CN112330267A - Chemical plant production operation management system - Google Patents
Chemical plant production operation management system Download PDFInfo
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- CN112330267A CN112330267A CN202011117794.1A CN202011117794A CN112330267A CN 112330267 A CN112330267 A CN 112330267A CN 202011117794 A CN202011117794 A CN 202011117794A CN 112330267 A CN112330267 A CN 112330267A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 50
- 239000000126 substance Substances 0.000 title claims abstract description 32
- 238000012423 maintenance Methods 0.000 claims abstract description 50
- 238000007689 inspection Methods 0.000 claims abstract description 45
- 238000005461 lubrication Methods 0.000 claims abstract description 31
- 238000000034 method Methods 0.000 claims abstract description 25
- 230000008569 process Effects 0.000 claims abstract description 21
- 238000007726 management method Methods 0.000 claims description 76
- 238000000354 decomposition reaction Methods 0.000 claims description 9
- 238000012545 processing Methods 0.000 claims description 9
- 238000010276 construction Methods 0.000 claims description 8
- 230000008439 repair process Effects 0.000 claims description 8
- 230000000977 initiatory effect Effects 0.000 claims description 7
- 238000011156 evaluation Methods 0.000 claims description 5
- 230000008859 change Effects 0.000 claims description 4
- 238000003745 diagnosis Methods 0.000 claims description 3
- 230000000694 effects Effects 0.000 claims description 3
- 238000012216 screening Methods 0.000 claims description 3
- 238000012384 transportation and delivery Methods 0.000 claims description 3
- 230000006872 improvement Effects 0.000 abstract description 4
- 239000000463 material Substances 0.000 description 8
- 238000004458 analytical method Methods 0.000 description 5
- 230000002159 abnormal effect Effects 0.000 description 4
- 238000013439 planning Methods 0.000 description 3
- 238000012552 review Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 230000010354 integration Effects 0.000 description 2
- 230000001050 lubricating effect Effects 0.000 description 2
- 230000002265 prevention Effects 0.000 description 2
- 238000011144 upstream manufacturing Methods 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- 238000012824 chemical production Methods 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000007405 data analysis Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000002360 explosive Substances 0.000 description 1
- 210000001503 joint Anatomy 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/10—Office automation; Time management
- G06Q10/103—Workflow collaboration or project management
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/20—Administration of product repair or maintenance
Abstract
The invention relates to a production operation management system of a chemical plant, which comprises: a basic device architecture module; a process inspection module; an autonomous security module; a lubrication management module; a professional spot inspection module; a maintenance management module: the system comprises an exception reporting module, an electronic approval module, a maintenance order sending module, a maintenance order receiving module and a maintenance acceptance module; an engineering management module; a special/metering equipment management module; TPM special module. The system can improve the timeliness of production operation and promote the safety of a chemical plant through the improvement on daily maintenance.
Description
Technical Field
The invention relates to a production operation management system for a chemical plant, and belongs to the technical field of plant operation management.
Background
Chemical industry is a basic industry of various types, and in order to meet various requirements of chemical production, chemical equipment is various in types and complex in operation conditions. According to the operation pressure, the vacuum, normal pressure, low pressure, medium pressure, high pressure and ultrahigh pressure are adopted, and according to the operation temperature, the low temperature, normal temperature, medium temperature and high temperature are adopted; most of the treated media are corrosive or inflammable, explosive, toxic and virulent. Sometimes there are both temperature, pressure and corrosion resistance requirements for a particular piece of equipment, and these requirements are sometimes mutually restrictive and sometimes certain conditions change frequently.
With the aggravation of market competition, the social requirements on safety and environmental protection of chemical enterprises are higher and higher, and the improvement of the comprehensive quality of the enterprises and the improvement of the operation efficiency are matters which are unbearable. The chemical enterprises have the special characteristics that the safety production is the most important point in the operation process of the chemical plants, and the attention is needed in order to improve the safety of the chemical enterprises. The safety production of the chemical enterprises not only lies in emergency treatment of emergency situations, but also lies in daily maintenance. Therefore, the invention provides a production operation management system of a chemical plant.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention provides a production operation management system of a chemical plant, which can improve the timeliness of production operation and promote the safety of the chemical plant through the improvement on daily maintenance.
