The electronic bypass system covered all the technological workshops of Kemerovo "Nitrogen"

2022: Commissioning of the third stage of electronic equipment bypass system

On March 30, 2022, the SPtsTek NPP company announced the commissioning of the third stage of the electronic bypass system of the Azot KAO equipment. The system, created on the basis of the TRIM software complex, covered another 12 workshops of the enterprise.

Process equipment bypasses are an important element of reliability control aimed at early detection of defects in order to eliminate them in a timely manner and prevent failures. The rational basis of bypasses is the idea of ​ ​ a defect as a precursor to failure. The effectiveness of the rounds depends on the reliability, completeness and speed of the collected data information about the actual state of the equipment.

Since February 2020, rounds in the KAO Azot are carried out using digital technologies. To this end, the enterprise has created an electronic equipment bypass system (ESO) - a multi-user system for collecting, accounting and analyzing data on the results of bypasses using mobile devices, and Web technologies. Digitalization of workarounds allows in real time to accurately record the nature and location of a defect or deviation of parameters, and reduce the time for bringing this data to persons making decisions in the field of operation and repairs.

The basis of the system is the TRIM-Mobile application, deployed on wearable mobile devices, which allows field personnel to enter data directly into and receive data from the corporate information system, moving along the route of the walk to the workshop and inspecting equipment. An important element of the system is the NFC tags on the equipment to identify each inspection object.

The system all this time developed functionally and expanded, passing through the stages of ESO-1, ESO-2 and ESO-3. The implementation of the third phase of the system began in June 2021. As part of this stage, the functionality of the mobile application was finalized and updated in six workshops in which the system was introduced earlier, and the system was scaled to the remaining 12 technological workshops. Quantitative parameters of ESO-3 at the time of commissioning: 1896 system users, inspection objects in the database of more than 19,500, NFC tags of about 3,000, about 10,000 inspections and more than 930 bypass routes in the database, about 500 mobile devices in the system.

The updated version of the TRIM-Mobile mobile application ensured the accumulation of statistics on each site by users and workshops, which made it possible to strengthen control and increase responsibility for performing rounds. Significantly reduced labor input when creating and planning workarounds. According to Sergey Tseplyaev, project manager, chief specialist of the digital management of production assets of Azot KAO, after the full implementation of ESO-3, more than 800 man-hours will be released every month.

We analyzed the statistics before and after the implementation of the system and found that the number of detected and detected defects increased significantly, somewhere even tenfold. This means that the quality of the rounds has increased significantly, "said Igor Karpov, head of the automation and communications department of Azot.

As part of our project, in our opinion, there was a real digital transformation of all customer activities related to bypasses. The plant can then scale the system itself. To do this, we conducted training, so the customer will be able to connect other divisions without involving the developer, "said Alexey Sukmanov, project manager from SpetsTek NPP.

2020

Completion of Electronic Equipment Bypass System Scaling

NPP "SpetsTek" January 27, 2021 announced the completion of the scaling of the electronic system of equipment bypasses Kemerovo in the joint-stock company "." Nitrogen The system is based on. software TRIM

The Electronic Equipment Bypass System (EPS) is a multi-user system for distributed collection, accounting and ordering of data on the results of bypasses, inspections of equipment and control of technological parameters of its operation, using mobile devices and web-technologies.

Earlier, the ESO of the first stage was created, which was deployed on 40 mobile devices (smartphones, tablets), integrated with the Galaktika ERP system. It covered 50% of the equipment of two workshops (ammonia-1 and carbamide), on which NFC tags were installed to identify inspection objects, and 65 bypass routes.

In September 2020, the second stage of the introduction of ESO began, the content of which was the expansion of equipment coverage in the ammonia-1 and carbamide workshops, the scaling of the system at the ammonia-2 workshop, No. 13, No. 15, the gas raw material workshop. To this end, the customer is licensed to use TRIM-Mobile software without limiting the number of users and the corresponding number of NFC tags.

As part of the second phase, an ESO database of more than 480 bypass routes and more than 5,000 inspection cards has also been created, the TRIM-Mobile mobile application has been deployed on more than 200 mobile devices. The work on functional development of ECS based on the results of operation of the system of the first stage was carried out.

