#8 2025

CONTENTS №8

Discussing a Topic…

Automated enterprise production and asset management systems

Molchanov A.Yu.  Automation of activity planning in EAM systems

Enterprise asset management is relevant for industrial enterprises. The task is addressed with the help of EAM systems. In important issue in asset management is the planning of activities for maintaining the assets in due condition. The paper describes the key entities used in activity planning process, as well as various aspects of its implementation in information systems.

Keywords: EAM management, EAM, information systems, work planning.

Slastenov I.V., Kushnikov V.A.  Predicting reliability characteristics in oil refining

The paper offers an approach to the prediction of time variations of process unit reliability characteristics in oil refining industry. Ensuring the reliability of oil refining units is a paramount task of process efficiency and safety improvement. Equipment reliability affects process uptime and refinery benefits, as well as overall environmental and industrial safety. In this context, the need increases for scientifically based methods for the analysis and prediction of reliability characteristic dynamics considering their time dependence under various factors. System dynamics, as a modeling tool for complex technical and production systems, allows for cause-and-effect relationships between system elements, as well as time delays, feedbacks, and nonlinearities typical for the processes of equipment performance degradation and recovery. The developed model is applied for selecting the optimal control impacts ensuring the attainment of reliability targets. The results obtained can be used for improving reliability analysis and optimization tools, as well as for integration into process and maintenance decision support systems.

Keywords: system dynamics, process reliability, oil refinery, process unit.

Gurko A.V.  Improving safety system performance based on MES concepts

ESM (Electronika Security Manager) is the new domestic safety system of PSIM (Physical Security Information Management) class, it implements MES approaches. The paper compares the development vectors of PSIM and MES. It shows that conventional safety systems do not perform the key MES function of data acquisition and analysis for loss detection. On implementing this function in ESM, the developers helped the clients in attaining their strategic tasks of production efficiency improvement.

Keywords: PSIM, MES, data acquisition and analysis, loss detection, automation pyramid.

Novikova T.A.  Organizational and technical method for equipment maintenance planning based on real-world statistics

The paper offers an organizational and technical method for planning equipment repair and maintenance of machine-building equipment. The new method is compared to the existing repair and maintenance strategies. Its advantages are illustrated with an application example.

Keywords: organizational and technical method, maintenance and repair, information knowledge model, reliability function, planning.

Nigmatulin A.D., Beketov S.M., Dergachev M.V.  Improving inventory control processes at an enterprise in electronics industry

The paper discusses the approaches to the improvement of an inventory control system at a small-scale electronics factory. Today, the Russian electronics industry has significantly increased the outputs owing to the government support and technology development. However, further growth is impeded by sanctions, which limit the procurement of high-quality electronic components. This increases the workload of employees, responsible for incoming inspection. The discrete-event simulation technique was used for estimating the efficiency of available solutions. Based on the analysis of actual enterprise processes conceptual and simulation as-is models were developed, and and further modified into to-be ones for each improvement approach. Numerical experiments were undertaken for evaluating the effect of changes on warehouse and incoming inspection employees. The approach with APC-analysis has demonstrated the highest efficiency. It enables 11% reduction of employee workload owing to the introduction of simplified inspection of some components. The study results can be used in electronic industry for logistics improvement and integration into decision support systems.

Keywords: inventory control, process improvement, electronics industry, simulation modeling.

Kvas E.S.  A procedure for noise level control and reduction at robotized bottling lines

The paper describes the topical problem of noise reduction at glass bottle filling lines. Significant noise level reduction can be attained by introducing an additional control loop with respect to the predicted maximum weighted sound pressure level. The manipulated variables in this case are the speeds of conveyor drives, wherefore an additional software module can be developed for the master controller, which implements the developed control algorithm. The maximum possible benefits from the novelty can be attained if the technology improvements are underpinned by organizational activities, such as noise source datasheets, regular equipment inspections for finу tuning of noise reduction algorithm parameters, architectural and construction solutions. The procedure was tested at the beverage bottling line with capacity 40 thousand bottles per hour. The application enabled peak noise reduction by average 5.2 dB(A) at the unchanged production rate.

Keywords: robotized bottling lines, noise level control, production, liquid bottling line.

