One of the promising ideas of tomorrow for any production is digital asset modeling: creating virtual copies of real objects that look and function exactly like their prototypes. Gazprom Neft is closely involved in digital twins at the company's refineries, and much of this innovative technology has already been implemented.
From drawings to 3D models
A bit of history. Drawings and diagrams have always been necessary for people, from the moment of the first inventions of the wheel and the lever, in order to transmit information to each other about the structure of these devices and the rules for their use. At first, these were primitive drawings containing only the simplest information. However, the designs became more complex, and the images and instructions became more detailed. Since then, technologies for visualizing, documenting and storing knowledge about structures and mechanisms have come a long way. However for a long time the main medium for fixing engineering thought was paper, and the working space was a plane.
In the second half of the twentieth century, it became clear that the usual army of draftsmen, armed with drawing boards, was no longer able to keep up with the rapid growth of industrial production and the complexity of engineering developments. Acceleration of the processing of voluminous and complex information (for example, a technological unit for atmospheric distillation of oil contains more than 30 thousand pieces of equipment) required changes in the work technology of designers, designers, builders, technologists, operation and maintenance specialists. The evolution of technical design tools made another round, and in the early 90s of the last century, computer-aided design systems (CAD) came to the oil industry. They first used 2D drawings, and then, towards the end of the 2000s, they came to 3D.
Modern design systems allow engineers to carry out the layout and design of industrial facilities in volumetric form, taking into account all the restrictions and requirements of the production process, as well as industrial safety requirements
Modern design systems allow engineers to carry out the layout and design of industrial facilities in volumetric form, taking into account all the restrictions and requirements of the production process, as well as industrial safety requirements. With their help, you can create a design model of a particular installation and correctly place technological and technical components on it without contradictions and collisions. Experience shows that by using such systems it is possible to reduce the number of errors and inconsistencies in the design and operation of various installations by 2–3 times. The figure is impressive when you consider that for large-scale industrial equipment, the number of errors that have to be corrected during the design review process is estimated at thousands.
From the point of view of designers and builders, the use of 3D models makes it possible to dramatically improve the quality of design documentation and reduce design time. The constructed information model of the object is also useful at the stage of operation. This is a new level of ownership of an industrial facility, where personnel can obtain any information required to make a decision or complete a task in the shortest possible time, based on the existing model. Moreover, when, after some time, the modernization of equipment is required, future designers will have access to all relevant information, with a history of repairs and maintenance.
Omsk pilot
Sergey Ovchinnikov,
Head of the Control Systems Department, Gazprom Neft
The development and implementation of an engineering data management system is undoubtedly an important part of the innovative development of the logistics, processing and sales unit. The functionality inherent in "SUPrID", the potential of the system will allow the block in particular and the company as a whole to become leaders in the digital management of engineering data in oil refining. Moreover, this software product is an important component of the entire line of related IT systems, which are the foundation of the BLPS Performance Management Center, which is currently being created.
In 2014, Gazprom Neft launched a project to create a system for managing engineering data for oil refining facilities - SUPrID. The project is based on the use of 3D modeling technologies for the design, construction and maintenance of industrial facilities. Thanks to their use, the terms of creation and reconstruction of oil refineries are reduced, the efficiency and safety of their operation are increased, and the downtime of the plant's technological equipment is reduced. Implementation modern system Engineering data management on the latest Smart Plant for Owners / Operators (SPO) platform is handled by specialists from the Department of Control Systems of the Logistics, Processing and Sales Unit, as well as from the subsidiary company ITSK and Avtomatika Servis.
Due to the use of automated design systems that create 3D models of objects, it is possible to reduce the number of errors and inconsistencies in the design and operation of various installations by 2-3 times.
At the end of last year, a pilot project was successfully completed to deploy the platform's functionality and set up business processes for the newly reconstructed primary oil refining unit of the Omsk Refinery - AT-9. The system implements the functionality for storing, managing and updating information about the installation throughout its entire life cycle: from construction to operation. Along with the system, regulatory and methodological documentation, requirements for the designer and standards for engineering data management were developed. "SUPrID" is a good assistant in the work, - said the head of the AT-9 unit at the Omsk Refinery Sergey Shmidt. - The system allows you to quickly access engineering information about any equipment, view its drawing, clarify technical parameters, localize the location and take measurements on a three-dimensional model that exactly reproduces the real installation. The use of "SUPRID" helps, among other things, to train new specialists and trainees. "
How it works?
The task of the SUPRID system is to cover all stages of the life cycle of a technological object. Start by collecting engineering information at the design phase and then updating the information at subsequent stages - construction, operation, reconstruction, displaying the current state of the facility.
It all starts with information from the designer, which is sequentially transmitted and loaded into the system. The initial data are: design documentation, information on the functional, technological and construction and installation structure of the facility, intelligent technological schemes. It is this information that becomes the basis of the information model, allowing you to instantly receive address information about construction objects and the technological scheme of the installation, making it possible in a few seconds to find the desired position of technological equipment, instrumentation equipment on the technological scheme, to determine its participation in the technological process.
In turn, using the project 3D-model of the object loaded into the system, you can visualize it, see the configuration of blocks, the spatial arrangement of equipment, the environment with neighboring equipment, and measure the distances between various elements of the installation. The formation of the operational information model is being completed by linking as-built documentation and 2D, 3D models "as built", which provide an opportunity to obtain detailed information on the properties and technical characteristics of any equipment or its elements at the stage of operation. Thus, the system is a structured and interconnected set of all engineering data of an object and its equipment.
Roman Komarov,
Deputy Head of the Department of Engineering Systems "ITSK", Head of Development "SUPrID"
After many years of assessing the benefits of the project and preliminary study, the pilot of the system was implemented in a short time. Implementation of "SUPrID" allowed the company to obtain a tool for managing engineering data of oil refining facilities. The next global step, which we will gradually approach, is the formation of a digital information model of an oil refinery.