As a result, the operational line staff of six workshops received a tool in the form of a smartphone with the TRIM-Mobile application installed, with which he can, being in the workshop, enter directly into the information system of the enterprise data on the results of inspections of the equipment, on the parameters of its condition and their primary classification. Scanning the NFC tags at the installation site allows you to automatically locate the NFC tags in the database and enter the results of the scan.

On the other hand, according to the same label, the location of the bypass is aligned with this equipment. After uploading the crawl data to the server, the manager will have the opportunity to check compliance with the crawl route, reading all the marks, how much time was spent on the crawl. This ensures the observability of the rounds and increases personal responsibility for their implementation.

If the crawler detects a mismatch, he registers the defect with the help of a mobile device, enters its description, including photo and video recording. These data are sent to the corporate system, where the defect is checked and approved, and work is planned to eliminate it.

The introduction of ESP has reduced the time between the monitoring of the equipment at the site of its installation and the receipt of control results by decision-making centers for reliability management and maintenance and repair. Strengthen control over the execution of bypasses and, as a result, increase the degree of their implementation. Improve the reliability of data collected by eliminating intermediate storage media.

Physical Asset Management Audit Completed

On March 2, 2020, SPtsTek NPP announced the completion of an audit of the physical asset management system and the creation of an electronic system for bypassing equipment of the first stage in the Kemerovo joint-stock company Azot.

According to the company, both projects involve the possibility of scaling to other divisions of KAO Azot. The field of audit of the asset management system was limited to workshop No. 15, and the electronic system of bypassing equipment of the first stage (ESO-1) covered the 50% of equipment of the ammonia-1 workshop and the carbamide workshop.

The audit criteria were the requirements of GOST R 55.0 02-2014/ISO55001: 2014 "Asset Management. Management systems. Requirements. " At the initial stage, experts of the SPTEC NPP held an introductory seminar with the aim of familiarizing audit participants with the specified standard and harmonizing audit criteria. Then they collected audit evidence using two methods: self-assessment and expert assessment.

During the self-assessment, the audit participants from the customer completed questionnaires and gave interviews in which they evaluated the asset management system and the enterprise's activities in this area. Regulatory and methodological documents and the customer's asset management activities were subject to expert assessment for compliance with audit criteria.

Using the obtained audit certificates, experts of SpetsTek NPP analyzed the existing asset management system (SSA) and made recommendations for its development. These results were reflected in the audit report, which was considered at the meeting of the working group, and subsequently supported the proposal of the Special Tech NPP for the development of MSA. Based on the results of the audit, a plan for the development of the asset management system on the scale of the whole KAO Azot was developed, as well as a terms of reference, a charter and a project schedule for the implementation of the customer's asset management information system.

In parallel with the audit of the SSA, work was carried out on the development and implementation of ESO-1. The project participants were tasked with introducing mobile devices into the practice of operational monitoring of the condition of equipment and control of its technological parameters.

To this end, the customer has a license to use, mobile application TRIM-Mobile which has been deployed on 40 devices. Together database , ESO-1 was created along bypass routes and inspection maps: employees of the Azot KAO collected information Excel templates, and specialists of the SpetsTek NPP loaded it into ESO-1. The Data Base was integrated with the database of the current information system at the Azot KAO and supplemented with a decomposition of equipment NSI and defects loaded from the "" system, Galaktika ERP as well as images of bypass route maps for their visual on visualization mobile devices.

For continuous interaction and data exchange between ESO-1 and the Galaktika ERP system, an integration module was developed and commissioned. NFC tags for identification of inspection objects have been delivered to the customer. They were installed by employees of Azot KAO on controlled equipment, and specialists of SpetsTek NPP tied them to the corresponding objects in the ESO-1 database. From February 20, 2020, ESO-1 was put into pilot operation.

As a result, the operational line personnel received a tool in the form of a smartphone with the TRIM-Mobile application installed, with which he can, while in the workshop, enter directly into the information system of the enterprise data on the results of inspections of the equipment, on the parameters of its condition and their primary classification. The installation of NFC tags allows you to automatically locate the equipment in the database and enter the results of its inspection at the installation site.

In addition to the automation of line personnel operations during the rounds, the ESO-1 project gave a number of results. The time between monitoring the equipment at the site of its installation and obtaining the results of monitoring by the decision-making centers for reliability management and maintenance. The level of monitoring of bypasses and, as a result, the degree of their actual implementation has increased. The reliability of data collected during bypasses has improved, since intermediate storage media are excluded.