A method for digital operation and maintenance management of cement plant equipment

Abstract

The present invention discloses a method for digital operation and maintenance management of cement plant equipment, the steps of which are as follows: (1) establishing a data dictionary; (2) three-dimensional modeling and equipment numbering; (3) model analysis; (4) system deployment; (5) data integration; (6) data display. The cement plant digital twin operation and maintenance platform equipment management system built based on the method of the present invention, as a digital product, realizes economic revenue generation; the present invention solves the problem of cross-system data query by cement plant operation and maintenance management personnel, solves the problem of data islands, and solves the problem of time-consuming on-site inspections, thereby improving operation and maintenance efficiency.

Description

Technical Field

[0001] The present invention relates to intelligent operation and maintenance of cement plants, and in particular to a method for digital operation and maintenance management of cement plant equipment. Background Art

[0002] At present, cement enterprises are promoting intelligent manufacturing in cement production lines, promoting intelligent production processes, cultivating new production methods, and improving the intelligent level of production, management and services of cement enterprises. Equipment is a key factor in factory operation, and efficient maintenance of equipment in the factory is the guarantee for the normal operation of the factory.

[0003] Patent No. CN20211014615 "Water Treatment Plant Operation and Maintenance System and Method Based on BIM and Internet of Things Technology" discloses a method for water treatment plant equipment operation and maintenance. This method collects real-time operation data of water treatment equipment through the perception layer, stores data at the data layer, processes data at the platform layer, pushes the processing results to the application layer, and generates a visual display of the water treatment plant digital operation and maintenance model. The staff scans the RFID tags on the physical equipment through the APP to obtain information related to equipment operation and maintenance.

[0004] The shortcomings of the prior art mainly include the following aspects:

[0005] 1. Binding operation and maintenance data through RFID tags will increase the cost of digital operation and maintenance;

[0006] 2. Using a handheld mobile terminal to scan the QR code and query data on site through the APP increases the inspection time;

[0007] 3. Production-related systems, including DCS systems, energy management systems, quality management systems, etc., usually operate independently, information cannot be effectively transmitted, and information islands exist;

[0008] 4. Information related to equipment operation is scattered in various systems. For example, querying equipment energy consumption in the energy management system and querying equipment output in the production management system are not conducive to a comprehensive query of the equipment operation status during the operation and maintenance process, and the efficient use of data is not achieved, and the data value is not fully utilized. Summary of the invention

[0009] Purpose of the invention: The purpose of the present invention is to provide a method for digital operation and maintenance management of cement plant equipment, so as to solve the problem of data islands in cement plants, especially to integrate all data related to the equipment and present it in the equipment management system, to provide managers with an efficient data query method, to improve the utilization rate of production operation data, to save the time consumed by equipment maintenance personnel in querying data, and thus to improve the operation and maintenance efficiency of factory equipment.

[0010] Technical solution: The method for digital operation and maintenance management of cement plant equipment described in the present invention comprises the following steps:

[0011] (1) Establishing a data dictionary, wherein the data dictionary includes professional category, equipment name, equipment code, section name, process name, and workshop name;

[0012] (2) 3D modeling and equipment numbering: Use 3D modeling software to build a 3D factory at a 1:1 ratio, and number each device so that it has a unique identification code. The identification code is written into the basic parameters of the device model and can be parsed by the operation and maintenance platform. The unique identification code of the device can be used to determine the workshop sub-item, specialty, and type to which the device belongs;

[0013] (3) Model parsing: Model parsing rules are formulated in the system. The rules extract the specified number of digits in the unique identification code of the device and classify the device by combining the device code and name in the basic data dictionary;

[0014] (4) System deployment: The system hardware includes database servers, application servers, and rendering servers. The database server and application server support private cloud or hyper-convergence deployment and should be deployed separately. The rendering server should have a graphics card configuration that meets the rendering requirements of the virtual scene, otherwise it will affect the operating experience and operation and maintenance efficiency. The system also requires display tools and interactive tools.

[0015] (5) Data integration: The data source is a single system or data center that runs independently during the production process, depending on the actual deployment on site; the content of the data should be selected based on the needs of on-site operation and maintenance management; the data and model are associated through the device's unique identification code. Usually, the scenes and naming methods of video surveillance images are diverse, and it is difficult to automatically match the monitoring name with the monitored device. By establishing a mapping relationship between the monitoring name and the device number, the monitoring and the device can be bound;

[0016] (6) Data display: Establish an equipment directory tree based on the work sections and process divisions in the data dictionary; each device is displayed in the directory tree structure using the "equipment number + device name" format; after the user selects a device in the directory tree through the interactive tool, the user is positioned at the device model in the virtual scene. At the same time, the system provides operation options for querying the operation and maintenance data of the selected device; the operator can view the complete operation and maintenance data of the device according to the options without switching function pages; based on the operating status of a single device, the system can generate an equipment inspection report and export various types of instantaneous data of the device.