In order to achieve the above object, the present invention provides a system for managing production operations of a chemical plant, comprising:
infrastructure module of basic device: the system comprises a basic equipment ledger information recording module and a BOM decomposition information recording module;
the process inspection module comprises: the system comprises an inspection receipt module, an inspection execution module, an inspection recording module and an inspection billboard module;
an autonomous security module: the system comprises a work order execution module, a missed order list module and an execution recording module;
a lubrication management module: the lubrication menu management system comprises a lubrication menu dispatching module, a lubrication menu receiving module, a lubrication execution module, a temporary lubrication module, a lubrication recording module and a lubrication billboard module;
professional point inspection module: the system comprises a point inspection order sending module, a point inspection order receiving module, a point inspection execution module, a point inspection recording module and a point inspection billboard module;
a maintenance management module: the system comprises an exception reporting module, an electronic approval module, a maintenance order sending module, a maintenance order receiving module and a maintenance acceptance module;
the engineering management module: the system comprises an engineering change module, a major repair management module and a project management module;
special/metering equipment management module: the system comprises a special equipment standing book information recording module, a special equipment checking and early warning module, a metering equipment standing book information recording module and a metering equipment checking and early warning module;
TPM special module: the system comprises a group activity module, a maintenance diagnosis module, an security ring checking module and a rationalization suggestion module.
Furthermore, the standing book information recorded by the basic equipment standing book information recording module comprises production equipment, electric instrument equipment, a pipeline valve, infrastructure equipment and office equipment, and corresponding two-dimensional codes or radio frequency cards are established on the production equipment, the electric instrument equipment, the pipeline valve, the infrastructure equipment and the office equipment.
Further, the working steps of the process inspection module, the autonomous security module and the professional spot inspection module comprise: standard making, plan dispatching, terminal execution, abnormity finding, work order generation, responsibility department processing and reporting department acceptance.
Further, the operation of the lubrication management module comprises: standard making, plan dispatching, terminal execution and picture display.
Further, the working steps after the terminal executes the process further comprise report approval, the report approval is realized in a paperless mode, and abnormal display is carried out after the report approval.
Further, the working steps of the maintenance management module include: the method comprises the steps of field personnel reporting, production approval, responsibility department order receiving, work order issuing, maintenance worker order receiving processing and acceptance initiating, wherein the acceptance initiating comprises production principal acceptance and maintenance principal acceptance.
Further, the working steps of the overhaul management module comprise: and (4) summarizing department proposals and examination and approval items, forming a work order, and checking and accepting work construction and projects.
Further, the working steps of the rationalization proposal module comprise: rationalizing suggested deliveries, screening, rating for evaluation, grading treatment, objection treatment, and feasibility judgment.
Furthermore, the running hardware comprises a PC end, a PDA end and a mobile end, and the PC end is interconnected with the PDA end and the mobile end through the cloud server.
The production operation management system of the chemical plant has the following advantages:
1. the timeliness of production operation is improved, and data of production equipment is collected and fed back in time;
2. production operation efficiency is improved, data systems are managed in a standardized mode, and decision management efficiency is improved;
3. the management capability of the TPM is improved, and the idea that all personnel participate in production maintenance, the equipment is managed in the whole life cycle and prevention management is implemented is really achieved through system construction.
Drawings
The present invention will be further described and illustrated with reference to the following drawings.
FIG. 1 is a system block diagram of a chemical plant production operation management system in accordance with a preferred embodiment of the present invention;
FIG. 2 is a hardware block diagram of a chemical plant production operation management system according to a preferred embodiment of the present invention;
FIG. 3 is a flow chart of the working steps of the process inspection module, the autonomous security module and the professional spot inspection module;
FIG. 4 is a flowchart of the operational steps of the lubrication management module;
FIG. 5 is a flowchart of the operational steps of the service management module.
Detailed Description
The technical solution of the present invention will be more clearly and completely explained by the description of the preferred embodiments of the present invention with reference to the accompanying drawings.
As shown in fig. 1 and 2, in a chemical plant production operation management system according to a preferred embodiment of the present invention, a hardware facility includes a PC terminal, a PDA terminal, and a mobile terminal that are interconnected via a network, the PC terminal is interconnected with the PDA terminal and the mobile terminal via a cloud server, the PDA terminal is used as a carrier of a data mobile phone, cloud storage is used as a processing tool, and data analysis is implemented at the PC terminal.
