GS Caltex, a leader in the energy sector, has successfully concluded a significant 200 billion won (approximately $135 million USD) turnaround at its Yeosu refinery. This extensive maintenance operation showcased the strategic integration of cutting-edge robotics, artificial intelligence (AI), and advanced digital tools, substantially enhancing both safety protocols and operational efficiency.
A turnaround is a critical, large-scale maintenance event where refining and petrochemical facilities temporarily cease operations for thorough inspections of vital production infrastructure. This essential process involves replacing aged components and consumables, forming the bedrock for maintaining safe, reliable, and highly efficient plant operations.
Commencing in May, GS Caltex executed these intensive turnarounds across nine distinct processes, involving a daily deployment of approximately 3,000 skilled personnel.
Notably, this particular turnaround underscored GS Caltex’s commitment to its overarching digital and AI transformation strategies, integrating a diverse array of advanced digital and AI solutions. By thoroughly digitalizing fundamental operational systems, these innovative technologies are poised to revolutionize workplace practices and significantly boost the company’s overall competitiveness within the industry.
One significant challenge in maintaining electric motor-operated valves, despite their critical need for regular upkeep, has been the difficulty in pinpointing their exact locations due to their vast number and extensive distribution across the facility.
To efficiently tackle this, GS Caltex innovated and developed “MOVision,” a proprietary application. Leveraging Google Earth and sophisticated 3D modeling, MOVision dramatically accelerates the valve location search process and visually indicates completed maintenance operations through intuitive color changes.
Furthermore, challenges in effectively cleaning heater tubes with their inherently complex structures often led to reduced thermal efficiency. To mitigate this, GS Caltex deployed an advanced tube-cleaning robot, specifically designed to access blind spots and thereby optimize cleaning efficacy, contributing to minimized fuel usage and enhanced operational output.
In a significant stride towards enhancing safety, GS Caltex seamlessly integrated AI-powered CCTVs into its turnaround safety management systems. These intelligent cameras provide real-time detection of various potential risk factors, such as verifying staff members are wearing appropriate protective gear and identifying instances where personnel approach heavy equipment, thereby significantly boosting the efficiency and responsiveness of on-site safety management.
“Our latest turnaround successfully fuses invaluable on-site expertise with cutting-edge digital and AI technologies, leading to significant advancements in both efficiency and safety,” stated Hur Sae-hong, Vice Chairman of GS Caltex. He added, “We are steadfast in our commitment to continually innovate the manufacturing sector, guided by our robust DAX (Digital and AI Transformation) strategies.”
