We encounter digitalization and technology in just about every part of our society, and there are few industries that have not been transformed through modernization and improved connectivity.
The refining industry is no exception, but there is no denying that the adoption of technology has been inconsistent, with many well-established plants exhibiting reluctance to or difficulty accepting such significant change. However, even the most traditional refinery plants will soon have no other option but to embrace a digital transformation.
This article explores how digitalization and technology are changing the refinery industry for the better and the potential barriers to digitalization.
Artificial Intelligence
Artificial Intelligence (or AI as it is often shortened) can drastically improve the efficiency of a refinery plant. If it can be integrated into the infrastructure and any existing technologies, AI, predictive learning, and expert process controls can potentially automate the lowest-risk processes. Automation, when used correctly, improves efficiency and removes the element of human error, leading to increased margins. However, the issue with AI is that it can be expensive and complicated to introduce into well-established plants, and a high level of organizational preparation is required.
Project management software
To ensure that a refinery plant operates as efficiently and safely as possible, sometimes Shutdowns, Turnarounds, and Outages (STOs) are necessary. When a plant is not operating, it is losing money, so it is important that the maintenance or repairs are carried out as quickly, safely, and thoroughly as they can be. This can present a problem when plants are relying on manual processes. Today, this is no longer necessary as digital software platforms are specifically designed to streamline these projects to save plants both time and money. The improvements in workflow, project visibility, data analysis, and implementation bring results for your staff, third-party contractors, and project managers.
Robotics
Robotics are used in a wide variety of ways as they can be integrated into existing technology or infrastructure. Robotics can remove a lot of risks involved in working in a refinery and can significantly improve the efficiency and accuracy of what used to be manual procedures. Robots can either take the place of a human staff or work alongside them.
Site interconnectivity
Refinery plants are big sites, and maintaining effective communication between staff spread all over can be difficult. Technology like GPS tracking systems and digital mapping software can help workers monitor other teams’ work and identify and alert others to problems. This can improve the safety, efficiency, and productivity of the site.
What are the potential barriers to digitalization?
While it is clear that there are many benefits to embracing technology and digitalization in the refinery industry, there are still barriers and obstacles to overcome.
The plant’s willingness or capacity to develop
If the plant is not particularly digitally developed, the staff is not used to working with other teams, and/or the leadership is not inclined to embrace technology, then it can be difficult to integrate into the operation. The World Economic Forum addresses the topic in their article: ‘Why do people resist new technologies?’.
The skill level of the workforce
If workers are not skilled or comfortable using technology, this can prevent successful integration. Any new technology and digital processes introduced into the operation must be accompanied by relevant training and support. Plants need to be forward-thinking and modern to attract talented apprentices and engineers who will support the digitalization process. It is also beneficial for plants to hire employees with skills in data analysis, Artificial Intelligence, and machine risk officers.
The age of the site
The oldest plants found in North America and Europe are more difficult and time-consuming to modernize, as their traditional systems are so well-established. This might include installing independent integration systems, but the positive impact on both margins and overall resilience is worth the effort. Plants that were built more recently, such as those in Asia and the Middle East (and, of course, sites that are being newly built) are significantly easier to digitalize.
Cybersecurity
Digitalization and connectivity are not without risk, as cybercrime poses a very real threat. A wireless network that enables different parts of the site to communicate could enable cybercriminals to intercept or corrupt sensitive data. It is also important that communication signals are reliable and strong, as malfunctions could lead to serious incidents or errors. With any digital transformation, organizations need to ensure their employees are trained in cybersecurity and able to spot potentially harmful cyberattacks. Tools like a zero trust security model verify user permissions, so they are vetted when they log in. It renders a traditional perimeter security model obsolete. Click here for more information on cyberattacks.
