Localisation and Development of Industrial Clusters
Import Substitution and Equipment Localisation for Rosneft’s Needs
In 2015, Rosneft launched an Import Substitution and Equipment Localisation Programme (the Programme).
Aligned with strategic goals and objectives set forth in the Rosneft–2022 Strategy and the Company’s Long-Term Development Programme,
the Programme aims to:
- facilitate the development of Rosneft as a high-tech oil and gas company;
- foster technological leadership in its core competencies, such as oil and gas production, oil refining and gas processing;
- secure the Company’s technologically sustainable position in the hydrocarbons market by increasing the share of Russian-made products and implementing projects to localise the manufacturing of foreign oil and gas equipment in Russia in cooperation with leading global producers;
- facilitate the development of infrastructure supporting exploration and production and refining, commerce and logistics projects as part of localisation efforts.
To this end, Rosneft keeps investing in proprietary solutions and products with a view to sustaining its technological self-sufficiency.
Given a bigger share of horizontal wells and rising geological and engineering complexities, there is a growing need for advanced well logging techniques along with other prospecting, exploration and development technologies of critical importance. Rosneft focuses on developing domestic capabilities in advanced well logging. Currently, the Company partners with Rosatom to develop instruments for measuring mineral composition of formations and logging while drilling horizontal wells. This will help provide for high-quality insights into complex reservoirs and ensure independence from expensive foreign services.
Also, Rosneft and Rostec developed a technology to produce synthetic proppants. The Company’s R&D efforts were successful resulting in batches of these proppants for pilot testing at Rosneft’s oil production sites. The parties are considering mass production of synthetic proppants at Rostec industrial sites.
Russian-made catalysts are key to sustaining the technological self-sufficiency of the Company’s refining segment reducing its reliance on foreign technologies. In 2019, RN-Kat specialising in catalyst production and the Ufa Refinery conducted industrial tests on the first batch of hydrotreating catalysts suitable for Euro5 compliant diesel fuel. This is a unique hydrotreating agent capable of fully replacing its foreign peers for the Russian refining industry. The tests proved that Rosneft’s proprietary catalyst was fit for the production of diesel fuel compliant with all the latest technical requirements.
In 2019, the Novokuibyshevsk Catalysers Plant launched Russia’s first-ever advanced pilot testing facility for hydrotreating catalysts. The new facility will help test technologies to manufacture catalysts for oil refining and petrochemical processes with a view to ramping up large-scale production. Until now, Russia has been lacking such technological capabilities. The cutting-edge platform will fast-track the implementation and commercialisation of Rosneft’s R&D initiatives focusing on catalysis and catalysts for the said processes.
The development of proprietary research-intensive specialist software is another strategic focus area for the Company. As of now, Rosneft’s production assets operate five software suites which model field geology (RN-Geosim, RN-KIM), simulate hydraulic fracturing operations (RN-GRID), manage field development (RN-KIN) and model drilling operations of any complexity (RN-Sigma).
In 2019, RN-Geosim added software modules to build simple geological models while RN-KIM designed modules for hydrodynamic modelling at large fields.
Over the year, RN-Yuganskneftegaz leveraged RN-GRID models to perform another multi-stage hydraulic fracturing operation on a horizontal well in an ultralow-permeability reservoir at the Bazhenov suite. With 610 tonnes of proppant injected, the Company obtained oil flow of ca. 6.5 t per day per stage, which is unprecedented in the Russian oil and gas industry. By now, RN-GRID has designed more than 8 thousand full-scale hydraulic fracturing operations, with R&D efforts ongoing to develop new functionalities in line with the newest challenges.
RN-KIN software suite covers 100% of operational tasks related to field development. The Group Subsidiaries are now testing the industrial version of RN-Sigma suite (geomechanical modelling of borehole stability while drilling). This software enables the Company’s engineers to capitalise on wider applications of geomechanical calculations for borehole stability and reduce risks while drilling directional and horizontal wells.
Fostering the Industrial Cluster
To ensure its technology self-sufficiency and implement localisation projects, Rosneft formed the Industrial Assets group (the Industrial Cluster) having technological and logistics capabilities to manufacture, maintain and repair equipment (including that designated to substitute imports) for the Company’s needs in a timely manner.
In 2020–2025, the Industrial Cluster will be focusing on:
- establishing R&D and manufacturing infrastructure to support re-engineering, innovations, and import substitution;
- running pilot projects and tests in line with the Company’s Target Innovative Projects;
- supplying capacities to support localisation projects in cooperation with foreign technology partners as well as joint ventures with Russian R&D centres and enterprises.
Industrial and Shipbuilding Cluster in the Russian Far East
Upon instruction from the Russian President, Rosneft is ramping up a shipbuilding cluster in the Far East to foster the domestic shipbuilding industry and energise the development of the country’s continental shelf. Zvezda Shipbuilding Complex in Bolshoy Kamen will be the core shipyard and Russia’s first-ever facility for the construction of large-capacity vessels.
Importantly, the shipyard will be manufacturing icebreakers and reinforced ice-class vessels, along with LNG-powered vessels. The shipyard boasts a unique set of competencies unparalleled among both domestic and leading global peers.
To cater to the needs of import substitution and equipment localisation, an industrial cluster for shipboard equipment and components is emerging around the shipbuilding complex.
In 2019, the first and the second phases of the shipyard construction saw a huge volume of works:
- 6.5 mcm dredged to deepen the waterways;
- over 700 th. cub m of soil dumped;
- over 36 th. cub m of concrete poured;
- over 16.5 th. sq m of construction sites developed;
- ca. 12 kt of steelworks assembled;
- 3.2 kt of sheet piles and 7 kt of piles installed.
In June 2019, the second Goliath giant crane with a lifting capacity of 1.2 kt was delivered and assembled at the dry dock, a unique hydraulic structure sized 485 x 114 x 14 m. The giant crane will help build the majority of existing and prospective vessel types with virtually unlimited tonnage and launching weight. With the construction works being ahead of schedule, the dry dock will be commissioned in 2020, three years earlier than planned.
In 2019, Zvezda and Samsung Heavy Industries Co. Ltd. (Republic of Korea) established a joint venture to manage projects for the construction of shuttle tankers with a deadweight from 42 to 120 kt at Zvezda Shipbuilding Complex. The joint venture relies on the agreement on exchanging experience in the design and construction of shuttle tankers signed in 2018. Samsung Heavy Industries will hand over base and detailed design documentation to the Zvezda Shipyard, and give a helping hand in developing working design documentation for shuttle tankers together with Lazurit Central Design Bureau.
In 2019, Zvezda signed contracts for the construction of nine vessels, thus providing for large-capacity vessels to be made in the Primorye Territory.
Sapphire Applied Engineering and Training Centre
An industrial cluster for shipboard equipment and components is emerging around Zvezda Shipbuilding Complex. The cluster accommodates a workshop to manufacture steerable thrusters for ice-class vessels, including gas carriers.
VRK Sapphire Plant, a joint venture of Rosneft and General Electric, manages the project to develop and localise the production of steerable thrusters, a key component of marine electric propulsion systems.
With the first construction phase completed, VRK Sapphire Plant was approved for commissioning in 2019 and started manufacturing 7.5 MW steerable thrusters for the third and fourth reinforced ice-class support vessels which are being built for the Company at Zvezda Shipbuilding Complex.