To date, more than 80,000 documents have been uploaded to the SUPrID electronic archive. The system allows you to search by positional information about any type of equipment, provide the user with comprehensive information on each position, including technical characteristics, dimensions, material design, design and operating parameters, etc. "SUPRID" makes it possible to view any part of the installation in a three-dimensional model or on a technological scheme, open scanned copies of documents related to this position: working, executive or operational documentation (passports, acts, drawings, etc.).
More than 80,000 documents have already been uploaded to the SUPrID electronic archive. The system allows performing search by positional information on any type of equipment, providing the user with comprehensive information on each position.
This variability significantly reduces the time spent on access to up-to-date information and its interpretation, avoids mistakes in the reconstruction and technical re-equipment of the facility, replacement of obsolete equipment. "SUPRID" helps to analyze the operation of the installation and its equipment in assessing the efficiency of operation, contributes to the preparation of changes in technological regulations, investigation of failures, malfunctions, accidents at the facility, education and training of maintenance personnel.
"SUPrID" is integrated with other BLPS information systems and forms a unified engineering data information environment, which, among other things, will become the basis for the innovative Block Efficiency Management Center. Interconnection with programs such as KSU NSI (corporate system for managing reference information), SAP TORO (maintenance and repair of equipment), SU PSD (design and estimate documentation management system) "TrackDoc", Meridium APM, forms a unique integrated automation system processes for managing the production assets of an oil refinery, allowing you to increase the economic effect of their joint use for the company.
Project efficiency
In a relatively short period of time, Gazprom Neft's IT specialists managed not only to master the intricacies of the SPO platform, on which the engineering data management system is built, but also to create a completely new infrastructure for the company, develop a set of regulatory documents, and ultimately develop a qualitatively new approach to construction of oil refining facilities.
At an early stage of the project, it became obvious that the system would be in demand by the plant's operating services and capital construction services. Suffice it to say that its use saves up to 30% of working time for searching and processing technical information on any object. When "SUPrID" is integrated with systems of reference information, maintenance and repair of equipment, design estimates and other relevant engineering data, it becomes available for prompt and high-quality service of technological equipment. The capabilities of the system also make it possible to create a simulator for maintenance services, which will undoubtedly increase the level of training of their specialists. For the capital construction departments of the refinery, the system will become a design tool at the stage of minor and medium repairs. This approach greatly simplifies control over the course of reconstruction of industrial facilities and improves the quality of repairs.
It is assumed that the investments made in the implementation of "SUPrID" will pay off in about 3-4 years. This will become possible due to a reduction in design time, an earlier transfer of installations from the stage of commissioning to commercial operation and, as a consequence, an increase in the volume of finished products. Another significant plus is the acceleration of the preparation and implementation of maintenance work and the implementation of reconstructions and upgrades of installations by reducing the time required for checking new design documentation by the refinery's operational services and timely detecting shortcomings and errors in the work of design and construction contractors.
The "SUPrID" implementation program is designed for the period up to 2020. It will be used to digitize both existing installations and the construction of new facilities. At present, specialists are preparing to replicate the system at the Moscow Refinery.
What is a Digital Twin?
The digital twin is a new word in modeling and production planning - a single model that reliably describes all processes and relationships both at a separate facility and within a whole production asset in the form of virtual installations and simulation models. Thus, a virtual copy of the physical world is created.
The use of a digital twin, which is an exact copy of a real asset, helps to quickly simulate the development of events depending on certain conditions and factors, find the most effective modes of operation, identify potential risks, integrate new technologies into existing production lines, and reduce the time and cost of project implementation. In addition, the digital twin helps define the steps to be taken to ensure safety.
Modern technologies make it possible to build digital twins of absolutely any production assets, be it an oil refinery or a logistics company. In the future, these technologies will allow remote control of the entire production process in real time. On the basis of the digital twin, it is possible to combine all systems and models used for planning and managing production activities, which will increase the transparency of processes, the accuracy and speed of decision-making.
The digital twin can also be considered as an electronic passport of a product, which records all data on raw materials, materials, operations performed, tests and laboratory research. This means that all information, from drawings and production technology to rules for maintenance and disposal, will be digitized and available for reading by devices and people. This principle allows you to track and guarantee the quality of products, to provide effective service.
Neural networks, digital twins, artificial intelligence. Industry 4.0 technologies will change the oil industry beyond recognition
Architects of the digital age
Spheres are usually considered the most technologically advanced. information technologies and biomedicine. Companies in traditional industries, such as metal rolling or oil production and refining, are treated differently. At first glance, they seem conservative, but many experts call them the main architects of the new digital age.
Industrial giants began to automate production processes back in the mid-30s of the last century. Over the decades, hardware and software complexes have been continuously improved and complicated. Automation of production processes - for example, in oil refining - has advanced far ahead. The operation of a modern oil refinery is monitored by hundreds of thousands of sensors and instruments, and fuel supplies are monitored in real time by satellite navigation systems. Every day the average Russian refinery produces over 50,000 terabytes of information. For comparison, the 3 million books that are stored in the digital storage of the Russian State Library occupy hundreds of times less - "only" 162 terabytes.
This is the very "big data", or Big Data, - a stream comparable to the information loading of the largest sites and social networks... The accumulated data array is a unique resource that can be used in business management. But traditional methods of information analysis are no longer suitable for this. Truly efficient work with such a volume of data is possible only with the help of Industry 4.0 technologies. In the context of a changing economic paradigm, rich production "historical experience" is a significant advantage. Big data is at the heart of artificial intelligence. His ability to learn, understand reality and predict processes directly depends on the amount of loaded knowledge. At the same time, industrial companies have a powerful engineering school, are actively involved in the implementation and improvement of new technologies. This is another circumstance that makes them key players in the "new economy".
