A new method for implementing production management systems in petrochemical enterprises
2026-04-06 07:21:29··#1
I. Introduction The surging information revolution of the 21st century has brought unprecedented opportunities and challenges to China's petrochemical industry. As one of the nation's pillar industries, the petrochemical industry is transforming from a traditional industry to a highly integrated, knowledge-based, and technologically advanced one, driven by information technology. Based on the current situation and development needs of China's petrochemical industry, Zhejiang University Control System Co., Ltd. (ZJUCC) has launched a comprehensive solution for the petrochemical industry, centered on a Production Information Management System (PIMS) framework, to help petrochemical enterprises achieve information-based management. The following introduces the core components of this comprehensive solution. The PIMS Production Information Management System is a software system for production management. It provides an information integration and management platform, primarily used for the collection, storage, viewing, processing, and management of plant-wide production data within an enterprise network environment. It truly realizes information communication between the office and the production site, enabling real-time data management, real-time process viewing, real-time trend browsing, alarm recording and viewing, switch quantity change recording and viewing, report data storage, historical trend storage and viewing, production process report generation, and production statistical report generation within the enterprise network environment. This achieves network integration and comprehensive management of the enterprise's process control system and information system. Users can log in to the PIMS Web Server using Microsoft Internet Explorer to browse production process information. II. Functional Modules of the Petrochemical Industry Production Information Management System The Petrochemical Industry Production Information Management System is a comprehensive, all-encompassing production information management system. Based on petrochemical production practices and combined with the actual management systems of petrochemical enterprises, the system is developed using advanced development tools and system architecture models. To flexibly implement diverse functions, the software architecture is correspondingly complex. The PIMS system includes the following functional modules: 1) Distributed real-time database module; 2) Development and configuration system function module; 3) Runtime system software module; 4) Web Server online publishing module; 5) SQL, DDE, OPC, and COM interface modules; 6) Script compilation and execution module; 7) Production report generation function module; 8) I/O device driver module; 9) Management statistical report generation module; III. Structure and Characteristics of the Petrochemical Industry Production Information Management System 1. Structure of the Petrochemical Industry Production Information Management System The system structure of the Petrochemical Industry Production Information Management System can be divided into three levels, from bottom to top: process control layer, plant management layer, and enterprise management layer. Among them, the enterprise management level completes the task of generating production management reports for managers and various functional departments; the factory management level completes the task of real-time monitoring of various functional departments. It connects to the field control layer below and to the enterprise management level above through the network. It is not only responsible for the real-time data acquisition of field control equipment, but also plays an important role in the system of up and down communication; the process control layer consists of controllers such as DCS, PLC, and intelligent instruments, and is the foundation of the entire production management system. [5] For example: In a certain petrochemical PIMS production management system project, there are 12 control systems: one Yokogawa CS3000, two Zhongkong JX-300X, one Siemens PLC, two Wanlida control systems, and six intelligent instruments. The control system is relatively complex. The server of the production information management system is located in the factory's dispatch center and completes functions such as data acquisition, data processing, and Web publishing. Communication between the factory management level and the process control layer is carried out through industrial Ethernet and RS-485 bus. Communication between the enterprise management level and the factory management level is carried out through Ethernet. The enterprise management level is equipped with a relational database for enterprise management and a statistical report generation software module for generating statistical reports. The project has been implemented and is running very well. 2. Characteristics of Petrochemical Industry Production Management System (1) Web Function: With the continuous development of Internet/Intranet technology, especially the continuous development of WEB-based information publishing and retrieval technology, the architecture of the entire application system has gradually evolved from the master-slave structure of C/S to a flexible multi-level distributed structure. [2] At present, the application of information network technology with Web technology as the core has given this multi-level distributed network structure a newer connotation, which is the browser/server (B/S) architecture. The B/S structure is actually a structure mode similar to the terminal/host system, and at the same time has the distributed