Digital Transformation Accelerates Energy Efficiency at Chevron Oronite Sivarajan Sankaran, IoT & Projects Lead, Chevron Oronite, Singapore Jonas Berge, Senior Director Applied Technology, Emerson Automation Solutions, Singapore
Chevron Oronite Singapore • Fuel and lubricant additives • Commissioned in 1999 • Located on the Jurong Island chemical hub
Energy Efficiency: Steam Trap Monitoring • Challenge • Failure cause steam losses • Inefficient heat transfer, requiring more steam, may lead to process upsets • Water hammer damage piping and flanges • Yearly steam trap surveys are too infrequent • Solution • On-premises steam trap monitoring sensors and analytics • Result: • Reduced steam losses
Energy Efficiency: Energy Management Analytics • Challenge • Lack of Energy Monitoring Dashboard may lead to inefficiency and high energy costs • Solution • Steam consumption monitoring at unit level • Analytics from historian • Result • Ability to pinpoint overconsumption to troubleshoot effectively
Safety: Access Control and Rescue Locating • Challenge • Manual paper-based sign-in / sign-out is disruptive to operators • Physical fencing would hinder evacuation • People may stray outside assigned areas • Locating man-down requires large search party • Hard to manage contractors during high risk activities such as start-up and shut-down • Solution • Real Time Locating System (RTLS) • Result • Faster locating of missing persons • Smaller search party • Effective geofencing • Good control of plant access • Increased contractor productivity
Reliability: Pump and Compressor Monitoring • Challenge: • Critical equipment vibration causes production downtime • Manual vibration data is time consuming • Solution • Vibration sensors • Vibration analytics software • Result • Ability to predict failures • Increased reliability • Reduced maintenance cost
Integrity: Corrosion Monitoring • Challenge: • Corrosion may lead to loss of containment • Solution: • Corrosion sensors • Predictive analytics • Result: • Scheduling of pipe section replacement • Help avoid loss of containment
Productivity: Worker Mobility • Challenge • Incomplete and sometimes inaccurate data capture using paper-based operations surveillance • Access to procedures, P&IDs, and maintenance request (SAP ERP) is only available in the control room • Most process and equipment data only in the DCS (control room) • Solution • Tablets using Wi-Fi infrastructure to access work orders, documents, and more • Result • Increased productivity
Summary • Improved energy efficiency • Plant is a safer place to work • Increased reliability • Greater integrity • Improved productivity
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