Best of the week
Finally, domestic industrialists know the price of business efficiency. Russia is a country of great distances. Often, production assets are located at a great distance from consumers. In these conditions, it is very difficult to quickly respond to market fluctuations. Traditional technologies can save no more than a tenth of a percent. Meanwhile, digital solutions today allow you to reduce costs up to 10-15% per month. The fact is obvious: in the era of the fourth industrial revolution, the one who learns the most effective use of new technologies in terms of accumulated experience will be competitive.
Petr Kaznacheev, Director of the Center for Raw Materials Economy, RANEPA: “Smart management and corporate planning could be considered as a first step towards an“ integrated ”artificial intelligence system in oil and gas. In this case, we could talk about creating an algorithm for digitizing all key information about the company's activities - from a field to a gas station. This information could be fed to a single automated center. Based on this information, using artificial intelligence methods, forecasts and recommendations for optimizing the company's work could be made. "
Leader of digital transformation
Recognizing this trend, industrial leaders in Russia and the world are rebuilding business processes that have been developing for decades, introducing Industry 4.0 technologies into production based on the industrial Internet of things, artificial intelligence and Big Data. The most intensive transformation is taking place in the oil and gas industry: the industry is dynamically “digitalizing”, investing in projects that seemed fantastic just yesterday. Plants controlled by artificial intelligence and capable of predicting situations, installations that prompt the operator to the optimal mode of operation - all this is already becoming a reality today.
At the same time, the maximum task is to create a production, logistics, production and sales management system that would unite smart wells, factories and gas stations into a single ecosystem. In an ideal digital model, the moment the consumer presses the lever of the fuel nozzle, the company's analysts in the operations center instantly receive information about what brand of gasoline is being filled into the tank, how much oil needs to be produced, delivered to the refinery and processed to meet the demand in specific region. So far, none of the Russian and foreign companies have managed to build such a model. However, Gazprom Neft has advanced the farthest in solving this problem. Its specialists are currently implementing a number of projects, which ultimately should become the basis for creating a unified platform for processing, logistics and sales management. A platform that no one else in the world has yet.
Digital twins
Today Gazprom Neft's refineries are among the most modern in the industry. However, the fourth industrial revolution opens up qualitatively new opportunities, while at the same time presenting new requirements for automation. More precisely, it is not so much about automation as about the almost complete digitalization of production.
The basis of the new stage will be the so-called "digital twins" - virtual copies of refinery installations. All processes and relationships that take place in real prototypes are accurately described in 3D models. They are based on the work of artificial intelligence based on neural networks. The "digital twin" can suggest optimal operating modes for equipment, predict its failures, and recommend repair times. Among its other advantages is the ability to constantly learn. The neural network itself finds errors, corrects and remembers them, thereby improving its work and forecast accuracy.
An array of historical information serves as the basis for training the "digital twin". Modern oil refining plants are as complex as the human body. Hundreds of thousands of parts, tens of thousands of sensors. The technical documentation for each installation occupies a room the size of an assembly hall. To create a "digital twin", all this information must first be loaded into a neural network. Then the most difficult stage begins - the stage of teaching artificial intelligence to understand the installation. It includes readings from sensors and instrumentation collected over the past few years of the installation. The operator simulates various situations, makes the neural network answer the question "what will happen if one of the work parameters is changed?" - for example, replacing one of the raw material components or increasing the power supply to the plant. The neural network analyzes the experience of past years and excludes non-optimal modes from the algorithm using the calculation method, and learns to predict the future operation of the installation.
Best of the week
Gazprom Neft has already fully digitized two industrial complexes involved in the production of automotive fuel - a catalytic cracking gasoline hydrotreater at the Moscow Oil Refinery and a plant operating at the company's oil refinery in Omsk. Tests have shown that artificial intelligence is able to simultaneously take into account a huge number of parameters of their "digital counterparts", make decisions and notify about possible deviations in work even before the moment when the trouble threatens to develop into a serious problem.
At the same time, Gazprom Neft is testing complex solutions that will minimize the impact of the human factor on the scale of the entire production. Similar projects are currently being implemented at the company's bitumen plants in Ryazan and Kazakhstan. Successful empirically found solutions can subsequently be scaled up to the level of large refineries, which ultimately will create an effective digital production management platform.
Nikolay Legkodimov, Head of Advanced Technologies Consulting Group, KPMG in Russia and the CIS:“Solutions that simulate various units, assemblies and systems have been known and used for a long time, including in the oil and gas industry. One can speak of a qualitative leap only when a sufficient breadth of coverage of these models has been achieved. If we manage to combine these models with each other, combine them into a whole complex chain, then this will really allow solving problems at a completely new level - in particular, simulating the behavior of the system in critical, unprofitable and simply dangerous working conditions. For those areas where retooling and upgrading equipment is very expensive, this will allow preliminary testing of new components. "
Performance management
In the future, the entire value chain in the logistics, refining and sales block of Gazprom Neft will be united by a single technological platform based on artificial intelligence. The “brain” of this organism will be the Performance Management Center, created a year ago in St. Petersburg. It is here that information from the "digital twins" will flow, here it will be analyzed and here, on the basis of the data obtained, management decisions will be made.
Already today, in real time, more than 250 thousand sensors and dozens of systems transmit information to the Center from all the company's assets included in the perimeter of the Gazprom Neft logistics, refining and sales unit. Every second, 180 thousand signals are received here. It would take a person about a week just to view this information. The digital brain of the Center does it instantly: in real time it monitors the quality of products and the quantity of petroleum products along the entire chain - from the exit from the refinery to the end consumer.
The strategic goal of the Center is to radically increase the efficiency of the downstream segment using the technologies and capabilities of Industry 4.0. That is, it is not just to manage the processes - this can be done within the framework of traditional systems, but to make these processes the most effective: through predictive analytics and artificial intelligence at every stage of the business, reduce losses, optimize processes and prevent losses.