Filatov A.S., Nikolaeva S.V.  Algorithmic conveyor for processing liquid media spectra for automated spectral analytics

The paper discusses the classification of liquid media by spectral data using clustering and dimension reduction techniques. An algorithmic conveyor is offered, which includes preliminary data processing by first-order discrete difference, nonlinear dimension reduction with the help of t-SNE or UMAP with Canberra distance, and the subsequent K-means clustering. Comparative analysis of the combinations of various clustering and dimension reduction on the open sets of IR and Raman spectra was undertaken. The paper shows that the proposed approach enables obtaining high (99.7%) accuracy of spectra classification that significantly exceeds conventional chemometric and machine-learning methods. The first-order discrete difference coupled with Canberra distance is highly effective for improving the sensitivity to local spectral differences. The method proposed is versatile, noise-immune, and easy-to-implement, that makes it promising for automatized spectral analytics in various applications.

Keywords: machine learning, classification, clustering spectral data, liquid media.

Kulikovsky M.A., Pyatetsky V.E., Chumakova E.V., Korneev D.G.  Neural network development for determining optimal process modes of gold-bearing granule dissolution during chemical base metal affinage

The paper discusses the application of artificial intelligence for predicting the results of acid dissolution of gold-bearing granules at the affinage refinery, namely, the weight of insoluble residue, gold content in insoluble residue, and extraction ratio of noble metal to solution. Based on the analysis of the learning sample, the paper examines the process of input parameters selection and neural model training for determining the optimal gold leaching parameters, which ensure maximum noble metal extraction to the solution. Such parameters include S/L ratio, reactor rotation speed, process temperature, and dissolution duration.

Keywords: chemical affinage, neural network modeling, artificial intelligence, gold-bearing granule dissolution process.

Kirillova E.V., Bobkov V.I., Labuzov V.V.  Investigating the characteristics of electrochemical transducer for detecting unsymmetrical dimethylhydrazine

The paper presents an electrochemical transducer developed for detecting the content of rocket propellant components in the working area air. The transducer structure with an open-type electrode structure ensures the necessary sensitivity to the measurand and significantly reduces the sample processing time. The transducer’s key characteristics were investigated, its applicability within a gas analyzer for continuous automatic control of the weight content of unsymmetrical dimethylhydrazine vapor at the maximum concentration limit in the working area air was confirmed. The transducer’s sensitivity to dimethylhydrazine was studied, its possible additional application for atmospheric dimethylhydrazine emissions was examined.

Keywords: electrochemical transducer, rocket propellant components, unsymmetrical dimethylhydrazine, hydrazine hydrate.

Fedyaev A.A., Grigorieva T.A., Ulianov A.D.  Controlling heat carrier’s dynamic behavior during lumber drying

The paper discusses the control of heat carrier’s dynamic behavior during lumber drying in convection drying chambers. The focus is made on the stabilization and optimization of thermodynamic parameters, which determine the drying efficiency and the finished product quality. The research results are presented, which demonstrate the effect of negative influence of uneven profiles of velocity and temperature in the drying kiln on the dry material quality and process duration. The application of Profile software suite makes it possible to capture and analyze the dynamics of process parameter changes in the drying chamber workspace and make timely corrections of process settings. The paper finally describes the developed and tested automation system, which includes simulation models and analytical software enabling on-line evaluation of process conditions and optimal tuning of drying mode.

Keywords: automatic control, velocity profiles, operating chamber, drying process automation, heat carrier, lumber.

Grigoriev M.S., Maslova K.A.  Revealing the ways for the modernization of HMI of Leningrad A-plant #2 control center by means of expert judgment

A series of polls of process operators at Leningrad A-plant #2 were undertaken for revealing control center problems based on commissioning and operation experience. The expert judgements and comments were analyzed. For the flaws detected, possible ways of HMI modernization were outlined, the facts along with underlying the human-factor-related issues determined to be allowed for during future design of power units.

Keywords: power unit’s control center, video frame, modernization, questionnaire, alarm system, HMI, expeert judgment.

Journal’s Club

1C:TOIR CORP with 1С:ITILIUM: from manual accounting to predictable and controllable service

Aerodynamica airport group has implemented a project on end-to-end integration of 1C:TOIR CORP and 1С:ITILIUM systems developed by Desnol. This has changed the infrastructure control processes at Sochi airport. The project resulted in the combination of a EAM system with IT Service Management into a unified ecosystem. Now, all employee requests come automatically to right services, and all asset, maintenance, and cost data are collected with a single click. The transfer from manual accounting to the predictable and controllable service has been performed successfully.

Keywords: airport, digital ecosystem, maintenance and repair, import independence, service for IT support of employees.