Taking refining and chemical enterprises as the background, this paper combines the requirements of Made in China 2025 for the integration of information technology and industrialization, analyzes the foundation of intelligent manufacturing construction in domestic refining and chemical enterprises, draws on the ideas of intelligent factory construction in domestic and foreign industries, and proposes the basic framework and construction content of intelligent factory construction in Chinese refining and chemical enterprises.
Made in China 2025; Smart factory; Integration of two industries; Intelligent construction of workflow;
Modern industry or manufacturing has gone through the process of mechanical manufacturing driven by steam engines, large-scale production driven by electricity, and automated manufacturing driven by electronic information technology. Germany, a manufacturing powerhouse, describes this industrialization process as the Industrial 1.0 era where machines replaced manual labor, the Industrial 2.0 era where assembly line production took place, and the Industrial 3.0 era where highly automated production took place. In recent years, with the rapid development of new information technologies such as the Internet, the Internet of Things, cloud computing, big data, and the deep impact of these technologies on the form of the manufacturing industry, Germany proposed the concept of Industry 4.0 at the 2011 Hanover Industrial Expo, and upgraded the policy of manufacturing power accompanied by this concept to the national strategy. At the same time, countries such as the United States, the United Kingdom, France, and Japan have proposed national manufacturing upgrading strategic plans that are suitable for their own industrial manufacturing development characteristics. In 2015, China also launched the "Made in China 2025" - the Chinese version of the "Industry 4.0" plan, which proposed the strategy of building a strong manufacturing country in China. At the same time, around the strategic goal of building a strong manufacturing country, the "Made in China 2025" plan clarified 9 strategic tasks and related key development areas. Compared with the manufacturing power strategy of other countries, Made in China 2025 emphasizes the integration of informatization and industrialization to lead and drive the development of the entire manufacturing industry, as well as the strategic idea of focusing on intelligent manufacturing, based on the actual situation of China's industrial manufacturing industry. The Ministry of Industry and Information Technology immediately released the list of pilot demonstration projects for intelligent manufacturing in 2015, focusing on this national strategic deployment. The construction of Sinopec Hainan Refining and Chemical Intelligent Factory will be used as a demonstration in the petrochemical industry. The paper will combine the national strategic direction, Sinopec Hainan Refining and Chemical Demonstration Practice, and the actual situation of PetroChina Refining and Chemical Enterprises to explore the manufacturing upgrading and intelligent factory construction of refining and chemical enterprises.
The positioning and direction of intelligent factories in the refining industry< br />
Faced with slow recovery from the international financial crisis and the domestic economy entering a new normal, the process of commodity marketization and globalization is gradually accelerating, and international market turbulence and competition are intensifying. The prices of bulk raw materials continue to fluctuate, the production and operation risks of refining enterprises continue to rise, and the requirements for green environmental protection continue to increase. At the same time as facing enormous pressure and challenges in the refining industry, there are also new opportunities and opportunities for upgrading and development. A series of preferential policies benefiting the development of the energy and chemical industry, such as the National Petrochemical Industry Adjustment and Revitalization Plan, Coal and Coal Energy Chemical Industry Plan, and Intelligent Manufacturing, have been successively introduced. The sustained development of the national economy requires more and better high-quality and low-cost energy and chemical products, and the situation of insufficient supply of domestic energy and chemical products will still exist& nbsp;
The refining industry is a typical capital and technology intensive industry, with a high dependence on equipment and equipment. The overall level of automation and informatization is relatively high. For domestic refining enterprises, automation and IT technologies such as intelligent instruments, distributed control systems (DCS), advanced control, oil blending, process simulation, planning, scheduling optimization, MES, ERP, etc. are all applied in refining enterprises. At the same time, in terms of new technology applications, the refining industry is actively utilizing new technologies such as the Internet of Things and cloud computing to make application attempts in remote equipment inspection, security management, and enterprise IT governance. It can be said that to a certain extent, there are not many obvious deficiencies in automation and information technology applications among domestic refining and chemical enterprises, especially in the large-scale information construction in recent years. The deployment speed of some advanced information systems even exceeds that of foreign counterparts (such as optimizing production scheduling). However, it is widely felt that the intelligent manufacturing capabilities of enterprises have not significantly improved, and there are occasional issues such as the unclear benefits brought by grassroots user application systems. Looking into the reasons, aside from personnel quality, this article believes that there are six aspects that need to be improved. One is that there are still outstanding debts in the automation of basic instruments, and the lack of instruments and self-control in key areas directly affects the application effect of upper level material balance and regional optimization. The second is that the long-term application mode and investment maintenance mode of device level optimization operation technology (process simulation, APC, online blending, RTO) need to be reformed. The third is the urgent need to integrate production management information systems. The complete PDCA management cycle of planning, scheduling, scheduling, operation execution, operation monitoring, balance analysis, and performance evaluation has not yet been formed, and the optimization on it has not been basically achieved. The fourth issue is the lack of new technological support for on-site operators, which is an important blind spot in the safety management of refining enterprises. Environmental monitoring needs to be strengthened, and wireless interconnection applications in refineries need to be launched. The fifth issue is the insufficient collection, analysis, and application of operational mechanism data for equipment and devices, making it difficult to scientifically evaluate the maintenance, potential improvement, and efficiency enhancement work of equipment and devices. The sixth issue is that investment management and project management in automation and information technology operate independently, with inconsistent steps and no spiral upward pattern of mutual promotion and compensation. There is no application synergy, resulting in a "1+1>2" effect.
