Post on 14-Mar-2021
Digital Transformation Accelerates Energy Efficiency at
Chevron OroniteSivarajan 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