CHEVRON ORONITE MODERNIZES PROCESS CONTROL WITH A FOCUS ON DIGITAL ACCELERATION - Case Study - Honeywell Process Solutions
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CHEVRON ORONITE MODERNIZES PROCESS CONTROL WITH A FOCUS ON DIGITAL ACCELERATION. Case Study
OVERVIEW
Chevron Oronite and Honeywell have worked
together to address technology obsolescence
and the need for improved batch automation and
operator effectiveness as they prepare for the future
generation of process automation.
BACKGROUND
Chevron Oronite, a subsidiary of
Chevron Corporation, is a leading
developer, manufacturer and marketer
of lubricant and fuel additives and
chemicals. Its products are designed
to help enhance the performance
and extend the life of many types of
transportation and industrial equipment.
The company’s operations include one
world-class facility in, US, France and
Singapore, as well as some smaller-scale
regional plants.
Chevron Oronite’s US based Oak
Point plant is located in Belle Chasse,
Louisiana, approximately 20 miles south
of New Orleans. As the second largest
Chevron Oronite seeks to manage the lifecycle of its existing automation assets while employing
additives plant in the world, it began new digital technologies.
operation in 1943 to produce diesel
engine additives. The plant is comprised
of a component manufacturing facility, A well-executed strategy for control system migration
captive power generation units, utilities, delivers significant operational and business benefits
and blending & shipping areas.
through seamless integration of new and existing plant
automation assets.
CHALLENGES
Change is not easy for any industrial
organization – especially when it comes
Over the years, Chevron Oronite’s control — Reap
early benefits from new
to process automation. Manufacturers
platform has included a combination technology – adapt some calculated
seeking to improve their control
of Honeywell TotalPlant™ Solution ‘high-risk high-return’ measures
performance, maintain IP need a strong
(TPS) and Experion® PKS systems,
vision and strategy, patience and support, Chevron Oronite required new ways to
Programmable Logic Controllers
and, most of all, ambition. Chevron manage the lifecycle of its automation
(PLCs), wireless systems, integration to
Oronite, has shown that change must be assets, and at the same time, employ
Enterprise Resource Planning (ERP), and
driven with a vision using bottoms up and new digital technologies combined
more. The company’s strategic outlook
top down approach, from management with data- driven insights to transform
on process automation is based on a
and business leaders to plant operators operations, boost agility and enhance
roadmap for meeting its modernization
and field technicians. strategic decision-making. Like other
requirements at its sites in US and
Manufacturers must strive to upgrade Singapore: industrial organizations, it is dealing
traditional platforms and infrastructure with the retirement of experienced
and deploy scalable solutions. An — Modernize
in a low-risk direction using personnel and the training of a new
effective digital transformation strategy is modular approach generation of workers not familiar
all about maximizing the value from these — Ensure
a five-year road map is with legacy Distributed Control
upgrades and leveraging the volumes of established and has the buy-in of all System (DCS) technology.
data generated by modern systems. stakeholdersSOLUTION Chevron Oronite is translating a standalone, class-based, virtualized
As part of a comprehensive control its modernization strategy to a batch system without the need for a
system modernization effort, Chevron digital vision by breaking down efforts separate batch server.
Oronite established a five-year into step-by-step deployments with
Virtualization solutions offered a way
migration plan, undertook one of the clear value propositions:
to preserve and extend investments
first major Honeywell Enhanced High in decades-old DCS technology. The
— Extend
the Experion control
Performance Process Manager (EHPM) project team had the flexibility to
environment
implementations in North America. choose physical or virtual solutions with
Migration activities have included: — Improve
configuration and change
an eye towards reducing overall system
management
“footprint.” Virtualization also improved
— Retaining
Intellectual Property while — Optimize
alarm and operations availability vs. a physical platform and
migrating to Experion PKS management helped to simplify the control system
— Deploying
EHPMs as peer-to-peer — Move
laboratory data into the PHD architecture. The deployment of
nodes with existing C300 and UOC historian for a single source of controllers and traditional LCN Nodes
controllers information for process analysis, in a virtual environment will be the next
— Utilizing
Fault Tolerant Ethernet quick visibility for operators, etc, major undertaking.
(FTE) technology to retain existing — Improve operator effectiveness For Chevron Oronite, an important
functionality and embedded and agility through ASM style part of the modernization program
applications High performance HMI, ProcOps, involved upgrading its current solution
— Integrating
legacy TPS controllers advanced reporting, Golden batch for detecting and averting abnormal
within Experion infrastructure etc. situations, and implementing effective
Chevron Oronite’s planning for a multi- alarm management aligned with
Key to the modernization is ensuring
year control system modernization industry standards, using Honeywell
that different generations of control
program started in 2013. The first DynAMo® alarm and operations
systems can run in the same
phase of the effort – Global User Station management software. This solution
environment with a common, seamless
(GUS) to Experion conversion, Experion helps to address alarm configuration
interface for plant operators. Preserving
Human-Machine Interface (HMI) and problems, eliminate alarm floods that
existing intellectual property is a very
Experion Universal Control Network overwhelm operators, establish an
important aspect of this initiative.
