Gas turbines, known as the "crown jewel" of the equipment manufacturing industry, are not only the heart of the energy system, but also the core power equipment of aircraft, ships and military systems, representing the most high-end technology in the field of global equipment manufacturing.
Figure 1: ENN Power E2100 megawatt gas turbine product
However, for a long time, gas turbine technology has been monopolized and tightly sealed by developed countries for a long time, and even if it has the ability to develop gas turbines, Europe and the United States will still adopt lower import prices of disposable equipment and raise the prices of later services such as spare parts and maintenance to gain competitive advantages.
01 Innovation path breakthrough "stuck neck technology"
Breaking through the gas turbine neck technology, China began to try as early as the beginning of the 21st century, but the radical technical route directly benchmarked the most advanced foreign products at that time, and a link jammed means that the previous efforts were lost.
As a pioneer in the clean energy industry, ENN Group started the research of micro and small gas turbines in 2012, and by 2013, ENN Energy Power Technology (Shanghai) Co., Ltd. (affiliated to ENN Group) was officially established in Shanghai, hereinafter referred to as "ENN Power". After ten years of development,ENN Power is the only micro and small gas turbine enterprise in China that is actively developing micro and small gas turbinesThe self-developed 100 kilowatts and megawatts micro and small gas turbines have been successfully put into use in industrial scenarios such as oilfields, ceramics, and textiles, helping enterprises solve energy pain points, save energy and reduce consumption, and reduce carbon emissions.And the core machine components have been 100% localized.
Figure 2: Core components of ENN Power gas turbines
After ten years of development, ENN Power has "passed the breakthrough stage of 'from scratch'", in the context of the digital age, ENN Power Head of Strategy and Digitalization Hu Hao said,"Next, we will make every effort to polish and polish the final gas turbine products, which requires us to fully focus on customer demand orientation for strategic transformation. ”
02 Digital comprehensive empowerment strategy transformation
The customer-oriented strategy means two things for ENN Power:
First: the combination of internal automation and digitalization, with the concept of lean production to achieve intelligent manufacturing.
Second: Combine external remote monitoring with unattended to achieve intelligent services driven by data.
Figure 3: ENN Power Gas Turbine Production Workshop
Why should we start from these two aspects, Hu Hao also gave an explanation for this: "As a high-end equipment, compared with the product price, users are more concerned about whether the quality is excellent, in order to win the trust of customers,New OlympicsPowerIt is necessary to do a good job in the construction of a quality management system for the whole life cycle of gas turbines, and at the same time use the ability of IoT to remotely monitor the operation of gas turbines，It is almost impossible without the support of digitalization. ”
In fact, from the perspective of the characteristics of the gas turbine equipment manufacturing industry, we can also have some insights:
On the one hand, the production and delivery cycle of a gas turbine is about 3 months, involving more than 100 production documents.It is difficult to synchronize the adjustment of front-end R&D design with back-end manufacturing accurately and in real time.
On the other hand, with the extension of the operating time of gas units, the maintenance volume is showing an increasing trend, and the demand for spare parts will also increase year by year.Tens of thousands of parts of gas turbines, how to quickly and accurately trace and locate the source of problems, is also a big challenge.
03 New Nuclear Cloud MES Breakthrough: Build a gas turbine quality resume
The quality management of the whole life cycle of ENN Power micro gas turbines mainly revolves around project quality management, including product research and development quality, supplier quality, manufacturing process quality and product operation quality. After nearly 100 meetings and discussions and multi-faceted verification of theory and practice,The New Nuclear Cloud team believes that the top priority is to connect the core process data and form a quality history to realize the traceability of the entire product development process and key parts of the equipment (turbine, compressor, rotor, combustion chamber)., initially achieve the goal of total quality management!
Figure 4: ENN Power's digital transformation goals
Step1: Multi-system integration and platform-based management
Before the introduction of the new core cloud MES, ENN had deployed a digital system for process nodes such as CRM, PLM, ERP, and TDM (test data management system). However, the whole process has not yet been linked, and the association between project orders and production orders, production orders and production orders is missing.MES is urgently needed to connect IT and OT, connect the top and bottom, and integrate operation and production data.
