Application of the hottest MES system in refining

Application of MES system in refining and chemical enterprises

in the early 1990s, the American Manufacturing Execution System Association (MESA) proposed the theory of "manufacturing process gap", which became the theoretical banner of the development of manufacturing execution system (MES). As a typical process industry enterprise, refining and chemical enterprises have increasingly urgent user needs for improving production efficiency and strengthening refined management level with the continuous rise of crude oil price and the intensification of competition between domestic and foreign enterprises. Under this background, the development and implementation of MES system in domestic and foreign refining and chemical enterprises have also developed rapidly

there are different ideas about the definition of MES system at home and abroad, Among them: American advanced manufacturing research institute AMR defines MES system as "a workshop oriented management information system located between the upper planning management system and the lower industrial control. MES system provides operators and managers with plan execution, tracking and current status information of all resources; while international manufacturing execution system association mesa positions MES on the workshop site, in addition to enterprise resource planning (ERP) , cad/cam and industrial control. Pay special attention to production operation, which is the general coordination of site level and operation related data

it should be said that the concept of MES system is constantly updated with the development of information technology, the understanding of user needs and the feedback of implementation effect. From the current situation of products and applications of MES system in process industry, the application of MES system in manufacturing enterprises mainly plays two important roles: one is the role of two-way data channel. That is, the implementation of MES system can effectively make up for the data gap between the enterprise process control system (PCS) layer and ERP layer. From bottom to top, through the collection, storage and correction of the underlying PCs layer data, a digital factory at the process control data level can be established, combined with the scheduling event information data at the production scheduling level, so as to provide accurate and unified production data for the upper ERP planning management level; From top to bottom, by summarizing the real-time production data, the upper ERP layer can adjust the production plan according to the future orders and the current production status, and issue the MES layer to decompose the plan and generate scheduling instructions to effectively guide the production activities of the enterprise. Therefore, the MES system acts as a bridge between PCs layer and ERP layer at the data level, and ensures the consistency and accuracy of production data, scheduling events and other information. On the other hand, the complexity of production activities has produced many actual user needs. In order to meet these user needs, MES system can also be regarded as a collection of functional modules. American mesa divides the MES system into 11 functional models, which are: resource allocation and status, operation/detailed scheduling, dispatch production unit, document control, data collection/acquisition, labor management, quality management, process management, maintenance management, product tracking production unit and performance analysis. These functional models are interconnected by data flow and cover the vast majority of user needs at the production level of the enterprise as an organic whole. It is worth noting that there are great differences in production activities in different industries, and the requirements and emphasis on the function of S system are completely different with the increasing requirements of me for products in modern society. In addition, it is difficult for each Asiatic genuine gold board to realize the real fire prevention class a MES system. The developer's understanding of the functional model is also different, resulting in some differences in the functional model of MES system products

the United States, Japan, Europe and other industrial developed countries attach great importance to the research and system development of MES technology, and have formed the MES software industry. The recent annual growth rate of the MES software market has remained at 35% - 40%. According to AMR survey, the implementation of MES system is very beneficial to the implementation of enterprise plan and the automation of operation process. It is estimated that it can reduce 45% of manufacturing cycle time, 75% of data entry time, 18% of product defects and 61% of paper work prepared for shift handover

with the proposal of the concept of MES and the development of technology, relevant international organizations have begun to realize that compared with two-component waterborne polyurethane adhesive, MES needs to be defined more clearly. Mesa association was the first and isa subsequently developed relevant models to describe MES and tried to standardize it through models. Among them, isa-sp95 is an enterprise and manufacturing integration standard defined by the Institute of instrumentation, systems and automation (ISA). As an international standard for elaborating the functions of MES, it clearly specifies the interface and functional composition of enterprise MES system. Isa-sp95 committee is composed of end users, manufacturers and other personnel (integrators, academia, etc.) on an equal footing. The committee mainly tests its Zui experimental force. The committee holds 4-5 meetings of 2-3 days each year to discuss the main methods of standard development. At present, this standard is jointly formulated and published by ANSI (American National Organization for Standardization)/isa, and is divided into several parts. Among them, parts 1, 2 and 3 become iec/iso 62264 after passing the evaluation of iec/iso

brief introduction of MES system in refining and chemical enterprises

mes system is produced for the production site and is closely related to the production status of the workshop, so there is a strong industry correlation. Due to the different production characteristics and circulation sequences of each industry, as well as its specific business processes, different industries have completely different requirements and priorities for MES. Based on the industry characteristics of manufacturing, MES system can be roughly divided into discrete manufacturing, process industry and batch production process

refining and chemical enterprises are typical process industrial enterprises, which have the characteristics of continuous production process, large production batch, relatively fixed process procedures and complex material flow direction. With the continuous rise of crude oil prices and the intensification of competition between domestic and foreign enterprises, refining and chemical enterprises have increasingly urgent user needs for improving production efficiency and strengthening refined management level. Under this background, In recent years, the development and implementation of MES system in domestic and foreign refining and chemical enterprises have developed rapidly