(EUCN) implementation, and historian alarm philosophy for the plant and
upgrades – began in 2014 and ended
in 2017. “Early adoption of new technologies comes with risk, but it
The second phase of the modernization can offer significant rewards. Chevron Oronite is fostering a
effort – domain upgrades, culture where Automation, Process, Operations and IT work
virtualization within the Process together as a collaborative team.”
Control Network (PCN), Experion
Local Control Network (ELCN) Bridge Nat Muthaiah, Senior Process Control Engineer, Chevron Oronite
and Experion Network Interface
Module (ENIM) deployment, EHPM to Chevron Oronite is upgrading existing reduce redundant alarms, and provide
Experion integration, and advanced Honeywell High- Performance Process operators with a real- time view of the
solutions implementation (Dynamo Managers (HPMs) to EHPMs and actions needed during an event.
Alarm management system, Starlims replacing older C200 controllers with
to Uniformance® PHD interface using DynAMo’s boundary management
modern C300 technology and adding
Asset Sentinel, operations monitoring, application alerts of an abnormal
UOC technology in order to enhance
etc.) – started in 2017 is currently situation before an alarm event occurs.
process control performance and
nearing completion. address obsolescence. Its objectives are Finally, Chevron Oronite has focused
The third phase of the program – to protect valuable intellectual property; on lifecycle management to optimize
migration to Experion Batch and retain control strategies, operator its control system infrastructure.
deployment of the ControlEdge™ displays, and history/trend information; The scope of this effort encompasses
Unit Operations Controller (UOC), and minimize disruption to plant the Experion control system, along
ENIMs, advanced batch visualization, operation. Modernization activities have with the ELCN, EUCN and EHPM
in-batch reporting, etc. – is now in the simultaneously addressed traditional installations. Migration will ensure a
design stage. LCN and modern Experion FTE, C300 common Experion front-end platform
and HPM, and architecture data flow across all control rooms while keeping
Completion of all migration, challenges. In addition, the addition of the back-end on a combination of
modernization and upgrade work ControlEdge UOC solution will provide EHPMs, C300s and ControlEdge UOCs.
across multiple global sites is expected
by 2021.RESULTS About Honeywell Migration Solutions
When it comes to accelerating digital
transformation, Chevron Oronite plans to
Honeywell has a history of supporting its customers’
better manage the lifecycle of its critical investments through continuous technology evolution.
control system assets while providing With our phased migration approach, plants can continue
leadership with enhanced, data-driven to operate and be supported on legacy equipment, while
decision-making capabilities.
avoiding changes to physical wiring and intellectual property.
The ongoing migration, modernization
and upgrade work is ensuring history and performance conditions. platform allowing them to stay ahead
operations are up to par with current Going forward, the Honeywell Trace of the technology curve. This paves the
technology; improving operator data collection software will expand way for continuous evolution and the
effectiveness through abnormal the visibility of configurations while next step in the company’s migration
situation management, integrated alarm automating the documentation of journey – batch upgrade and data-driven
management, automated procedures, actions taken by plant workers. visualization with new tools providing
etc.; expanding interfaces to the first-hand information of what is yet to
business and third-parties; streamlining happen in the process.
data flow from business to DCS; and SUMMARY
implementing better analytics. By being an early adopter, Chevron Most importantly, Chevron Oronite is
Oronite has achieved a flexible and fostering a culture where automation,
Chevron Oronite has found that a digital adaptable solution for automation Process and IT work together as a
platform for process control can directly technology upgrades. The company’s collaborative team to significantly
improve workflow efficiencies and modernization program supports IT/OT improve business results. There is a
operator effectiveness. For example, convergence to eliminate boundaries proven path to a sustainable future,
it now has a simple solution to meet between information and operational which allows for technology upgrades
change management requirements technologies. while harmonizing new and existing
within its process control environment. assets, increasing the life expectancy
This solution makes it easy to determine Chevron Oronite has demonstrated
of installed hardware and software, and
interactions with the control system; that early adoption of new technologies
reducing total cost of ownership with
identify when configuration changes comes with risk, but it can offer
less risk and greater efficiency.
were made; and collect and report on significant rewards. Control room
system information, configuration operators have gained a future-ready
Experion®, Uniformance® and DynAMo® are registered trademarks, and TotalPlant™ and
ControlEdge™ are trademarks of Honeywell International Inc. All other trademarks are the
property of their respective owners.
For More Information
To learn more about how
Honeywell Migration Solutions
can improve performance, visit
www.honeywellprocess.com
or contact your Honeywell
Account Manager.
Honeywell Process Solutions
1250 West Sam Houston Parkway
South Houston, TX 77042
Honeywell House, Arlington
Business Park Bracknell, Berkshire,
England RG12 1EB UK
Shanghai City Centre, 100 Zunyi
Road Shanghai, China 200051
SS-19-7-ENG I 09/19
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