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China’s First "Intelligent Factory" for Offshore Oil and Gas Equipment Manufacturing Successfully Put into Operation

Release date:2023-04-04    
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  •   On June 26, the reporter learned from Offshore Oil Engineering Co., Ltd. (hereinafter referred to as "COOEC"), an enterprise in Tianjin Port Free Trade Zone, that China's first "intelligent factory" for offshore oil and gas equipment manufacturing located in the port area of Free Trade Zone - the intelligent manufacturing base of COOEC Tianjin was officially put into production, marking a major breakthrough in the intelligent transformation of China's offshore oil and gas equipment industry.


      The "Intelligent Factory" has a total area of about 575,000 square meters, with core facilities including three intelligent production centers, seven auxiliary workshops and eight assembly stations, a design capacity of 84,000 structural tons per year, as well as a high-quality wharf with a total length of 1,631 meters, suitable for large offshore vessels and FPSOs to dock. In the future, the Base will concentrate on developing high-end offshore products such as oil and gas production platforms and upper modules, FPSO modules and liquefied natural gas (LNG) modules, and build a comprehensive base integrating functions such as intelligent manufacturing of offshore engineering, intelligent guarantee of oil and gas field operation and maintenance, as well as R&D platform for original innovation of offshore technology. According to Yu Yi, Chairman of CNOOC, as a demonstration base for digital transformation of central enterprises, CNOOC Tianjin Intelligent Manufacturing Base has applied extensive advanced technologies such as 5G, industrial big data and artificial intelligence. By analyzing and summarizing the technologies and experiences of the enterprise in project planning, production organization and workshop execution in large engineering structures over the years, it has realized the intelligence of the overall process from project control, workshop construction to plant management, provided the offshore oil and gas equipment industry with a digital intelligent operation and management model that can be replicated and promoted, and facilitated the active transformation of enterprise operation and management to digitalization.


      Lean Integration Technological Application


      The "intelligent factory" mainly includes the production system based on flat segmentation production line, process pipeline production line and automatic three-dimensional warehouse, as well as the software management system based on digital intelligent manufacturing management system, production execution system and warehouse management system, the site support system based on information collection system, intelligent security system and kinetic energy monitoring system, and the workshop production logistics and material distribution system, etc. With the application of intelligent manufacturing technology and refined integration of various systems, vigorous momentum has been injected to drive the marine equipment manufacturing from traditional "manpower factory" to modernized "intelligent factory".


      Cost Reduction and Efficiency Improvement Safety Assurance


      In addition, the "intelligent factory" has applied over 400 sets of advanced intelligent production equipment including automatic cutting, automatic grinding, intelligent grouping, intelligent welding and intelligent storage, thereby realizing the intelligence of the workshop prefabrication process from material admission to scribing, grouping, grinding and welding, with the automatic cutting rate of 90% for plates and the automatic welding rate of 70% for deck pieces, so that the overall production efficiency has been improved by more than 20% compared with the traditional mode, and the cost control and quality and safety management level has been greatly enhanced. "The 'Intelligent factory' has not only significantly reduced labor input, but also controlled the output process parameters through intelligent equipment to avoid hidden quality hazards arising from human factors and enhance the process while safeguarding the construction safety of personnel.” Geng Xiaomin, Senior Technician of Structural Prefabrication Workshop of CNOOC Tianjin Construction Branch, said.


      Filling the Gaps and Breaking the Bottlenecks


      It is learned that the traditional offshore oil and gas equipment manufacturing falls into the labor-intensive industry, featuring multiple product types, long manufacturing processes, a large proportion of customization, low standardization and other significant factors, and the data fragmentation of each production link is a serious problem, making it extremely difficult to achieve digital intelligence, thereby becoming an important bottleneck that restricts the quality and efficiency of the industry. To this end, CNOOC has established a core technology team of more than 200 members, and coordinated domestic and foreign high-quality resources with the renowned domestic universities and scientific research institutions to overcome key technical problems in intelligent manufacturing such as intelligent scheduling, intelligent positioning grouping, automatic cutting and welding as well as intelligent storage, and innovated and applied 10 domestic "industry first" advanced technologies such as "large-scale robotic welding of offshore oil and gas equipment" so as to realize digitalization of offshore oil and gas equipment manufacturing process management, production task work order, automation of production equipment and visualization of production process, and filled many technical gaps in the field of digitalization and intelligent manufacturing of offshore oil and gas equipment in China.


      The commissioning of the intelligent manufacturing base of CNOOC Tianjin marked an important milestone in recent years for CNOOC to actively implement the new energy security strategy of "Four Revolutions and One Cooperation" and accelerate the digital transformation and green low-carbon development. As a next step, CNOOC will closely concentrate on the overall development idea of "1534", continue to strengthen original and leading scientific and technological research, vigorously improve the manufacturing capacity of offshore oil and gas equipment, firmly seize the equipment manufacturing by itself, and endeavor to contribute to the high-quality development of offshore equipment industry in Tianjin Port Free Trade Zone and even Tianjin, and spare no efforts to build a strong engine for marine science and technology in China to achieve a high level of self-reliance and self-improvement, guarantee national energy security and build a strong ocean power.


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