[Report] AI Protects Factories... GS Caltex Evolving Digitally

AI CCTV Detects Intruders and Fires
MFC Integrated Management Platform Established
"DX Driven by Field Team Leadership"

"Intrusion detected. Intrusion detected."

On the morning of the 12th, an alarm suddenly sounded in the emergency response team office at the GS Caltex Yeosu Plant. When the CCTV detected the movement of a person entering the plant, artificial intelligence (AI) alerted with a warning sound.

The GS Caltex emergency response team uses about 200 CCTVs equipped with AI to monitor the plant perimeter, which is twice the size of Yeouido, 24 hours a day. The system detects human movement to identify intruders or immediately sounds an alarm in case of fire. Inside the plant, 655 AI CCTVs are installed, allowing each production team to monitor worker safety in real time. A total of 855 "eyes" watch over the plant day and night.

GS Caltex AI CCTV Utilized for Yeosu Plant Monitoring.
[Photo by GS Caltex]

Since 2022, GS Caltex has been developing technology to detect abnormal situations such as fires and intrusions, applying it to all CCTVs installed in the plant this year. Kim Jong-in, head of the emergency response team, emphasized, "Intrusion detection is specialized for humans, so it can recognize people lying down, crawling, or bending over," adding, "The current detection accuracy reaches 99%."

GS Caltex is accelerating company-wide digital transformation (DX), starting with the Yeosu Plant. Last year, 315.8 billion KRW was invested in the Yeosu Plant's overhaul (TA) to introduce AI and digital technologies. Since equipment management in the refining and petrochemical sectors is directly linked to corporate competitiveness, the goal is to improve equipment management efficiency through digital technology. To this end, an integrated equipment management platform has been introduced to enhance plant operational efficiency.

In the MFC (Mixed Feed Cracker) control room, it was possible to grasp at a glance the real-time integrated management of the entire process. MFC is a COTC (Crude Oil to Chemical) process that directly utilizes by-products from refining to produce petrochemical products such as ethylene and propylene. GS Caltex recently invested 2.7 trillion KRW in this area alone.

GS Caltex reheating furnace virtual sensor and scanning system.
[Photo by GS Caltex]

Ryu Ki-won, head of the MFC production team, explained, "If key process variables such as pressure, temperature, or flow rate go beyond normal ranges, an alarm sounds. The operating supervisors in the control room monitor the situation 24 hours a day, and if action is needed on-site, they communicate via radio to the operators to perform necessary tasks."

GS Caltex is applying digital technology not only to improve production efficiency but also to reduce carbon emissions. A representative example is the ‘Zolo Scanning’ technology, which precisely monitors the inside of the furnace. The furnace is equipment that boils petroleum to extract LPG, naphtha, and other products, and the internal burners must deliver heat uniformly. In the past, skilled workers visually checked the condition, but with Zolo Scanning technology, real-time data analysis contributes to reducing both energy consumption and carbon emissions.

GS Caltex Yeosu National Industrial Complex No. 1 Tenant Company Monument.
[Photo by GS Caltex]

GS Caltex is expanding digital transformation by having all employees, not just a few experts, lead the effort. Through the 'Digital Academy,' internal experts are nurtured, and 'DX Day' events allow employees to directly experience and share various digital technologies.

Kang Jae-min, head of the Digital Innovation Team, said, "In the past, the IT department handled all digital tasks, so the issues of the field were often not well reflected," adding, "We decided that DX should be led by the field itself." He further noted, "This is probably the biggest difference between GS Caltex and other companies attempting DX."

GS Caltex plans to accumulate these DX success cases and pursue certification as a 'Lighthouse Factory' selected by the World Economic Forum (WEF). The company aims to establish digital capabilities at the level of leading DX companies and undergo objective verification. A company official emphasized, "Along with stable growth of existing businesses, we will prepare to leap forward as a 100-year company through 'Deep Transformation' (fundamental innovation)."