In the near future, the Center should learn how to solve several key tasks that affect the efficiency of business management. Including forecasting the future 60 days ahead: how the market will behave in two months, how much oil will need to be refined to meet the demand for gasoline at the current time, what state the equipment will be in, whether the installations will be able to cope with the upcoming load and whether it is needed repair them. At the same time, in the next two years, the Center should reach 50% capacity and begin to monitor, analyze and predict the amount of reserves of petroleum products at all oil depots and refueling complexes of the company; automatically monitor more than 90% of production parameters; analyze the reliability of more than 40% of technological equipment and develop measures to prevent the loss of oil products and a decrease in their quality.
By 2020, Gazprom Neft sets a goal to reach 100% of the capabilities of the Performance Management Center. Among the declared indicators - analysis of the reliability of all equipment, prevention of losses in quality and quantity of products, predictive management of technological deviations.
Daria Kozlova, senior consultant at VYGON Consulting:“In general, integrated solutions bring significant economic benefits for the industry. For example, according to Accenture estimates, the economic effect of digitalization could be more than $ 1 trillion. Therefore, when it comes to large vertically integrated companies, the implementation of integrated solutions is highly justified. But it is also justified for small companies, since improving efficiency can free them up additional funds by reducing costs, increasing the efficiency of working capital management, etc. "
Discuss 0
IBM will introduce the latest cloud technologies and the Internet of Things in the Port of Rotterdam.
In the near future, the port of Rotterdam is expecting a new record: it will become not only the largest European port in terms of cargo turnover, but also the smartest port in the world. And IBM will help him in this.
Joint efforts will be focused primarily on the implementation of the system "Connected shipping"(connected shipping), similar to connected cars in the automotive industry. Vessels with access to the system are autonomously operated and communicate for safe navigation. According to the administration of the Port of Rotterdam, they plan to receive the first autonomous vessels in 2025.
The digitalization program is designed for several years. As a result, the 42-kilometer territory of the port will be organized into a single digital space using cloud technologies IBM Cloud and the Internet of Things IBM IoT, and the port of Rotterdam will be rightfully called the smartest port in the world.
To build such a system, a port digital twin- an accurate digital model of all operations, which will accurately reflect resources and port capacities, ship movements, infrastructure, weather, geographic and hydrological conditions with 100% accuracy.
More than 140 thousand ships pass through the port annually; many stakeholders are involved in the cargo handling process. The digital model will allow you to see the big picture, test port scenarios, and use a centralized control panel to better coordinate the actions of all participants. This will increase the speed of port operations and the volume of cargo handled, as well as ensure compliance with the most stringent security standards. In the end the time spent by the vessel in the port will be reduced by an average of 1 hour... For port operators, this translates into order savings. USD 80,000, and for the port - in increasing the number of ships received.
The port will use IoT and Augmented Intelligence technologies, as well as intelligent meteorological and hydrological data, with which carriers can determine the most favorable time to enter the Port of Rotterdam. Favorable navigation conditions allow to save fuel, optimize approach and mooring speeds and ensure better cargo safety.
For this purpose, berths and buoys will be equipped with Digital dolphins- intelligent sensors that provide support for cargo transshipment, record vacancy or occupancy of mooring terminals, generate data on the status of port operations at a particular point in time, and also monitor environmental conditions that directly or indirectly affect navigation. Digital dolphins will be self-learning, and their real-time readings are claimed to be 100% accurate. The port plans to transmit this information to users through a specially developed application for planning and controlling operations.
Another initiative of the Port of Rotterdam is the creation of a Production Support Laboratory (RAMLAB). Its goal is to supply shipyards with quality industrial parts on demand. This is the first 3D printing laboratory focused on ports and sea carriers, able to reduce the waiting time for the desired part from 1.5-2 months to several days.
Speed and efficiency are the top two strengths of any port - Paul Smits
“Speed and efficiency are the two main strengths of any port,” says Paul Smits, Chief Financial Officer of the Port of Rotterdam Authority. “They are the ones that attract business and allow us to increase cargo turnover.” It is obvious that the innovations of the Port of Rotterdam directly serve to achieve these two goals.
We are grateful to the editorial staff of the corporate magazine Sibirskaya Neft PJSC Gazprom Neft for providing this material.
What is a Digital Twin?
The digital twin is a new word in modeling and production planning - a single model that reliably describes all processes and relationships both at an individual facility and within a whole production asset in the form of virtual installations and simulation models. Thus, a virtual copy of the physical world is created.
The use of a digital twin, which is an exact copy of a real asset, helps to quickly simulate the development of events depending on certain conditions and factors, find the most effective modes of operation, identify potential risks, integrate new technologies into existing production lines, and reduce the time and cost of project implementation. In addition, the digital twin helps define the steps to be taken to ensure safety.
Modern technologies make it possible to build digital twins of absolutely any production assets, be it an oil refinery or a logistics company. In the future, these technologies will allow remote control of the entire production process in real time. On the basis of the digital twin, it is possible to combine all systems and models used for planning and managing production activities, which will increase the transparency of processes, the accuracy and speed of decision-making.
The digital twin can also be considered as an electronic passport of a product, which records all data on raw materials, materials, operations performed, tests and laboratory research. This means that all information, from drawings and production technology to rules for maintenance and disposal, will be digitized and available for reading by devices and people. This principle allows you to track and guarantee the quality of products, to provide effective service.
From drawings to 3D models
A bit of history. Drawings and diagrams have always been necessary for people, from the moment of the first inventions of the wheel and the lever, in order to transmit information to each other about the structure of these devices and the rules for their use. At first, these were primitive drawings containing only the simplest information. However, the designs became more complex and the images and instructions more detailed. Since then, technologies for visualizing, documenting and storing knowledge about structures and mechanisms have come a long way. Nevertheless, for a long time, paper remained the main medium for fixing engineering ideas, and the working space was a plane.