take foreign refining and chemical enterprises as an example. 1. After the merger of ExxonMobil and Mobil, ExxonMobil of the United States uniformly implemented the second generation MES system project of pois-2. This project is divided into three stages: the first stage is the transformation of general infrastructure, including upgrading DCS and LAN, setting up standardized desktop system, installing Honeywell real-time data platform uniformity and laboratory information management system LIMS; The second stage is the application of production statistics management, including the realization of production statistics, tank component tracking, etc; The third stage is operation management application, including operation monitoring, device balance, energy balance, material movement, blending management, etc. 2. Petrobras is a large refining and chemical enterprise with 11 refineries and 2 fertilizer plants. Its MES scheme includes: planning and scheduling system; The real-time database application system is responsible for collecting the data of production devices, tank farms, equipment, and product quality data; Realize material balance, data adjustment and production report generation; Realize enterprise level information collection and summary

since 1999, domestic refining and chemical enterprises have gradually realized the importance of the development and implementation of MES system for plant information construction. This process is mainly divided into two stages. In the first stage, refining and chemical enterprises mainly develop and implement some independent and unsystematic MES modules in the plant according to the actual production and application needs, such as the material balance system of Jinzhou petrochemical, the data integration and material balance system of Maoming Petrochemical, and the material balance and data correction system of Zhenhai Refining and chemical; In the second stage, refining and chemical enterprises began to pay attention to the system and integrity of MES, set up a unified plant real-time/relational data platform on PCS system, and connect ERP system upward to form a complete three-tier structure of enterprise integrated automation system; The user needs of refining and chemical enterprises in production activities are solved through the structure and implementation of functional modules. At this stage, the refineries subordinate to PetroChina and Sinopec, two large state-owned enterprises, are the main representatives. PetroChina is one of the companies that carried out MES system planning and implementation earlier in China. In November 2000, PetroChina completed the "PetroChina Information Technology Master Plan", and divided the IT projects to be implemented by PetroChina in the next five years into seven main lines, a total of 34 work packages

Figure 1 functional architecture of PetroChina MES system

Figure 2 functional architecture of petrochemical MES system

in July 2002, PetroChina organized the feasibility study and pilot design of downstream project B1: refining and chemical operation system (MES) project in the information technology master plan. On the basis of the feasibility study, the PetroChina MES project was officially launched throughout the company in May 2004. In order to reduce the risk of system construction, gain experience as soon as possible and make full preparations for promotion, PetroChina has adopted the overall implementation strategy of "overall planning, step-by-step implementation" and "pilot first, then promotion". In August, 2004, the pilot implementation of PetroChina MES system was launched. After 15 months of pilot implementation, it was officially put into operation on December 17, 2005. After the pilot implementation was successfully launched, according to the next arrangement of the project implementation plan, phase I project promotion was carried out in four refining and chemical enterprises, Jinzhou petrochemical, Jinxi Petrochemical, Daqing Petrochemical and Daqing Petrochemical, and the four were successfully launched at the same time on March 30, 2007. Since October, 2006, the project has carried out phase II promotion work in Lanzhou Petrochemical, Harbin Petrochemical, Urumqi Petrochemical and Dushanzi petrochemical, and started phase II promotion in Jilin, Fushun and Liaoyang in April, 2007. At present, the second phase of the promotion of PetroChina MES system is nearing the end, and the third phase is expected to start in June 2008 in 14 domestic refining and chemical enterprises of PetroChina. In April, 2004, with the support of the Ministry of science and technology, Sinopec headquarters decided to start the construction of Sinopec production execution system, and successively carried out the construction of "MES development and pilot of petrochemical enterprises (oil refining)" and "MES system improvement and promotion of petrochemical enterprises". Sinopec MES system project focuses on independent development, and adopts the iterative development implementation strategy of centralized development → pilot implementation → centralized development. In September, 2004, the project researched and developed the version of SMEs v1.0, which has been implemented in three pilot enterprises of Sinopec Jingmen Branch, Anqing branch and Maoming Branch since October, 2004. At present, the system has been officially launched. In September, 2005, the development of SMEs v2.0 was planned. After the pilot implementation of Maoming Branch, Tianjin Branch, Luoyang Branch, Shijiazhuang refining and chemical fiber branch, Baling Branch and Jiujiang Branch, the development of SMEs v2.0 was officially completed in early 2006. SMEs V3.0 has been designed and developed since the middle of 2007. At present, it has passed the acceptance test and is ready for pilot implementation in 4-5 branches under Sinopec

Figure 3 functional architecture of central control MES system

mes system and manufacturer introduction

foreign refining and chemical enterprise MES system software manufacturers started early, such as Honeywell, Aspen and others have their own MES software products, Honeywell business FLEX@PKSTM As an important part of Honeywell's high-tech solution, the production execution system software suite can help enterprises achieve real-time coordination, increase the transparency of management, and continuously improve the flexibility and efficiency of enterprise production. It includes five main application suites, with a total of more than 30 application modules, including advanced planning and scheduling optimization, operation management, oil blending and storage and transportation automation, production management and value chain management.