Digital life cycle management of petrochemical equipment

The digitalization of production equipment is the application of information technology to transform information such as engineering equipment planning and design, equipment manufacturing, equipment installation, operation, and maintenance into structured data or unstructured data, to establish a data organization model and express, transmit, and process the system in digital form.

In the traditional equipment management mode, the design, procurement, installation and operation, and maintenance of equipment are independently operated by different departments, and the degree of data information sharing is low, resulting in some special states and needs, the equipment information can not be shared and transmitted in time, which not only cannot ensure the security and accuracy of data, but also is not conducive to the accumulation of equipment operation and management experience, but also increases the difficulty of follow-up work of equipment management.  The establishment of the digital life cycle system can not only enhance the accuracy of equipment management work, and realize the intelligent association of digital information throughout the life cycle of equipment, but also improve the quality of equipment management, ensure the safe and efficient operation of the device, and create more economic benefits for enterprises.

The digital life cycle management system of petrochemical equipment consists of five parts: equipment planning and design, equipment manufacturing management, equipment installation and commissioning, equipment operation and maintenance management, and equipment asset management system, among which equipment planning and design is the top-level design of the digital life cycle and the basis for comprehensive application and business processing of equipment digitalization. In the actual process, it is necessary to carry out information integration work such as equipment planning, selection, and design according to the process flow and equipment layout scheme, and establish a digital integration platform. Based on the digital integration platform, equipment procurement, manufacturing, and transportation management. After transporting the equipment to the project site, the equipment is first accepted, and the installation and single machine commissioning are carried out after the experience is qualified. From the entire plant planning to commissioning, all information is aggregated in a digitally integrated platform and delivered to the customer in its entirety.

According to the structural characteristics of the equipment involved in the project, establish an integrated equipment design platform. The planning and design of equipment is the first step in the whole life cycle management of equipment, generally planned and designed by the design unit, and the standard data format and finished product documents submitted by the design unit are closely related to the perfection and level of the equipment model. Therefore, it is important to ensure the top-level design work of data coding, standards, and quality, and try to avoid the extreme case of tearing down the wheel and starting over. The integrated design platform for equipment described here includes 3D intelligent design, engineering drawings, BOMs, and design analysis collaborative design.

The concept of the whole life cycle should be introduced into the procurement process of equipment, and the cost of the whole life cycle of the equipment should be calculated through full demonstration and research, combined with the analysis of equipment safety risks, and equipment with large safety and environmental risks must take equipment reliability as the first element of procurement. The equipment enters the manufacturing process through procurement, and then the enterprise summarizes statistics according to the equipment planning and design plan, bids according to the equipment parameter information provided, and signs contracts with equipment manufacturers capable of construction.

The realization of equipment operation and maintenance is based on equipment planning and design, manufacturing, and installation, based on the analysis of equipment operation performance, the equipment management is advanced from the equipment level to the part level, the data assets of vulnerable parts and parts are effectively managed, and the operation safety is ensured through intelligent value-added applications, the pressure on operation and maintenance costs is reduced, the pressure on operation and maintenance costs is reduced, unplanned downtime is reduced, and remote operation is achieved to achieve the goal of reducing equipment failure rate and reducing inspection and maintenance costs.

The internal workshop of chemical plants often has a large number of equipment and complex pipelines, so it is of great significance to monitor the production status of the main equipment in a fast, real-time, and visual manner, and to monitor the equipment site status without dead ends. Therefore, the monitoring of equipment mainly includes two aspects: visualization of equipment operation and video surveillance. Among them, the visualization of equipment operation is to select the equipment model in the three-dimensional scene, in which not only the temperature, pressure, liquid level, vibration, operating data, design parameters, trend chart, and other information of the equipment can be viewed, but also the design parameters can be compared with real-time monitoring data to visually display alarm information. At the same time, with the help of the video surveillance system in the digital model, the owner can not only identify the monitoring equipment but also quickly call and obtain one or more monitoring videos through “video surveillance” to display the monitoring picture, to achieve monitoring coverage of the whole process inside and outside the factory.

Under the premise of digital monitoring and visualization, establish a digital operation center. The key indicators are displayed in 3D throughout the plant, and the corresponding system diagram and the corresponding 3D model of the system can be displayed for each system at the same time, and real-time data can be displayed in the system diagram and 3D model. Moreover, in the three-dimensional platform, the relevant data in the production process can be uniformly managed according to different classification methods, which is convenient for data query analysis and use in the entire system application process. At the same time, it allows customers to easily create various types of information, and continuously expand the classification of information to plan the data, functions, and display of the system, and provide detailed data information for the operation and maintenance of equipment.

The equipment asset management system mainly includes two functional modules, namely, statistics and scrap treatment, the main functions are the management of equipment spare parts, inventory management, system management and equipment performance management, and other basic modules. Through systematic decision-making, the static equipment and moving equipment that is seriously corrosive, have no transformation and maintenance value, or has serious accident hazards and exceeds the service life specified in the design documents shall be scrapped promptly, and the registration authority shall be promptly deregistered by the relevant rules and regulations.

Through the management of equipment assets, establish a complete equipment information system, improve the operation efficiency and utilization rate of equipment, further improve the effectiveness of equipment, and ensure the safe and efficient operation of equipment. When the equipment reaches the state of scrapping, timely scrapping treatment can effectively improve the operating efficiency of enterprise equipment assets.

The Observant Engineer – Life Cycle Of Process Equipment for Oil Gas and Petrochemical Plant – YouTube