[0017] The step (2) is specifically:

[0018] (2.1) Use 3D modeling software to build a 3D factory at a 1:1 scale, and the model will be lightweight before delivery;

[0019] (2.2) The appearance of the device model must be consistent with the actual device, and each device model must be able to be displayed independently;

[0020] (2.3) Each device is numbered so that it has a unique identification code. The identification code is written into the basic parameters of the device model and can be parsed by the operation and maintenance platform. The unique identification code of the device can be used to determine the workshop sub-item, specialty, and type to which the device belongs.

[0021] The step (6) is specifically as follows:

[0022] (6.1) As there are many types of equipment in cement plants, in order to facilitate the structured and refined management of equipment, an equipment directory tree is established according to the sections and processes in the data dictionary;

[0023] (6.2) To facilitate device identification and search, each device is displayed in the directory tree structure in the form of "device number + device name";

[0024] (6.3) After the user selects a device in the directory tree through the interactive tool, the user is located at the device model in the virtual scene. At the same time, the system provides operation options for querying the operation and maintenance data of the selected device, including spare parts information, equipment lubrication records, equipment inspection records, fault shutdown records, equipment real-time operation DCS data, equipment real-time monitoring screen, equipment design data (design drawings and equipment material list, design parameters), and alarm records;

[0025] (6.4) Operators can view the complete operation and maintenance data of the equipment according to the options without switching function pages; for the operating status of a single device, the system can generate an equipment inspection report and export various types of instantaneous data of the equipment, so as to facilitate comprehensive analysis of various types of data and judge the operating status of the equipment as a basis for managers' decision-making.

[0026] A system for digital operation and maintenance management of cement plant equipment, the system adopts the above-mentioned method for digital operation and maintenance management of cement plant equipment, and includes the following modules:

[0027] DCS data module: used to view the real-time DCS data of the equipment, including equipment ready signal, equipment fault signal, equipment trip time and reason, equipment operation status and operation time, and equipment measurement point temperature, pressure, and vibration; Lubrication task module: used to view the equipment lubrication task, including lubrication parts, lubricating oil, lubrication cycle, last lubrication time, next lubrication time and responsible person;

[0028] Ledger information module: used to view the equipment name and number, equipment specifications, model, importance level, workshop, and status;

[0029] Spare parts information module: used to view the relevant information of equipment spare parts, including supplier name, spare parts specifications and models, spare parts storage location and quantity;

[0030] Fault information module: used to view equipment fault records, including the time when the equipment fault occurred, the person responsible for handling the fault, the fault handling status and the fault handling method;

[0031] Energy consumption module: used to view information related to equipment power consumption, water consumption, and gas consumption, and reflect the energy consumption trend of equipment;

[0032] Material module: used to view equipment output, material quality information, and reflect output trends.

[0033] A computer storage medium stores a computer program, which, when executed by a processor, implements the above-mentioned method for digital operation and maintenance management of cement plant equipment.

[0034] A computer device comprises a memory, a processor and a computer program stored in the memory and executable on the processor, wherein the processor implements the above-mentioned method for digital operation and maintenance management of cement plant equipment when executing the computer program.

[0035] Beneficial effects: Compared with the prior art, the present invention has the following advantages:

[0036] 1. The equipment management system of the cement plant digital twin operation and maintenance platform built based on this method, as a digital product, realizes economic revenue;

[0037] 2. The present invention solves the problem of cross-system data query by cement plant operation and maintenance managers, solves the problem of data islands, and solves the problem of time-consuming on-site inspections, thereby improving operation and maintenance efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 is a flowchart of the steps of the method of the present invention;

[0039] Figure 2 This is a schematic diagram of the platform architecture. DETAILED DESCRIPTION

[0040] The technical solution of the present invention is further described below in conjunction with the accompanying drawings.

[0041] like Figure 1-2 As shown, a method for digital operation and maintenance management of cement plant equipment includes the following steps:

[0042] 1. Create a data dictionary

[0043] The data dictionary is usually compiled during the project design process, and its content includes professional division, work section and process division, and equipment type division.

[0044] 2. Modeling and equipment numbering

[0045] (1) Modeling

[0046] The modeling depth is at the equipment level, so factory-level and workshop-level modeling such as oblique photography cannot meet the conditions and is only suitable for environmental illustration. The three-dimensional modeling software used in the present invention includes Revit, Solidworks, and CAD. The files exported by various software need to be converted, and finally the model workshop is integrated in Revit and the whole field is integrated in the operation and maintenance platform. In the three-dimensional model, the appearance of the equipment model is consistent with the actual one; the spatial position of the equipment model in the virtual scene is consistent with the actual one.