A chemical plant production operation management system comprises:
infrastructure module of basic device: the BOM decomposition information recording module comprises a basic equipment ledger information recording module and a BOM decomposition information recording module. The machine account information recorded by the basic equipment machine account information recording module comprises production equipment, electrical instrument equipment, a pipeline valve, infrastructure equipment and office equipment, wherein corresponding two-dimensional codes or radio frequency cards are established on the production equipment, the electrical instrument equipment, the pipeline valve, the infrastructure equipment and the office equipment, one machine and one file are established, and full-period management is realized. And the ledger information in the basic ledger information recording module and the BOM decomposition information recording module can be revised, added and deleted. And the warehouse logistics system is in butt joint with the database of the production operation system. The spare parts can be directly used at the PDA end.
The process inspection module comprises: the system comprises an inspection receipt module, an inspection execution module, an inspection recording module and an inspection billboard module. As shown in fig. 3, the workflow includes: standard making, plan dispatching, terminal execution, abnormity finding, work order generation, responsibility department processing and reporting department acceptance. And the terminal executes the report examination and approval, the report examination and approval is realized in a paperless mode, and the report is subjected to exception display after the report examination and approval. The inspection personnel firstly confirm the order at the mobile terminal, scan the radio frequency card or the two-dimensional code through the PDA, confirm that the personnel arrive at the appointed route, fill in the work order content, and submit the work order after the completion of the filling.
An autonomous security module: the system comprises a work order execution module, a missed order list module and an execution recording module. As shown in fig. 3, the workflow includes: standard making, plan dispatching, terminal execution, abnormity finding, work order generation, responsibility department processing and reporting department acceptance. And the terminal executes the report examination and approval, the report examination and approval is realized in a paperless mode, and the report is subjected to exception display after the report examination and approval. The independent maintenance personnel firstly click the independent maintenance work order at the mobile terminal to execute, select the work order to be executed, scan the two-dimensional code or the radio frequency card receiving order by using the PDA, and submit the work order after filling.
A lubrication management module: the lubrication menu distributing module comprises a lubrication menu distributing module, a lubrication menu receiving module, a lubrication executing module, a temporary lubrication module, a lubrication recording module and a lubrication billboard module. As shown in fig. 4, the workflow includes: standard making, plan dispatching, terminal execution and picture display. And the terminal executes the report examination and approval, the report examination and approval is realized in a paperless mode, and the report is subjected to exception display after the report examination and approval. The lubrication personnel firstly lubricate the receiving order at the mobile end motor, scan the two-dimensional code or the radio frequency card to fill in the work order, and generate the execution record after filling in. In addition, through plan report, the lubricating plan is automatically generated, early warning can be carried out in advance, daily lubricating work is tracked in real time, oil consumption is counted, and department and machine statistics summary is realized.
Professional point inspection module: the system comprises a point inspection order sending module, a point inspection order receiving module, a point inspection execution module, a point inspection recording module and a point inspection billboard module. As shown in fig. 3, the workflow includes: standard making, plan dispatching, terminal execution, abnormity finding, work order generation, responsibility department processing and reporting department acceptance. And the terminal executes the report examination and approval, the report examination and approval is realized in a paperless mode, and the report is subjected to exception display after the report examination and approval. The professional point-checking personnel firstly confirm the order receiving at the mobile terminal, then scan the radio frequency card or the two-dimensional code through the PDA, confirm that the personnel arrive at the designated route, fill in the work order content, and confirm the submission after the completion of the filling.
A maintenance management module: the system comprises an exception reporting module, an electronic approval module, a maintenance order dispatching module, a maintenance order receiving module and a maintenance acceptance module. As shown in fig. 5, the working steps of the maintenance management module include: the method comprises the steps of field personnel reporting, production approval, responsibility department order receiving, work order issuing, maintenance worker order receiving processing and acceptance initiating, wherein the acceptance initiating comprises production principal acceptance and maintenance principal acceptance. The initiation of the maintenance work order can be realized at both the mobile terminal and the PC terminal, and if abnormity is found in the spot inspection and autonomous security work order execution processes, the abnormal reporting module can be directly jumped to. And the abnormal reporting module is attached with a picture for displaying, so that an approver can conveniently and directly check the fault point. The repaired pictures shot by the maintenance personnel can be checked in the maintenance acceptance module, and the images can be amplified and conveniently checked. The maintenance acceptance needs to pass through three-level acceptance and approval, and the reliability is increased for a maintainer, a production main task and a maintenance main task in sequence.