Based on the above analysis, we believe that the construction of Industry 4.0 or smart factories in domestic refining and chemical enterprises needs to propose a reasonable construction model based on a profound analysis of industry characteristics and their own reality. As a relatively weak market competition, high-risk, and large-scale process processing industry, the automation and informatization level of refining enterprises is relatively high. The focus of intelligent factory construction in the refining industry should be on improving mature automation and informatization technologies, as well as the integration of automation and informatization. Through the process of integration of the two, it can promote the optimization and progress of technology and management, achieve intelligent equipment, management, decision-making, and ultimately achieve intelligent manufacturing.
Specifically, the symbols or features of the integration of refining and chemical industries or intelligent manufacturing can be summarized into the following four aspects:< br />
Data: Firstly, it is necessary to maximize the use of various sensors, measuring equipment, and storage devices to achieve the collection and information management of factory design data, product data, equipment dynamic and static data, research and development data, material data, operational data, sales data, and customer data for refining enterprises. Satisfy the need for "perspective" on enterprises.
Interconnection: It is necessary to be able to use industrial Ethernet/wireless network/4G, 5G intelligent handheld or wearable terminals to achieve networked connection of devices, personnel, and communication facilities. Through the internet, people and machines are interconnected to meet the information and operational needs of personnel and equipment devices& nbsp;
Optimization: Based on data and interconnection, achieve high self-control rate in the process control layer, and combine planning, demand, and benefit data to achieve optimized control of device and local operations; Implement a PDCA closed-loop production management system at the production management level, while combining ERP information to optimize factory wide planning, scheduling, and equipment maintenance; Optimize supplier raw material procurement, enterprise financial resources, and product sales at the management decision-making level& nbsp;
Innovation: The integration of automation and information technology should have a profound impact on the production and operation mode of enterprises. It is a process of innovative development, inevitably accompanied by innovation in technology, products, and management modes. If we simply emphasize technology and equipment, we cannot optimize and improve the operation mode of the enterprise, nor can we represent the realization of intelligent manufacturing. Key Construction Content of Integration of Two Industries and "Intelligent Factory" in Refining and Chemical Enterprises< br />
The core idea for the construction of intelligent factories in refining and chemical enterprises is to improve and enhance automation and information related systems, especially the integration of automation and information technology. The main content of the construction of an intelligent refining factory revolves around three main business lines, which can be summarized into three aspects: first, the integration of production control, vertically integrating ERP, MES, RTO, APC, PCS and other systems; The second is to integrate the supply chain from crude oil procurement, processing, transportation to end customer service horizontally; The third is the full lifecycle management of assets, from project preparation, project design, to construction and delivery, to factory operation and equipment maintenance, to digital management of asset scrapping and exit from the entire lifecycle process.