[0047] (2) Coding

[0048] Each professional equipment should have a unique identification code as the unique identity of the equipment in the factory. The identification code coding rules should be consistent. In the present invention, the unique equipment identification code adopts a multi-segment code, which contains project information, workshop information, professional information, equipment code, and equipment serial number. The multi-segment code is written into the basic parameters of the equipment model by the designer during the modeling process.

[0049] (3) Model lightweight

[0050] There are many types of model lightweight tools on the market today. When choosing a tool, you should pay attention to the following three points:

[0051] a. Achieve lightweight effect;

[0052] b. Use lightweight tools to convert files, and the converted file format must meet the requirements of the operation and maintenance platform;

[0053] c. After the file is lightweighted, all attributes of the model should be retained. The present invention uses a self-developed lightweight tool to minimize and export the model based on the Revit plug-in.

[0054] 3. Data analysis

[0055] Formulate the parsing rules of the model in the system. After the model is uploaded to the operation and maintenance platform, the platform can parse the unique identification code of the device according to the parsing rules, determine the profession to which the device belongs, and automatically classify the devices by profession based on the data dictionary. By splitting and identifying the corresponding characters in the unique identification code of the device, the device number and device name can be extracted.

[0056] 4. System deployment

[0057] The system hardware includes database server, application server, rendering server, and the software is an intelligent operation and maintenance platform. The database server requires a memory of no less than 64G, and the application server requires a memory of no less than 32G. The application server supports private cloud or hyper-convergence deployment and should be deployed separately; the rendering server should have a graphics card configuration that meets the conditions and meets the rendering requirements in the virtual scene, otherwise it will affect the operation and operation efficiency.

[0058] 5. Data Integration

[0059] The data source can be a single system running independently in the production process, or it can be a data middle platform. The system interface can be in the form of mainstream interfaces such as OPC and HTTP. Data integration can satisfy other systems to push data after processing, and also satisfy the operation and maintenance platform to retrieve from other business systems. It depends on the actual deployment situation on site. Before data docking, other systems should process the data. The data should meet the fields required for operation and maintenance. The equipment number is a necessary condition. The data of other systems is associated with the equipment number parsed according to the unique identification code in the operation and maintenance platform through the equipment number. For example, the equipment management system should provide equipment lubrication information including equipment number, equipment name, lubrication part, lubrication standard, last lubrication time, planned next lubrication time, and responsible person; the energy management system should provide equipment information including equipment number, equipment energy consumption on the day, and equipment energy consumption on the month. The equipment number is used to establish an association with the model and data in the operation and maintenance platform. However, for data such as video surveillance, the equipment management system binds monitoring and equipment by establishing a mapping relationship between monitoring name and equipment number. Since multiple parts of key equipment need to be monitored in cement plants, when establishing a mapping table, it supports binding multiple monitoring names to one equipment number.

[0060] 6. Data display

[0061] Since there are many equipments and types in cement plants, in order to facilitate the structured and refined management of equipments, an equipment directory tree is established according to the equipment sections and processes. The first level of the directory tree is the section, the second level is the process, and the third level is the equipment. In order to facilitate the identification and search of equipments, each equipment is displayed in the directory tree structure in the manner of "equipment number + equipment name", and the equipment number and equipment name are derived from the results of data analysis. Users select equipments in the directory tree through interactive tools and locate the equipment model in the virtual scene. At the same time, the system provides operation options for querying equipment operation and maintenance data. The options provided by the present invention include spare parts information, equipment lubrication records, equipment inspection records, fault shutdown records, equipment real-time operation DCS data, equipment real-time monitoring screen, equipment design data (design drawings and equipment material table, design parameters), and alarm records. Operators can view detailed equipment operation and maintenance data according to the options. For example, when the system prompts an equipment alarm, you can view the equipment operation data in the same environment to determine whether the data is abnormal; open the real-time monitoring screen of the equipment at the same time. For key equipment, you can open multiple monitoring screens at the same time to determine whether the equipment environment is abnormal; check lubrication records, maintenance records, and check whether there are omissions in daily maintenance, etc., which saves time in cross-system data query and efficiently provides managers with decision-making basis.

