Transforming Control Rooms with AI in Industrial Automation
Honeywell has partnered with TotalEnergies to pilot the AI-assisted Experion Operations Assistant at the Port Arthur Refinery in Texas, USA. This initiative supports operators in making timely decisions while increasing operational autonomy. By leveraging artificial intelligence, the solution integrates operational analytics with real-time predictive insights, enhancing efficiency in complex refinery operations.
Enhancing Safety and Reducing Downtime
Built on Honeywell’s Experion distributed control system (DCS), the solution enables operators to forecast maintenance events before they occur. Consequently, this predictive capability minimizes risks associated with unsafe operations, reduces downtime, and prevents production losses. As a result, plant efficiency and safety are significantly improved.
Raphael Duflos, VP and General Manager of TotalEnergies’ Port Arthur Platform, stated, “Partnering with Honeywell is a crucial step toward operational excellence. This solution enhances safety, reduces downtime, and minimizes product losses.”
Early Pilot Results Demonstrate Impact
The initial pilot focused on the delayed coking unit (DCU) at Port Arthur. Early results show that the AI system successfully predicted five potential events. On average, the system alerted operators 12 minutes before alarms, allowing corrective actions to prevent disruptions and reduce emissions from flaring. This demonstrates practical benefits for industrial automation and control systems in real operational settings.
Leveraging Honeywell Expertise for Operational Excellence
Jim Masso, President and CEO of Honeywell Process Solutions, emphasized, “Our decades of domain expertise allow us to bridge autonomous technology with operators who maintain facility safety and efficiency.” Honeywell’s expertise in industrial automation, PLC, DCS, and control systems ensures that AI solutions are not only technologically advanced but also practical for real-world plant operations.
Strategic Importance of Port Arthur Platform
Located near the Gulf Coast, the Port Arthur Platform refines crude oil into transportation fuels and produces petrochemicals used in plastics, rubber, and pharmaceuticals. The pilot represents a successful collaboration between Honeywell, TotalEnergies’ operations team, and OneTech, its technology headquarters, showcasing how factory automation and AI integration can create measurable operational benefits.
Author Insight: AI in Industrial Automation
The pilot highlights a key trend: AI integration in control rooms is becoming essential for modern industrial automation. Operators can now rely on predictive insights to make faster decisions. In addition, combining human expertise with AI allows plants to operate more safely and efficiently, bridging traditional PLC/DCS control systems with emerging autonomous technologies.
Application Scenarios
- Predictive Maintenance: Anticipate equipment failures to prevent downtime.
- Operational Safety: Reduce unsafe events with AI-driven alerts.
- Production Optimization: Minimize product losses and flaring emissions.
- Training and Co-Op Programs: Provide operators with hands-on experience using AI-assisted control systems.
- Process Monitoring: Enhance workflow efficiency in complex refinery and petrochemical operations.