The engineering management module: the system comprises an engineering change module, a major repair management module and a project management module. Wherein the working steps of the overhaul management module comprise: and (4) summarizing department proposals and examination and approval items, forming a work order, and checking and accepting work construction and projects. Entering an approval process after the department proposes, entering item summary of the proposals passing through the approval process, entering a overhaul pool if the proposals fail to pass through the approval process, and implementing after budgeting and time are in place. The work order and the disassembly table are formed through approval proposal, the disassembly table is subjected to workload decomposition and technical decomposition, manual accounting is carried out after the workload decomposition, material accounting is formed after the technical decomposition, then the material is purchased and prepared, the material is checked with the work order after being manually put in place, operation construction is carried out, and after construction, project acceptance, completion and filing are carried out to form a major repair report.
Special/metering equipment management module: the special equipment checking and early warning system comprises a special equipment checking and early warning module, a metering equipment checking and early warning module and a metering equipment checking and early warning module.
TPM special module: the system comprises a group activity module, a maintenance diagnosis module, an security ring checking module and a rationalization suggestion module. The working steps of the rationalization proposal module comprise: rationalizing suggested deliveries, screening, rating for evaluation, grading treatment, objection treatment, and feasibility judgment. The rationalized advice is delivered to the enterprise and planning department in a plurality of ways, the enterprise and planning department collects, screens and submits to a committee for primary review, and the committee scores and gives corresponding reward grades in the primary review. And (4) filing the rationalized suggestions meeting the standard, classifying and submitting the rationalized suggestions to secondary evaluation, judging whether the feasibility exists after the secondary evaluation, submitting the feasibility to corresponding departments and feeding back, and feeding back the feasibility to the enterprise and planning department. The rationalized suggestions that did not reach standards in a review can be re-reviewed by a review program.
The system automatically collects the total work order number and the completion condition of the professional spot inspection module, the process inspection module, the self-service security module and the lubrication management module, and pushes examination and approval items and abnormal information.
The production operation management system of the chemical plant has the following functions:
1. and realizing basic ledger management:
1) realizing the real object ledger management of the equipment; realizing the real object ledger management of the stock materials;
2) clear correspondence between the corporate financial asset accounts and the physical equipment accounts is realized, and the actual condition of inventory materials is realized.
2. Equipment process management:
1) realizing asset whole life cycle process management and tracking the life transition history of the asset;
2) the device records (including data formed by various maintenance processes) are collected for management and the device state is grasped.
3. And (4) maintenance flow management:
1) maintenance standardized system construction (including various maintenance, fault systems of various equipment and the like);
2) various kinds of maintenance work process management (including: fault repair, routine maintenance, lubrication, scheduled preventative maintenance, emergency repair, project repair, etc.);
3) and maintenance resource management (including internal maintenance personnel and external maintenance personnel management) provides data basis for post performance.
4. Material flow management:
1) the management of the purchasing process of various materials is completed in the SAP system, and the interface work is done;
2) and managing the business of various material warehouses.
5. The system integration mainly comprises the following two aspects:
1) through integration with upstream and downstream and related systems, management of the full life cycle of the assets is realized, and integrity and communication of related data and processes of the assets are realized;
2) interfaces with corporate upstream management systems, such as: links to existing systems of the company (e.g., WMS, HR systems, OA systems, etc.).
6. Comprehensive management and analysis:
1) the system can realize multi-angle cost (such as single machine cost accounting, equipment cost accounting, department cost accounting and operating system cost accounting) statistics, efficiency statistics (single equipment asset comprehensive efficiency analysis, equipment comprehensive efficiency analysis and the like), state analysis (company asset state analysis and the like) and the like of company function management departments, production units, workshops, groups, equipment and the like;
2) the method can provide a basis for the cost budget of company equipment; data bases can be provided for future asset acquisition and disposition management decisions.
In summary, the chemical plant production operation management system of the present invention has the following advantages:
1. the timeliness of production operation is improved, and data of production equipment is collected and fed back in time;
2. production operation efficiency is improved, data systems are managed in a standardized mode, and decision management efficiency is improved;
3. the management capability of the TPM is improved, and the idea that all personnel participate in production maintenance, the equipment is managed in the whole life cycle and prevention management is implemented is really achieved through system construction.