In the second half of the twentieth century, it became clear that the usual army of draftsmen, armed with drawing boards, was no longer able to keep up with the rapid growth of industrial production and the complexity of engineering developments. Acceleration of the processing of voluminous and complex information (for example, a technological unit for atmospheric distillation of oil contains more than 30 thousand pieces of equipment) required changes in the work technology of designers, designers, builders, technologists, operation and maintenance specialists. The evolution of technical design tools made another round, and in the early 90s of the last century, computer-aided design systems (CAD) came to the oil industry. First they used 2D drawings, and then, towards the end of the 2000s, they came to 3D.
Modern design systems allow engineers to carry out the layout and design of industrial facilities in volumetric form, taking into account all the restrictions and requirements of the production process, as well as industrial safety requirements
Modern design systems allow engineers to carry out the layout and design of industrial facilities in volumetric form, taking into account all the restrictions and requirements of the production process, as well as industrial safety requirements. With their help, you can create a design model of a particular installation and correctly place technological and technical components on it without contradictions and collisions. Experience shows that through the use of such systems, it is possible to reduce the number of errors and inconsistencies in the design and operation of various installations by 2-3 times. The figure is impressive when you consider that for large-scale industrial equipment, the number of errors that have to be corrected during the design review process is estimated at thousands.
From the point of view of designers and builders, the use of 3D models makes it possible to dramatically improve the quality of design documentation and reduce design time. The constructed information model of the object is also useful at the stage of operation. This is a new level of ownership of an industrial facility, where personnel can obtain any information required to make a decision or complete a task in the shortest possible time, based on the existing model. Moreover, when, after some time, the modernization of equipment is required, future designers will have access to all relevant information, with a history of repairs and maintenance.
Omsk pilot
Sergey Ovchinnikov, Head of the Management Systems Department, Gazprom Neft:
The development and implementation of an engineering data management system is undoubtedly an important part of the innovative development of the logistics, processing and sales unit. The functionality inherent in "SUPrID", the potential of the system will allow the block in particular and the company as a whole to become leaders in the digital management of engineering data in oil refining. Moreover, this software product is an important component of the entire line of related IT systems, which are the foundation of the BLPS Performance Management Center, which is currently being created.
In 2014, Gazprom Neft launched a project to create a system for managing engineering data for oil refining facilities - SUPrID. The project is based on the use of 3D modeling technologies for the design, construction and maintenance of industrial facilities. Thanks to their use, the terms of creation and reconstruction of oil refineries are reduced, the efficiency and safety of their operation are increased, and the downtime of the plant's technological equipment is reduced. The implementation of a modern engineering data management system on the newest Smart Plant for Owners / Operators (SPO) platform is carried out by specialists from the Department of Control Systems of the Logistics, Processing and Sales Unit, as well as from the subsidiary company ITSK and Avtomatika Servis.
At the end of last year, a pilot project was successfully completed to deploy the platform's functionality and set up business processes for the newly reconstructed primary oil refining unit of the Omsk Refinery - AT-9. The system implements the functionality for storing, managing and updating information about the installation throughout its entire life cycle: from construction to operation. Along with the system, regulatory and methodological documentation, requirements for the designer and standards for engineering data management were developed. "SUPrID" is a good assistant in the work, - said the head of the AT-9 unit at the Omsk Refinery Sergey Shmidt. - The system allows you to quickly access engineering information about any equipment, view its drawing, clarify technical parameters, localize the location and take measurements on a three-dimensional model that exactly reproduces the real installation. The use of "SUPRID" helps, among other things, to train new specialists and trainees. "
How it works?
The task of the "SUPrID" system is to cover all stages of the life cycle of a technological object. Start by collecting engineering information at the design phase and then updating the information at subsequent stages - construction, operation, reconstruction, displaying the current state of the facility.
It all starts with information from the designer, which is sequentially transmitted and loaded into the system. The initial data are: design documentation, information on the functional, technological and construction and installation structure of the facility, intelligent technological schemes. It is this information that becomes the basis of the information model, allowing you to instantly receive address information about construction objects and the technological scheme of the installation, making it possible in a few seconds to find the desired position of technological equipment, instrumentation equipment on the technological scheme, to determine its participation in the technological process.
In turn, using the project 3D-model of the object loaded into the system, you can visualize it, see the configuration of blocks, the spatial arrangement of equipment, the environment with neighboring equipment, and measure the distances between various elements of the installation. The formation of the operational information model is being completed by linking as-built documentation and 2D, 3D models "as built", which provide an opportunity to obtain detailed information on the properties and technical characteristics of any equipment or its elements at the stage of operation. Thus, the system is a structured and interconnected set of all engineering data of an object and its equipment.
Roman Komarov, Deputy Head of the Department of Engineering Systems "ITSK", Head of Development "SUPrID":
After many years of assessing the benefits of the project and preliminary study, the pilot of the system was implemented in a short time. Implementation of "SUPrID" allowed the company to obtain a tool for managing engineering data of oil refining facilities. The next global step, which we will gradually approach, is the formation of a digital information model of an oil refinery.
To date, more than 80,000 documents have been uploaded to the SUPrID electronic archive. The system allows you to search by positional information about any type of equipment, provide the user with comprehensive information on each position, including technical characteristics, dimensions, material design, design and operating parameters, etc. "SUPRID" makes it possible to view any part of the installation in a three-dimensional model or on a technological scheme, open scanned copies of documents related to this position: working, executive or operational documentation (passports, acts, drawings, etc.).
This variability significantly reduces the time spent on access to up-to-date information and its interpretation, avoids mistakes in the reconstruction and technical re-equipment of the facility, replacement of obsolete equipment. "SUPRID" helps to analyze the operation of the installation and its equipment in assessing the efficiency of operation, contributes to the preparation of changes in technological regulations, investigation of failures, malfunctions, accidents at the facility, education and training of maintenance personnel.
