AI tool boosts safety & efficiency at TotalEnergies Port Arthur
Honeywell has deployed an artificial intelligence (AI) assisted control room tool at TotalEnergies' Port Arthur refinery in Texas, offering new predictive and decision-support capabilities for plant operators. The system, Experion Operations Assistant, is designed to identify emerging operational issues before they become critical, giving staff more time to respond and reduce risks such as downtime and emissions events.
AI-backed operations
TotalEnergies has piloted the Experion Operations Assistant within its Delayed Coking Unit (DCU), integrating the AI-powered technology with its control systems. Early findings from the site have shown the solution predicted five operational events, with alerts generated, on average, twelve minutes before a conventional alarm would have triggered. These advance warnings allowed operators to initiate corrective actions, reducing periods of flaring and other disruptions.
By generating guidance for operators in addition to standard notifications, the system aims to accelerate operators' insight and expertise. This is particularly relevant as the manufacturing and energy sectors face workforce shortages and increased demands to reshore operations and modernise infrastructure.
Operator empowerment
TotalEnergies stated the collaboration marks a significant step towards enhancing plant safety and productivity. The solution is intended to help meet the company's operational excellence standards across its platform.
"Partnering with Honeywell at our Port Arthur Refinery represents an important step in our journey toward operational excellence across our facility. We believe this solution could contribute to safer operations, reduced downtime, and minimized product losses," said Raphael Duflos, VP and General Manager of TotalEnergies' Port Arthur Platform.
Broader industry trends
The adoption reflects a wider trend among European manufacturers and energy companies, many of which contend with skills gaps due to demographic changes and recruitment challenges. AI-assisted tools are seen as a means to equip less-experienced employees with insights typically held by more seasoned personnel.
Honeywell is also collaborating with companies including Chevron, ADNOC and Borouge on similar AI implementations, signalling increased momentum for automation technologies in the sector.
Technology integration
The Experion Operations Assistant operates alongside Honeywell's distributed control system. The deployment combines machine learning analytics with plant data, enabling a real-time view of asset conditions and supporting both predictions and prescriptive recommendations.
By linking predictive insights with operator guidance, the tool aims to lower the barrier to effective plant oversight, regardless of tenure or previous experience.
Collaborative development
The project at Port Arthur involved input from TotalEnergies' local platform, its technology headquarters branch OneTech, and Honeywell. The refinery processes crude oil for transport fuels and petrochemical products.
"Honeywell's decades of domain expertise and industry knowledge are helping to solve our customers' toughest challenges with tangible solutions like Experion Operations Assistant. This pilot with TotalEnergies will mark a meaningful milestone for bridging the gap between autonomous technology and the operators that keep these facilities running safely and efficiently every day," said Jim Masso, President and CEO of Honeywell Process Solutions.
