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