Figure 5: New Core Cloud Multi-System Integration Solution
The new nuclear cloud is implementedMES and multi-system integrated solutionsAll gas turbine production and other production tasks of ENN Power will be uniformly distributed through the digital system integration platform, and all production process data will be recorded in real time to achieve production transparency. The production project of a single equipment lasting three months effectively establishes a comprehensive project management system through platform management, closed-loop management, and information collaboration from the R&D and design end to the production and manufacturing end to effectively respond to customer demand changes, and the workshop production capacity has increased from the original 35-40 units per month to more than 50 units, a significant increase of 25%.
Figure 6: Visual management of workshop signage
Step2: SN serial number management to build a quality control system for the whole process of production
The SN (serial number) solution given by New Core Cloud runs through the whole process of procurement of incoming materials, production process (machining, core machine/complete machine assembly, testing process), and delivery.
First of all, the materials (purchased parts) managed by SN are enabled in the procurement process, and the SN serial number is generated when the outsourcing is entered into the warehouse, and the SN is printed out of the QR code, pasted on the material, and the quality department conducts inspection, issues an inspection report, and transmits it to ERP.
Figure 7: SN serial number management
Secondly, the production process data is also synchronized with ERP, ERP transmits the production task to MES through the interface, the MES system initiates the picking/returning task, and the ERP executes the delivery of materials with SN information in and out of the warehouse to the MES line side warehouse; the final inspection personnel need to upload the inspection report to the MES system, and the process specification significantly reduces the production line repair task by 40%, and the one-time pass rate of the product increases from 63% to 86%. In the assembly process of the whole machine, the key parts binding scheme is applied, the SN association binding is carried out for the key parts, the finished product is assembled and the SN code is posted, and the relevant binding relationship is recorded.
Figure 8: PDA device scans SN code to report work
In the whole machine testing process, through the TDM system test data and MES integration, the completion report is finished for testing, and the MES system outputs the final inspection report of the whole machine. Finally, when the gas turbine equipment is produced off the production line, the binding relationship between the serial number and the factory code is carried out in the MES system through the formulation of the factory code and the SN serial number management, so as to facilitate the query and quality traceability during later after-sales maintenance.
Figure 9: Batch export of abnormal information
Step3: IOT technology is equipped with Internet of Things monitoring for gas turbines
By building an IOT IoT system, the equipment delivered to the customer realizes the Internet of Things through the IOT system, collects the operation data of the gas turbine turbine and its ancillary equipment, and when the gas turbine sends out an abnormal signal of the equipment, the abnormal information will be returned, the abnormal situation will be understood in time, and the follow-up solutions will be arranged, so as to realize the centralized control center, APP, WEB, and PC data sharing, and grasp the operation status of the equipment in real time, and at the same time effectively monitor the operation status of each energy station with the gas turbine as the core, such as production capacity, energy efficiency and other data, to avoid large deviations in the operating state, and to carry out status warning, fault handling, and ensure the safe operation of the equipment in a timely manner during operation.
Figure 10: Platform-based control of equipment IoT IOT system
Step4: Inquire about information products anytime and anywhere through the gas turbine resume
Through serial number management, enter the factory code of the whole machine or its internal serial number to efficiently query the information of the key parts of the gas turbine, quality information, abnormal information in the production process and abnormal after-sales service, etc., quickly query the production process of the whole machine or its core components, realize quality traceability, provide accurate data support for the review and review of quality problems, and help ENN Power initially build the goal of total quality management.
Figure 11: Resume of the whole life cycle of the gas turbine
Today, the digital achievements of ENN Power empowered by the new nuclear cloud have been replicated from the Langfang factory to the Shanghai factory, helping the unified management and operation of the two places to continuously improve the overall quality management level of gas turbines. Relying on the digital platform, ENN Power will continue to focus on the field of gas turbines, focusing on the needs of different industries for energy conservation, emission reduction and carbon reduction, and focusing on both technical and quality to provide customers with stable, reliable, technical, and economical micro and small gas turbine products and solutions.