Integrated production control and management< br />
The integration of production control mainly relies on the design and implementation of four projects: MES2.0, APC, process simulation, and oil blending. The seamless connection of data flow between each project enables collaborative achievement of production control optimization goals& nbsp;
Plan scheduling statistics closed-loop management: Integrate MES and APS to achieve PDCA closed-loop management of refinery production and operation& nbsp;
Production operation optimization control: Promote the application of APC system, and integrate and interact model data with process simulation and scheduling modules. Enhance the level of intelligence and refinement in operational control& nbsp;
Safety, environmental protection, and quality management: Integrate energy consumption, hazard sources, key area videos, environmental monitoring, and quality information. Establish a complete enterprise QHSE management system& nbsp;
2.2 Supply Chain Integration< br />Based on the APS system of the current headquarters, add product price information (including prices and basic trends, which need to be obtained from the sales ERP), production cost information (which needs to be obtained from the production ERP), transportation cost information (which needs to be obtained from the regional transportation department), and combine sales demand and product production capacity requirements to establish a reasonable linear programming model and optimize enterprise efficiency. Constructing automated systems for tank farms in demonstration enterprises& nbsp;
In the field of chemical industry, establish an integrated supply chain for chemical products, realizing the full process integration of chemical products from customer demand forecasting, production planning, scheduling, production, sales configuration, warehousing management, transportation management, distribution management, and technical services& nbsp;
While promoting the integration of refining ERP applications, we should consider building an e-commerce platform for chemical products in China. Because the establishment of e-commerce platform has a particularly strong Internet feature, technology, operation and capital are the three core key points. The success of the website requires a large amount of early venture capital investment for market promotion. At the same time, it requires a professional Internet marketing team to carry out long-term operation and maintenance, and in accordance with the survival characteristics of Internet enterprises (only by achieving the first and second place in the industry can we survive, and the enterprises ranking lower have little room for survival). It is suggested that the project adopt the operation mode of industry websites such as China Steel Network, and jointly build a chemical e-commerce platform through joint ventures with third-party companies. The establishment and long-term good operation of chemical e-commerce platforms will greatly promote the sales of chemical products by enterprises and the collection of industry demand information, occupying the sales channels of the domestic chemical product market& nbsp;
Asset lifecycle management< br />
Long cycle operation of equipment: Integrating with ERP around equipment maintenance and operation management, realizing the business chain of equipment maintenance and operation status monitoring& nbsp;
Based on the design of a digital factory, the implementation of three-dimensional digitalization in the refinery is carried out. The three-dimensional model of the digital factory is integrated with equipment and production operation data, and virtual and reality are combined. From the three-dimensional digital model, equipment fault location and operation simulation can be quickly carried out, improving equipment fault prediction and forecasting. Simultaneously integrating with ERP to achieve financial management and scrap management of equipment assets& nbsp;
3 Conclusion < br />
The construction process of smart factories will enhance and integrate the existing professional application systems of enterprises. The construction of smart factories will achieve excellent operation of the factory, improve labor productivity, reduce energy and material consumption, improve product quality, and increase economic benefits. By building an integrated refining and chemical process optimization platform, the entire process of planning, scheduling, and operation can be optimized, forming a complete PDCA closed-loop and collaborative production new model. Facing production operations, internal and external operation collaboration improves on-site disposal efficiency, enhances production quality and efficiency. Targeting energy management, applying energy management online optimization technology to achieve visualization of energy flow, maximization of energy efficiency, and online optimization. Targeting HSE management, combined with IoT, mobile terminals, and network technology, we achieve a closed-loop monitoring mode that integrates on-site operations, personnel, and environment. Targeting devices, achieving 3D visualization of equipment, process, HSE data, and videos, improving maintenance decision-making ability and equipment management level. Targeting decision support, we aim to establish real-time monitoring and comprehensive analysis of operations, achieving comprehensive real-time monitoring, prediction, warning, dynamic analysis, and mobile access. Provide comprehensive support for managers to grasp the overall situation, identify problems, analyze and make decisions. By utilizing wireless internet technology, a unified integrated communication platform is built to lay the foundation for further intelligent applications< br />
Definition: Based on the customer's product functional requirements, OEM or ODM of the product, changing the internal and external attributes of the product to meet the customer's customized needs& nbsp;
Customized content
1. The product elements consist of exterior color matching, nameplate logo, power on/off screen, UI interface, software, built-in information, and accessory packaging
2. Customization of special functional requirements (fingerprint recognition, RFID, private network intercom, laser one/two-dimensional code reading and writing, GNSS, RTK precise positioning, satellite short message, AIS system, and 4-channel 1080P wireless image transmission, etc.)
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Customization requirements
According to the different customization needs of customers, corresponding fees will be charged based on the overall evaluation of research and development difficulty and procurement quantity< br />
We can provide the following services:
1. Provide comprehensive solutions for ID/MD/software/hardware of various special three proof intelligent terminal products< br />
2. Provide appearance design and manufacturing production of various materials for the shells of various special three proof intelligent terminal products< br />
3. Provide design proposals for packaging/posters and other promotional materials for various special three prevention products< br />
4. Provide a series of problems such as the application and solutions of various special three defense intelligent terminals in different industries
5. Provide internal and external structural design, functional modules, software and other modifications for company related products
6. Please feel free to contact us for specific details regarding the requirements< br />
Shenzhen Wanwei Communication Technology Co., Ltd. is a high-tech enterprise specializing in the R&D and sales of three prevention electronic products, communication information equipment and Internet terminal products.
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