computing characteristics of the client/server mode. Its main feature is centralized management, that is, software programs, databases and other components are all concentrated on the server side. The user side does not need any other software or related management and maintenance work except for the browser and its operating system. In this way, the data that the user needs to query and the data of the printed documents all come from the same database, thus ensuring the consistency, timeliness and integrity of the data. From the perspective of management, the maintenance and update of program code, the backup of database and daily maintenance can all be carried out on the server side. In addition, by using WWW technology, the enterprise management system can be published on the Internet, thereby realizing remote management. (2) Real-time performance and openness: The system adopts a reasonable method of allocating data transmission volume to balance the load of the system network, improve the transmission speed, and make the system have good real-time performance. The openness of industrial control software system is an inevitable requirement for the close integration of industrial control technology and information technology in the network era. It has also attracted more and more attention from software manufacturers and hardware manufacturers, and has gradually become a competitive hot spot in industrial control software. No matter what technology is used, as long as the software can provide sufficient openness and compatibility, it will be accepted by the majority of users. In PIMS software, we exchange data with other applications through various methods such as DDE, OPC, and ODBC to meet the needs of different customers. (3) User-friendly human-machine interface: The software is designed entirely according to the customized interface design concept, making it more convenient for users to use. The fully localized system software adopts the configuration method for secondary development, and can design software functions according to the habits of operators. The system software adopts the standard Windows and IE interfaces, which are easy to operate and easy to learn and use. 3. Functions realized by the petrochemical industry production management system (1) Data acquisition function: Realize the real-time acquisition of data of the automatic control system of the production process. (2) Flowchart Screen Viewing: The flowchart screen vividly reflects the process principle and status, enabling the management of the enterprise to easily understand and analyze the equipment status and production situation. (3) Real-time Trend and Historical Trend Monitoring: The real-time trend data change curve can reflect the production situation of the current time period in a timely manner; the historical trend can be viewed to understand the long-term production situation. When an accident occurs, the historical trend can be used to recall the accident and analyze the cause of the accident. (4) Automatic Generation of Production Reports: It can automatically generate production data reports such as shift reports and daily reports. The data reflected is true and accurate. (5) Real-time Alarm and Historical Alarm Functions: When a certain process parameter reaches the alarm condition such as "HH high high limit", the corresponding alarm information will be generated immediately, and there will be alarm information such as sound, flashing and color change. (6) Management Statistical Report Generation Function, implemented by the software of the enterprise management. Complete the analysis and management of the production information of the whole plant and the enterprise. Based on real-time data, a statistical analysis was conducted on the main indicators of the entire plant, comparing them with the same period of the previous year, including power generation, coal consumption for power supply, comprehensive standard coal price, fuel costs, and other production and economic conditions. The analysis used charts and tables to provide a more intuitive description of the data, which is of profound significance for relevant professionals or leadership to prepare for future work. IV. Conclusion: The application of the PIMS production information management system in a petrochemical production management system project is a successful case of combining the PIMS system with the production control system. It played a significant role in the company's informatization construction, reduced labor intensity, improved the speed of information flow, and generated good economic benefits. About the Author: Gao Chunguang, born in 1966, male, from Daqing City, Heilongjiang Province, graduated from the Department of Computer Science, Harbin Shipbuilding Institute in 1989 with a bachelor's degree in Computer Applications. He is an engineer, engaged in professional technical work in automation instrumentation and software development, and has published 4 papers. Mailing address: Zhejiang Supcon Technology Co., Ltd., No. 309, Liuhe Road, Binjiang District, Hangzhou, Zhejiang Province, China. Postcode: 310053. Tel: 0571-86667251, 13858098061. Email: [email protected]. References [1] Roger SP, Software Engineering - Research Methods for Practitioners, Machinery Industry Press, 1999. [2] Ma Guohua, Monitoring Configuration Software and Its Application, Tsinghua University Press, 2001. [3] Zhang Chenyan, Characteristics and Transaction Processing of Real-Time Database Systems, Instrumentation, No. 4, 2001. [4] International General Management Standards - Production Management System, Peking University Press, 2003. [5] Shao Yusen, Process Control and Instrumentation, Shanghai Jiaotong University Press, 1995.