Repost: A Brief Discussion on the Application of 3D Digital Factory Technology in Refineries

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A Brief Discussion on the Application of 3D Digital Factory Technology in Refineries Fu Qiang, Pang Yanli, Wei Wei, Yao Peidong (Changqing Petrochemical Branch, China National Petroleum Corporation) Abstract: The 3D digital factory serves as the foundation for smart factories. As the most representative industry in the process industry, the refining sector is at the forefront of the application of 3D digital factory technology. This article introduces the use of this technology in refineries, covering its development background, current status, characteristics and application directions, as well as the effects of its application. Keywords: 3D digitization ； Security domain ； Management domains: With the continuous progress of science and technology, it took humans nearly 200 years to transition from an agricultural civilization to an industrial one. We are now in a period marked by the outbreak of a new industrial revolution characterized by intelligence; the Germans have proposed \"Industry 4.0\", while we have put forward concepts such as \"intelligent manufacturing\". The carrier platform for intelligence in the process industry, what we commonly refer to as the \"skeleton,\" is the 3D digital factory platform. 1. Current development status of 3D digital factories. A 3D digital factory is one that uses advanced 3D digital technologies to transform a physical factory into a digital model, which is then stored on servers. By utilizing the modeled 3D digital factory platform, we can make the model intelligent in order to achieve the desired digital twin outcome. Currently, there are two methods for 3D modeling: one is forward modeling, also known as data import. This method is simple and fast, but it does not offer high precision and it is not possible to reduce the model size according to actual conditions ； Another approach is reverse modeling, which uses scanning technology to create a 3D model as a digital twin at a 1:1 scale. This method requires a longer modeling time, but it offers high precision and good scalability; it is closer to the actual conditions, thus possessing greater practical value. 2. Platform Introduction and Current Development Status There are many popular 3D modeling platforms today, and each of these platforms has its own characteristics. Therefore, when making selections and using them, it is essential to choose based on one’s own actual circumstances. PTC’s pro/E platform in the United States enables the conversion of 2D designs into 3D models, as well as optimizing the design process. The current mainstream CATIA platform emerged in the 1970s; it was developed by the French company Dassault Aviation. The most famous application of this platform is the development of the Mirage 2000 and Rafale fighter jets, but it still has some shortcomings for process industries. For the process industry, the currently popular platform is SeaLINx from the American company INOVx. This platform is designed based on the concept of full hotspots, utilizing internal and external data related to those hotspots, as well as lifetime data from various areas such as enterprise production, equipment, and safety management. Similar software design companies have emerged in our country as well, but most of them still use foreign platforms similar to SeaLINx for development of their core technology systems. 3. Characteristics and application areas of 3D digital factories 3.1 Characteristics The technology of 3D digital factories has many characteristics, which vary depending on the industry in question. For example, in the manufacturing industry, the key aspects are \"high precision, scalability, and networking\", while in the refining industry they are \"optimized production, intelligent operation, and centralized integration\". In the petrochemical industry, 3D digital factory technology enables various intuitive methods for presenting site plans and optimizing measurements. Thanks to the high precision of 3D digital factory models, which can reach the millimeter level, the measurement errors are very small. Using such data to determine material requirements can significantly save budget funds. Using 3D models for technical briefings simultaneously has greatly saved manpower and resources. So the first feature is optimizing production. The smart factory model defines three management domains. The three-dimensional digital factory not only addresses the issues related to system and facility management, thus forming the foundation for building a smart factory, but it also creates a data cloud based on assets, providing 3D models and data services for technical and corporate management. It is therefore the cornerstone of a smart factory; the second characteristic is thus intelligent operation. The 3D digital factory technology for reverse modeling usually involves three steps: scanning, point cloud modeling, and intelligence. The model created in this way only has basic functional capabilities; it can measure and retrieve PID data, but it cannot be utilized to its full potential. Therefore, 3D digital factory models often integrate many production-related systems, enabling the model to become truly \"dynamic.\" For example, by integrating MES data, decision-makers can view real-time production data through the 3D model while sitting in their offices. If maintenance is required, equipment management data can also be accessed via the model, thus facilitating coordinated operation management. So the third feature is centralized integration. 3.2 Scope of Application There are mainly three application areas for 3D digital factories: one is the digital factory that focuses on the full lifecycle management of engineering information, with an emphasis on the collection, correlation, configuration, and change management of such information ； The second type is the digital factory that focuses on the production, operation, and maintenance of factories, emphasizing business support and management in areas such as production management, safety management, and equipment management ； The third type is large-scale 3D models, used for visits and promotion. 4. Application of 3D digital factories in petrochemical enterprises: At present, not many petrochemical enterprises use 3D digital factory platforms. However, those that do utilize such platforms integrate static and dynamic data from areas such as factory production management, equipment management, and safety management around models, thereby enabling 3D digital virtual factories to provide data, models, simulations, and intelligent services for production, equipment, maintenance, and safety management. As an enterprise management platform centered around assets, the 3D digital factory forms the foundation of smart factories. The advancement of this technology lies in its ability to integrate three-dimensional space with dynamic and static data related to all assets, big data technologies, and expert knowledge (artificial intelligence), thereby enabling various management functions within an enterprise to operate in a 3D virtual environment. It provides 3D models, data, and simulation services to support the automation of these management functions, improving the overall efficiency of enterprise management while reducing management costs and security risks. 5. Conclusion: The 3D digital factory is the foundation of intelligent factories and represents a new direction for development. At present, this technology is not widely used in refining enterprises. However, it is believed that as 3D technology matures and the technical bottlenecks faced by refining companies become more severe. Whether it’s management domains, security domains, etc., further improvements are needed. The 3D digital factory platform is a crucial step that cannot be overlooked in the improvement process. In the near future, 3D digital factories will surely become an important \"catalyst\" for technological innovation in the petrochemical industry.