"SUPrID" is integrated with other BLPS information systems and forms a unified engineering data information environment, which, among other things, will become the basis for the innovative Block Efficiency Management Center. Interconnection with programs such as KSU NSI (corporate system for managing reference information), SAP TORO (maintenance and repair of equipment), SU PSD (design and estimate documentation management system) "TrackDoc", Meridium APM, forms a unique integrated automation system processes for managing the production assets of an oil refinery, allowing you to increase the economic effect of their joint use for the company.
Project efficiency
In a relatively short period of time, Gazprom Neft's IT specialists managed not only to master the intricacies of the SPO platform, on which the engineering data management system is built, but also to create a completely new infrastructure for the company, develop a set of regulatory documents, and ultimately develop a qualitatively new approach to construction of oil refining facilities.
At an early stage of the project, it became obvious that the system would be in demand by the plant's operating services and capital construction services. Suffice it to say that its use saves up to 30% of working time for searching and processing technical information on any object. When "SUPrID" is integrated with systems of reference information, maintenance and repair of equipment, design estimates and other relevant engineering data, it becomes available for prompt and high-quality service of technological equipment. The capabilities of the system also make it possible to create a simulator for maintenance services, which will undoubtedly increase the level of training of their specialists. For the capital construction departments of the refinery, the system will become a design tool at the stage of minor and medium repairs. This approach greatly simplifies control over the course of reconstruction of industrial facilities and improves the quality of repairs.
It is assumed that the investments made in the implementation of "SUPrID" will pay off in about 3-4 years. This will become possible due to a reduction in design time, an earlier transfer of installations from the stage of commissioning to commercial operation and, as a consequence, an increase in the volume of finished products. Another significant plus is the acceleration of the preparation and implementation of maintenance work and the implementation of reconstructions and upgrades of installations by reducing the time required for checking new design documentation by the refinery's operational services and timely detecting shortcomings and errors in the work of design and construction contractors.
The "SUPrID" implementation program is designed for the period up to 2020. It will be used to digitize both existing installations and the construction of new facilities. At present, specialists are preparing to replicate the system at the Moscow Refinery.
Text: Alexander Nikonorov, Alexey Shishmarev,Photo: Yuri Molodkovets, Nikolay Krivich
From the editorial site: At the end of May, the Siemens PLM Connection forum was held in Moscow, the main topics of which were the creation of a digital twin, 3D printing, the Internet of Things and increasing the competitiveness of Russian products.
Note that the term digital twin in Russian-language publications is translated as both “digital twin” and “digital twin”.
The hall could hardly accommodate everyone
Five steps to building a digital enterprise
Modern technologies are revolutionizing the way we manufacture products. Companies are shortening their processes, increasing flexibility and efficiency, and improving quality. Siemens believes that focusing only on one stage of production is not enough for this. The entire chain must be taken into account, from product development to use.“Once you create and optimize these processes, you can integrate them, connect your suppliers and get a single holistic approach to building your business. Moreover, it will provide the opportunity to create a digital twin of your enterprise, which allows you to simulate its operation in order to identify bottlenecks in advance, for example, where surpluses are generated or where delays are anticipated, ”said Jean Luca Sacco, Siemens PLM Software Marketing Director EMEA - It sounds like fantasy, but it is already quite feasible. All you need to do is take five steps, and the digital twin can help your company. "
The first step - product development, Jean Luca Sacco illustrated with a real example of one of the products created by Siemens itself with maximum reuse of its previous generations and taking into account subsequent verification without creating a physical prototype of all its properties, including heating, cooling and protection against electromagnetic influences ... “Our focus is systems-based product development, based on an information-rich digital twin of the product that is stored in the Teamcenter collaboration environment so that everyone involved in the development has access to it,” he said.
The second step is the development of production technology, which implies modeling not the product itself, but manufacturing operations. “With Plant Simulation, we simulate all production operations even before the workplace is created to anticipate any difficulties ahead of time. And this applies not only to one workplace, but to the entire plant as a whole. This will optimize material flows, energy consumption and simulate production processes long before the shop floor investment begins, ”said Jean Luca Sacco and presented an example showing how the model can avoid dangerous spinal curvature of a worker during assembly.
The third step - preparation and launch of production, is associated with the use of another digital twin, this time for technological processes and equipment. According to Jean Luca Sacco, Siemens is the only company in the world that can offer an integrated computer-engineering complex that allows a complete digital twin, including all disciplines such as mechanics, electrical and software, to be tested before production begins. He stressed the importance of integrating all the components of such a twin: “After all, everything in life is interconnected. We design a product, on this basis we develop a process, and the peculiarities of the technical process impose requirements for product development. "
The fourth step is the production of the product, which is also realized with the help of a digital twin. Indeed, without it, it is impossible to draw up a real work schedule in order, for example, to determine the loss of time and optimize production processes. Traditionally, this required a lot of paper instructions, which was inefficient and error-prone, and digital modeling provides the ideal set of instructions for manufacturing and assembling a product. Jean Luca Sacco explained that such a solution is complex, it covers all the resources of the enterprise, such as people, materials, tooling, machine tools, and with the help of a digital twin it allows you to manage production. Electronic information transmitted to the operator at that moment. when he needs her. In the workplace, he can use augmented reality technology and better understand what he needs to do with the incoming workpiece and thereby minimize assembly errors. But even if errors do occur, comparing the real product with its digital counterpart will eliminate them. “This approach removes the walls that have always existed between designers and workers, and thus makes it possible to significantly improve the quality of products,” said Jean Luca Sacco.
The fifth stage - maintenance, will become more effective if you use a solution that allows you to collect and analyze the information that the product generates during its operation.
To take these five steps, Siemens offers the Digital Enterprise Software Suite, which includes Teamcenter, NX, Tecnomatix and others, which takes into account the value chain processes for different industries. According to Jean Luca Sacco, this solution shows the state of the product at all stages - from the initial idea to consumer use, and all this in a single environment. At the same time, at each stage, people use the developments of their colleagues, gaining benefit from the fact that they have data not only about the current stage, but also about all previous and subsequent ones.
