Honeywell, TotalEnergies Pilot AI Assistant at Port Arthur: Faster Calls in the Control Room
Honeywell and TotalEnergies are running an AI-assisted pilot at the Port Arthur Refinery in Texas. The Experion Operations Assistant brings predictive insights into the control room so operators can act sooner, cut risk, and keep units running within targets.
What's Being Tested
The assistant runs on Honeywell's Experion distributed control system and blends operational analytics with real-time predictions. The goal is straightforward: give operators early notice of abnormal conditions, guide corrective actions, and reduce production losses and unsafe states.
"Partnering with Honeywell at our Port Arthur Refinery represents an important step in our journey toward operational excellence across our facility," said Raphael Duflos, VP and General Manager of TotalEnergies' Port Arthur Platform. "We believe this solution could contribute to safer operations, reduced downtime, and minimized product losses."
Early Results from the Delayed Coking Unit (DCU)
TotalEnergies has piloted the assistant on the DCU. The system forecasted five potential events and flagged them an average of 12 minutes before an alarm would have fired. That buffer gave the team time to respond, avoid unplanned downtime, and cut flaring-related emissions.
Why This Matters for Operations Leaders
- From alarms to foresight: Early warnings let teams intervene before alarms cascade. This reduces alarm floods and stabilizes operations.
- Safer, steadier runs: Predictive cues help operators stay within safe operating envelopes and avoid trips that ripple across upstream/downstream units.
- Less flaring, fewer losses: Avoided upsets mean lower emissions and tighter loss control-useful for ESG reporting and permit compliance.
- Faster decisions, consistent responses: Guidance in the console standardizes actions and preserves know-how across shifts.
- Operator autonomy: The assistant supports judgment in the room; it doesn't replace it. This builds trust and adoption.
Implementation Notes (What to Get Right)
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