The above detailed description merely describes preferred embodiments of the present invention and does not limit the scope of the invention. Without departing from the spirit and scope of the present invention, it should be understood that various changes, substitutions and alterations can be made herein by those skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims and their equivalents. The scope of the invention is defined by the claims.
Claims (9)
1. A chemical plant production operation management system, comprising:
infrastructure module of basic device: the system comprises a basic equipment ledger information recording module and a BOM decomposition information recording module;
the process inspection module comprises: the system comprises an inspection receipt module, an inspection execution module, an inspection recording module and an inspection billboard module;
an autonomous security module: the system comprises a work order execution module, a missed order list module and an execution recording module;
a lubrication management module: the lubrication menu management system comprises a lubrication menu dispatching module, a lubrication menu receiving module, a lubrication execution module, a temporary lubrication module, a lubrication recording module and a lubrication billboard module;
professional point inspection module: the system comprises a point inspection order sending module, a point inspection order receiving module, a point inspection execution module, a point inspection recording module and a point inspection billboard module;
a maintenance management module: the system comprises an exception reporting module, an electronic approval module, a maintenance order sending module, a maintenance order receiving module and a maintenance acceptance module;
the engineering management module: the system comprises an engineering change module, a major repair management module and a project management module;
special/metering equipment management module: the system comprises a special equipment standing book information recording module, a special equipment checking and early warning module, a metering equipment standing book information recording module and a metering equipment checking and early warning module;
TPM special module: the system comprises a group activity module, a maintenance diagnosis module, an security ring checking module and a rationalization suggestion module.
2. The chemical plant production operation management system of claim 1, wherein the ledger information recorded by the basic device ledger information recording module comprises production equipment, electrical instrument equipment, pipeline valves, infrastructure equipment and office equipment, and corresponding two-dimensional codes or radio frequency cards are established on the production equipment, the electrical instrument equipment, the pipeline valves, the infrastructure equipment and the office equipment.
3. The chemical plant production operation management system of claim 1, wherein the working steps of the process inspection module, the autonomous security module and the professional spot inspection module comprise: standard making, plan dispatching, terminal execution, abnormity finding, work order generation, responsibility department processing and reporting department acceptance.
4. The chemical plant production operation management system of claim 1, wherein the operation of the lubrication management module comprises: standard making, plan dispatching, terminal execution and picture display.
5. The chemical plant production operation management system according to claim 3 or 4, wherein the working step after the terminal executes the process further comprises report approval, the report approval is realized in a paperless manner, and the report approval is followed by exception display.
6. The chemical plant production operation management system of claim 1, wherein the step of operating the maintenance management module comprises: the method comprises the steps of field personnel reporting, production approval, responsibility department order receiving, work order issuing, maintenance worker order receiving processing and initiating acceptance, wherein the initiating acceptance comprises production principal acceptance and maintenance principal acceptance.
7. The chemical plant production operation management system of claim 1, wherein the major repair management module comprises: and (4) summarizing department proposals and examination and approval items, forming a work order, and checking and accepting work construction and projects.
8. The chemical plant production operation management system of claim 1, wherein the operation steps of the rationalization proposal module comprise: rationalizing suggested deliveries, screening, rating for evaluation, grading treatment, objection treatment, and feasibility judgment.
9. The chemical plant production operation management system of claim 1, wherein the operation hardware comprises a PC terminal, a PDA terminal and a mobile terminal, and the PC terminal is interconnected with the PDA terminal and the mobile terminal through a cloud server.
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| CN202011117794.1A CN112330267A (en) | 2020-10-19 | 2020-10-19 | Chemical plant production operation management system |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN112949877A (en) * | 2021-04-01 | 2021-06-11 | 苏州艾斯莫科信息科技有限公司 | Intelligent management platform system for factory department |
| CN113065840A (en) * | 2021-03-05 | 2021-07-02 | 上海五航航空技术有限公司 | Equipment management system and management equipment |
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2020
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Patent Citations (4)
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| CN107766457A (en) * | 2017-09-27 | 2018-03-06 | 华能国际电力股份有限公司上海石洞口第二电厂 | A kind of thermal power plant's operation management system and its task executing method |
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