Russian realities
This innovative approach will come in handy and Russian companies, since they are in the same development trend as the entire world industry. “We have the same problems as everywhere else - the increasing complexity of products. This is typical not only for aviation and the automotive industry, but for the entire machine-building industry, ”said Viktor Bespalov, vice president, general manager of Siemens PLM Software in Russia and the CIS. "In addition, new business models are emerging associated with the diffusion of advanced technologies such as the Internet of Things, additive manufacturing, human-machine interfaces, and big data."Despite all the difficulties, our companies create complex innovative products, solving problems that have not been solved before. As an example, Viktor Bespalov cited several developments. So, when creating a new Il-76 transport aircraft, a digital mock-up was built and a single information space was implemented, covering the head organization - Design Bureau im. Ilyushin, and suppliers.
During the development of the new KamAZ-5490 tractor, almost all assembly processes were simulated prior to the start of production, which corresponds to the Siemens concept, and when creating a new PD-14 engine, which is now being tested, its complete digital model was developed, which is used not only in production. but in technology services.
At the same time, Viktor Bespalov stressed, Russian enterprises have to solve many problems. Thus, due to the increasing complexity of products, traditional methods of product decomposition cease to work. Therefore, it is necessary to deal with requirements management and compliance with certification standards at the earliest stages.
Making changes during the development phase and in the following phases remains a daunting task. The use of digital modeling and various calculation methods helps here, however, the complexity of this task suggests that there is still work to be done. There are resource management issues associated with the interaction between PLM and ERP.
Victor Bespalov: “Despite all the difficulties, the majority of our Russian customers
plans to expand the use of Siemens PLM Software products. "
There are also national problems. Our companies work not only locally, they enter global markets, because otherwise it is impossible. Viktor Bespalov cited data obtained from a Russian aviation holding company and its foreign competitors, which show that our company spends almost twice as much time on fine-tuning production as they do. In his opinion, this is an alarming signal that Western companies bring their products to the market much faster, and Russian producers should try to reduce these losses.
To do this, our companies must use technologies that make them competitive. In this regard, Viktor Bespalov believes that it is necessary to be careful about the choice of technologies: “I strongly disagree with the statements of some Russian developers that have appeared recently in connection with the import substitution policy, in which he emphasizes that Russian PLM systems are 80% satisfy the requirements of our enterprises. And what about the remaining 20%? How can our domestic companies compete in such a situation? How to deal with global players who are already equipped with modern technologies? "
As an answer to these rhetorical questions, Viktor Bespalov cited the results of a survey of Russian customers, which show. that despite all the difficulties, most of them plan to expand their use of Siemens PLM Software products.
Apparently, the attention that the Russian office shows to the requirements of customers plays an important role in this. Moreover, today we are no longer talking about the design of drawings, but about the functional requirements. At the last conference, the consideration of the requirements of the OKB im. Sukhoi and ANTK them. Antonov in the NX CAD system.
This work continues for other products, in particular, the integration of the Sinumetrik CNC system and NX CAM has been strengthened to combine the real and virtual worlds, the integration of NX and Fibersim for aviation programs has been improved, the Product Cost Management system has been adapted to Russian cost calculation methodologies, and Teamcenter and Test systems have been integrated. Lab for an end-to-end requirements verification process.
This topic worries Russian users. So Michael Rebruch, director of development for NX, was asked from the audience a question about how you can convey your problems to the NX developers and influence development. To which he replied that the company continues to cooperate with customers in Russia, listening to the wishes and taking them into account: "It is important for us to understand how they work, where they are experiencing difficulties, and then we will try to help." For his part, Viktor Bespalov promised that immediately after the forum he would continue to work with customers to define requirements and create a plan for their satisfaction in the next versions of the products.
Attention is also paid to the topic of creating a prototype of a standard solution. “PLM is not a cheap technology, so customers are interested in getting a quick return on investment. In this regard, over the past four years, our efforts have been focused on reducing the implementation time, ”said Viktor Bespalov.
Already created special pre-configured data models, NX templates to support ESHD, templates for change management processes, libraries for standard parts, materials, technological resources, etc., a methodology has been developed quick launch into operation. According to Siemens estimates and data from pilot projects, the implementation time can be halved due to the fact that almost 80% of the work is covered by the standard solution, and only 20-30% falls on the customer's specifics.
In addition, in the implementation of the industrial approach announced several years ago, Siemens is promoting in Russia a set of industry-specific Catalyst pre-configured solutions, which includes best practices and basic processes for various industries such as shipbuilding, automotive, mechanical engineering, electronics, energy, etc. ... According to Viktor Bespalov, these solutions allow introducing new solutions into existing processes in such a way as to reduce the gap between advanced technologies and what the company actually uses.
The speeches of Russian customers showed how we implement the listed Siemens technologies. Thus, Vasily Skvorchuk, Head of the IT Department of Ural Locomotives LLC, said that when the new production of Lastochka electric trains was launched, it was decided to create an integrated automation system at the enterprise, including Teamcenter, NX CAD / CAM / CAE from Siemens, Russian Belarusian ERP-system Omega (Russian-Belarusian) and "1C: Manufacturing Enterprise Management".
Vasily Skvorchuk: "Now about 1100 people work in the integrated corporate system"
LLC Uralskiye Lokomotivy, a joint venture with Siemens, was established in 2010. "From that moment on, our plant began a rapid development of information technology," said Vasily Skvorchuk and added that now about 1,100 people work in the integrated corporate system, and management can observe the progress of work on the manager's panel, which receives all the basic information. Thanks to these systems, all divisions have access to a single source of up-to-date information necessary for the production of high-quality equipment for Lastochka.
