological advancement, alongside the construction of a research and development center in Kazan. Both projects attract top specialists to Tatarstan and are poised to become centers of excellence within the holding. The scientific research center at "Kazanorgsintez" will consolidate SIBUR’s R&D potential, while the RMP, catering to the needs of "Nizhnekamskneftekhim" and other enterprises, will set a new benchmark for repair operations nationwide.
Originally commissioned in 1964, the plant has long required modernization. As one of the largest repair enterprises in Tatarstan and across Russia, it covers an area of 40,000 square meters and is responsible for maintaining 450,000 units of equipment. Currently, 970 machines operate within the facility, most of which are outdated analog systems in need of replacement. The modernization project, initiated in late 2023, consolidates optimal solutions to all accumulated challenges.
Construction work began in 2024. The project involves a complete overhaul of the building, replacing engineering networks such as heating, lighting, and ventilation, as well as establishing specialized workshops. The main building of the RMP will be entirely dismantled and rebuilt. Demolition of outdated equipment and structures has been completed, and foundation pouring, installation of wall panels, and ceiling structures are underway.
A total of 1,000 obsolete machines will be replaced by 144 modern, multifunctional, high-precision, energy-efficient machines with a high degree of automation and CNC capabilities. This includes universal and CNC machines, test benches, preparatory equipment, presses, furnaces, 3D scanners, and printers. Currently, 30% of the new equipment has already been delivered to the site. Additionally, 129 units of auxiliary equipment (lifting systems, forklifts, elevators, welding semi-automatic machines) and 515 units for production infrastructure (shelving, workbenches, storage cabinets, and specialized containers) will be procured.
With the upgraded equipment, the speed of operations at the RMP will increase by a factor of 2 to 40. The plant’s product range will expand from 1,500 to 3,500 items.
A Scale Beyond Tobolsk
In 2022, the modernization of "ZapSibNeftekhim’s" repair plant increased efficiency from 49% to 62%, with an investment exceeding 2 billion rubles.
The investment in modernizing NKNK’s RMP is significantly larger. This project is expected to not only enhance production efficiency but also strengthen the technological independence and resilience of the entire SIBUR group.
– "This will be the most technologically advanced repair plant in the country, surpassing even the Tobolsk facility in scale and modernity. The scope of operations will be significantly expanded. This project is the most ambitious within our company’s repair facility development strategy," emphasized Pavel Okhrimenko, Head of SIBUR’s Repair Production Department.
A significant portion of the new production equipment for the RMP is sourced from domestic manufacturers. Machines and test benches will be installed once the workshops are enclosed and climate control systems are fully operational.
Optimized Layout and IT Architecture
The main building of the RMP will consist of five primary sections:
- Repair of shut-off and control valves
- Repair and production of large static equipment
- Metalworking with CNC and universal machines
- Repair and testing of electric motors
- Repair of pumps and compressors, along with an additive manufacturing section with 3D printers
A state-of-the-art 3D printing facility will produce serialized spare parts, with specialists trained at the "Innovative Center for Additive Manufacturing" established at Bauman Moscow State Technical University.
Thirty specialized workshops will be constructed on the RMP site, with the first tool shop launched in February 2024. It accommodates mechanics, electricians, and instrumentation specialists. Additionally, three self-propelled mobile workshops have been acquired.
– "Parallel to this, smaller workshops are also being renovated. Ten production facilities are already completed, with work continuing in fifteen more," added Pavel Okhrimenko.
The modernization will allow the RMP to expand its scope of work and take on contracts from other SIBUR enterprises. This will be facilitated by the introduction of automated monitoring, planning, and equipment utilization systems.
The new IT architecture will enable real-time tracking and management of repair orders, ensuring efficient distribution across SIBUR facilities while maximizing equipment utilization. The repair plant will be integrated with key enterprise systems, including resource allocation, planning, accounting, and documentation. As a result, the RMP at NKNK will become a central hub for SIBUR’s repair operations, standardizing, managing, and automating core maintenance and repair processes across the entire holding.
Workforce Transformation
In parallel with the modernization, "Nizhnekamskneftekhim" is conducting workforce retraining to meet higher standards for repair quality and complexity. Employees will undergo diagnostics followed by specialized training programs developed by "SIBURINTECH" in collaboration with eight training centers. Over 320 specialists will receive training, with 19 educational programs, webinars, and e-courses available. Seven internship programs will be held within the company, with six training programs conducted directly at the RMP.
– "Intellectual transformation is just as important as technological upgrades. The RMP staff is fully prepared for the changes. I have personally witnessed their enthusiasm and ability to quickly grasp project requirements during site visits. They understand their role and contribution to the company’s development," stated Alexey Tashpaev, Director of the Dehydrogenation and Polypropylene Production Complex (DGP-2) at "ZapSibNeftekhim."
During the RMP modernization project, thousands of engineering documentation units were reviewed, and manufacturing processes for critical components were developed.
– "We leveraged best practices in effective repair production, studying facilities in Chelyabinsk, Tyumen, and Kazakhstan. Together with SIBUR’s team of professionals, we designed a new operational model for the repair plant with an optimal technological equipment lineup. This facility will be capable of manufacturing and repairing the most advanced machinery components for Russia’s petrochemical industry, ensuring its technological independence," noted Dr. Alexey Morozov, Director of "Smart Manufacturing."
– "No other company in Russia is moving at this pace. We are completely rebuilding the facility, dismantling obsolete equipment, and replacing it with state-of-the-art systems. There have been no projects of this scale completed in such a short timeframe before. This RMP will be the best in the country, and that is a huge motivation for our team," concluded Mikhail Rubtsov, Director of the Repair and Mechanical Plant.