GS Caltex Completes Major Turnaround at Yeosu Plant Using Digital and AI Technologies

Turnaround Maintenance on Nine Processes with an Investment of 200 Billion Won
Enhanced Work Efficiency and Safety Based on DAX Strategy

GS Caltex announced on July 16 that it has successfully completed its major turnaround maintenance (TA) for the first half of this year at the Yeosu refinery.

GS Caltex Yeosu Refinery Mid-Year Major Maintenance Site. GS Caltex

TA refers to a large-scale, scheduled maintenance operation in which the operations of oil refining and petrochemical plants are halted and major production facilities are thoroughly inspected. This process involves servicing equipment and replacing aging or worn parts to create a foundation for safe and efficient plant operations.

Beginning in May, GS Caltex carried out the first half turnaround maintenance on a total of nine different processes over approximately 60 days. The operation involved a budget of around 200 billion won and an average of about 3,000 personnel per day.

Notably, a variety of digital and AI solutions based on the company's Digital & Artificial Intelligence Transformation (DAX) strategy were applied to this TA. Through these technologies, GS Caltex enhanced both efficiency and safety throughout the entire TA process, from planning to on-site operations and safety management.

The incorporation of digital and AI technologies in traditional manufacturing industries such as oil refining and petrochemicals is viewed not simply as technological adoption, but as a transformation that fundamentally changes operational methods and competitiveness.

MOV (Motor Operated Valve), which are valves operated by electric motors, require periodic inspection. However, because there are a large number of them randomly distributed across all processes, identifying their locations is very time-consuming. To manage this, GS Caltex developed the 'MOVision' app, utilizing Google Earth and 3D modeling. The app marks the location of each MOV on Google Earth and provides detailed information through 3D models, significantly accelerating inspection speed. It also changes color when work is complete, giving clear visibility to remaining tasks.

Certain tubes inside heaters have structural characteristics that make cleaning difficult, which can lead to decreased heat efficiency due to foreign substance buildup. To address this issue, GS Caltex introduced a tube cleaning robot. By using the robot, previously inaccessible areas can be precisely cleaned, which is expected to improve heat efficiency and reduce fuel consumption.

Additionally, the company advanced its safety management system at the TA site by adopting AI-embedded CCTV capable of detecting multiple risk factors. This system simultaneously and in real time monitors various hazards, such as whether workers are wearing protective equipment, using safety hooks, and the approach of heavy machinery, enabling more effective management of high-risk work zones.

GS Caltex Vice Chairman Heo Sehong stated, "This TA is a meaningful example where on-site expertise and digital–AI technologies have come together to enhance both efficiency and safety. Moving forward, we will continue to accelerate innovation in manufacturing operations based on our DAX strategy and strive to secure future competitiveness."

This content was produced with the assistance of AI translation services.