The company's plans include the use of a three-dimensional electronic model of the product for parts processed on a CNC machine. A pilot project has already been carried out.
The transition to an electronic model of the product is also underway at the Ulan-Ude Aviation Plant, which develops and manufactures Mi-8 helicopters. The plant's IT director Maxim Lobanov spoke about two projects to organize a digital process of technological preparation of production according to the original design documentation in the form of an electronic layout.
First, for the new model of the helicopter, the project "End beam" was implemented, during which the equipment and the beam itself were created, and then the project "Cargo floor", made entirely using paperless technology. As part of this project, the process of assembling the tooling was worked out, which made it possible to increase the accuracy of the assembly and reduce the time.
According to Maxim Lobanov, in connection with the transition to paperless technologies, it became necessary to integrate the Teamcenter PLM system with the planning system used at the plant, as well as to create a modern information system for bringing a digital layout to each workplace.
Foreign examples
From the point of view of global competition, it is interesting to see how the digital transition is evolving in foreign enterprises. For example, Konecranes, a manufacturer and service company for cranes and other lifting equipment, embarked on a journey to harmonize its approach to digitalization in 2008.“Manufacturing and service is an interesting combination, to get the most out of it, these elements need to be brought together. We have about half a million pieces of equipment in service and digitalisation is very important here, ”explained Matti Leto, Director of Product & Engineering Process at Konecranes.
According to him, first, the definition of the processes was carried out, and then the search for a solution began to ensure these processes in such a way that the systems would continue to work in the future for many years. A list of platforms was compiled, including ERP, CRM, etc., but the company considers the PLM system the most important from the point of view of long-term sustainability, as it contains information about the products. The choice fell on Teamcenter.
On the this moment some of the systems have been implemented, the rest are being implemented. Meanwhile, Konecranes is moving to the next level of digitalization by leveraging IoT technology to automate equipment maintenance and streamline other processes. For this, a portal has been created for the exchange of information between the company, partners and customers.
The IoT project at Konecranes has successfully kicked off. More than 10 thousand pieces of equipment are connected to the network. “The PLM system significantly increases the value of the Internet of Things because product data, together with equipment monitoring data, enable fast, informed decisions, ”said Matti Leto. "We believe that the Internet of Things is a new business model with the future."
The digital twin as the basis for future production
The industrial revolution that is taking place now is transforming business, posing difficult tasks for enterprises. Development processes are changing, for example, through the use of crowdsourcing and a systems-oriented approach to design, and in the field of manufacturing, change occurs through the use of additive manufacturing, modern robotic systems and intelligent automation.“Creating a digital twin to manage the lifecycle of the entire manufacturing system allows enterprises to reach a new level of innovation,” said Robert Meschel, Siemens PLM Software Senior Director of Manufacturing Engineering Software, and said that by acting in this direction, the company is developing the direction of manufacturing engineering. and digital production. “Several new products that we are currently working on are helping to bridge the gap between design and production,” said Robert Meschel.
In addition, robots are increasingly being used, which are now much more flexible than before. 3D printing, which until recently was considered suitable only for prototyping, is starting to be applied in real production. As proof, Robert Meschel cited case studies from the aerospace, shipbuilding, mechanical engineering and automotive industries that show that this is a radical acceleration: "We are updating our products to provide customers with the opportunity to use this technology."
Virtual commissioning using an integrated hardware and software suite is another promising innovative approach. According to Robert Meschel, all this indicates that reality modeling will form the basis of future production, and an important prerequisite for this is a digital twin - a model with a high degree of detail.
It is also important that the use of a digital twin allows the integration of calculations and field tests, as well as models and data. According to Wooter Dehandshutter, CTO, Siemens PLM Software, the challenge here is to make the most of the information generated at different stages and link it together, but now there are a number of stages in which engineering information is produced in isolation.
Wooter Dehandshutter: "Using a digital twin allows the integration of calculations and field tests"
He showed that this problem can be solved with the help of a digital twin, analyzing the product at the earliest stages through virtual testing, managing this twin and increasing its level of detail and accuracy, so that in field testing, you can focus precisely on meeting requirements, and not on finding solutions.
As an example, Wooter Dehandshutter cited the Irkut corporation, which applied this approach in the design of the MC-21 aircraft, using the LMS Imagin.Lab and LMS Amesim products to calculate the system's behavior. At the same time, not only individual parts were modeled, but the overall interaction of systems, which made it possible to check even at the design stage how an entire aircraft would behave and, according to Irkut, reduce the creation of the most complex models by five times compared to the previously used solution.
What's new in NX 11
While promoting the concept of the digital twin, Siemens has not forgotten its core products. Michael Rebruch, Director of Engineering for NX, Siemens PLM Software, has revealed some of the new features coming in NX 11 in August and NX 11.01 in November.However, one new product is already available. This is a free Catchbook mobile app designed for development. “By freehand sketching on a tablet, the result of which is converted to geometry, we can add dimensions and control the positioning of sketches. You can also take a photo with your mobile phone and use this system to explore the possibilities of this project, ”explained Michael Rebrukh.
Michael Rebrukh talks about new products in NX 11
Along with NX 11, a new product, Converging Model, will be released, which allows you to combine precise geometry and cell-based face-based representation in a single model. According to Michael Rebrukh, clients who have already met him say he has changed the way he works, so the model can be used in design, testing and new methods such as 3D printing and hybrid manufacturing.
NX 11 will also include Lightworks' Iray +, powered by Nvidia's Iray technology, for photorealistic rendering and includes a library of materials and scenes.
In addition, in NX 11, it will be possible to scan and download huge point clouds and interact with them in the same way as in the real world to design in the context of the physical environment.
NX 11.01 will introduce a new topology optimization technology designed to create complex surfaces, optimize shape, weight, materials used, dimensions and topology of structures while maintaining part function. This is expected to improve interactions with additive manufacturing. ->