Claims

1. A method for digital operation and maintenance management of cement plant equipment, characterized in that: The following steps are involved: (1) Establishing a data dictionary, wherein the data dictionary includes professional category, equipment name, equipment code, section name, process name, and workshop name; (2) 3D modeling and equipment numbering: Use 3D modeling software to build a 3D factory at a 1:1 ratio, and number each device so that it has a unique identification code. The identification code is written into the basic parameters of the device model and can be parsed by the operation and maintenance platform. The unique identification code of the device can be used to determine the workshop sub-item, specialty, and type to which the device belongs; (3) Model parsing: Model parsing rules are formulated in the system. The rules extract the specified number of digits in the unique identification code of the device and classify the device by combining the device code and name in the basic data dictionary; (4) System deployment: The system hardware includes database server, application server, and rendering server; Database servers and application servers support private cloud or hyper-converged deployment and should be deployed separately; The rendering server should have a graphics card configuration that meets the rendering requirements of the virtual scene, otherwise it will affect the operating experience and operation and maintenance efficiency; the system also requires display tools and interactive tools; (5) Data integration: The data source is a single system or data center that runs independently during the production process, depending on the actual deployment on site. The content of the data should be selected based on the needs of on-site operation and maintenance management. The data and model are associated through the unique device identification code. Usually, the scenes and naming methods of video surveillance images are diverse, and it is difficult to automatically match the monitoring name with the monitored device. By establishing a mapping relationship between the monitoring name and the device number, the monitoring and the device are bound. (6) Data display: Establish an equipment directory tree based on the work sections and process divisions in the data dictionary; each device is displayed in the directory tree structure in the form of "equipment number + device name"; after the user selects a device in the directory tree through the interactive tool, the user is located at the device model in the virtual scene. At the same time, the system provides operation options for querying the operation and maintenance data of the selected device; the operator can view the complete operation and maintenance data of the device according to the options without switching function pages; based on the operating status of a single device, the system can generate an equipment inspection report and export various types of instantaneous data of the device.

2. A method for digital operation and maintenance management of cement plant equipment according to claim 1, characterized in that: The step (2) is specifically: (2.1) Use 3D modeling software to build a 3D factory at a 1:1 scale, and the model will be lightweight before delivery; (2.2) The appearance of the device model must be consistent with the actual device, and each device model must be able to be displayed independently; (2.3) Each device is numbered so that it has a unique identification code. The identification code is written into the basic parameters of the device model and can be parsed by the operation and maintenance platform. The unique identification code of the device can be used to determine the workshop sub-item, specialty, and type to which the device belongs.

3. A method for digital operation and maintenance management of cement plant equipment according to claim 1, characterized in that: The step (6) is specifically as follows: (6.1) As there are many types of equipment in cement plants, in order to facilitate the structured and refined management of equipment, an equipment directory tree is established according to the sections and processes in the data dictionary; (6.2) To facilitate device identification and search, each device is displayed in the directory tree structure in the form of "device number + device name"; (6.3) After the user selects a device in the directory tree through the interactive tool, the user is located at the device model in the virtual scene. At the same time, the system provides operation options for querying the operation and maintenance data of the selected device, including spare parts information, equipment lubrication records, equipment inspection records, fault shutdown records, equipment real-time operation DCS data, equipment real-time monitoring screen, equipment design data, and alarm records; (6.4) Operators can view the complete operation and maintenance data of the equipment according to the options without switching function pages; for the operating status of a single device, the system can generate an equipment inspection report and export various types of instantaneous data of the equipment, so as to facilitate comprehensive analysis of various types of data and judge the operating status of the equipment as a basis for managers' decision-making.

4. A system for digital operation and maintenance management of cement factory equipment, the system adopts a method for digital operation and maintenance management of cement factory equipment as claimed in any one of claims 1 to 3, characterized in that: Includes the following modules: DCS data module: used to view the real-time DCS data of the equipment, including equipment ready signal, equipment fault signal, equipment trip time and reason, equipment operation status and operation time, and equipment measurement point temperature, pressure, and vibration; Lubrication task module: used to view the equipment lubrication task, including lubrication parts, lubricating oil, lubrication cycle, last lubrication time, next lubrication time and responsible person; Ledger information module: used to view the equipment name and number, equipment specifications, model, importance level, workshop, and status; Spare parts information module: used to view the information related to equipment spare parts, including supplier name, spare parts specifications, spare parts storage location and quantity; Fault information module: used to view equipment fault records, including the time when the equipment fault occurred, the person responsible for handling the fault, the fault handling status and the fault handling method; Energy consumption module: used to view information related to equipment power consumption, water consumption, and gas consumption, and reflect the energy consumption trend of equipment; Material module: used to view equipment output, material quality information, and reflect output trends.

5. A computer storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, a method for digital operation and maintenance management of cement plant equipment as described in any one of claims 1 to 3 is implemented.

6. A computer device comprising a memory, a processor and a computer program stored in the memory and executable on the processor, characterized in that: When the processor executes the computer program, a method for digital operation and maintenance management of cement factory equipment is implemented as described in any one of claims 1-3.

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