Mobile Inspector: A Mobile Solution for Real-Time Equipment Monitoring

From Paper Logs to Digital Control

Ensuring industrial safety at large chemical plants requires continuous monitoring of equipment condition. Traditional inspection methods using paper logs leave room for human error: the risk of missing critical control points, delayed transmission of defect information, and difficulties with analytics. The implementation of digital tools is becoming a natural stage in the development of production risk management systems.

During the webinar, Maksim Romashkin, Chief Specialist of the Production Control Group at Acron PJSC, shares his experience in implementing the "Mobile Inspector" system. The speaker details the transition process from manual route creation to an automated control system that allows for the prompt identification and elimination of equipment defects at fire and explosion hazardous facilities.

Architecture and Functionality of the "Mobile Inspector" System

The system is a complex of software and hardware (explosion-proof smartphones, NFC tags) integrated with the corporate maintenance and repair (M&R) system. The speaker uses an example to show how the workflow is structured:

• Task Planning: The shift supervisor creates an inspection route in the system, specifying a particular assignee and time. This personalizes responsibility and eliminates the possibility of starting work without a clear task.
• Executing the Inspection: The operator receives the task on a mobile device. During the round, they scan NFC tags on the equipment, confirming their presence, and fill out checklists (up to 7 questions on the condition of insulation, instrumentation and controls, and valves).
• Defect Recording: If a malfunction is detected, the worker records it in the app, attaching a photo, video, or audio. This gives maintenance personnel a clear picture of the problem before going to the site.
• Data Processing: After completing the round, the data is transmitted to the server (the system allows offline work, synchronizing when a connection is available). The shift supervisor verifies the defects, assigns them an urgency category ("normal", "for shutdown", "emergency"), and transfers them to the M&R system.

Integration with Maintenance Services and Analytics

The key value of the "Mobile Inspector" is not just recording defects, but accelerating their resolution. The presentation details the interaction process between operating and maintenance personnel. Daily at operational meetings, maintenance engineers review identified defects, assign executors, and monitor deadlines (for example, a resolution period of up to 7 days is set for "normal" defects).

To monitor the effectiveness of the system itself, BI (Business Intelligence) analytics are used. Summary dashboards allow management and the production control service to see the completeness of inspections, the number of unread tags, and defect statistics by department and shift. Color-coded deviation indicators help to quickly respond to violations of the inspection regulations.

What you will learn from this webinar:

• How to organize control over the execution of equipment inspection routes using NFC tags?
• How to build a process for transferring defect information from the operator to the maintenance service without paperwork?
• What urgency categories are assigned to defects and how does this affect maintenance planning?
• How to use BI systems to analyze inspection discipline and equipment failure statistics?
• What are the requirements for mobile devices operating in fire and explosion hazardous facilities?