"Honeywell helped us change our operator function from reacting and adjusting the process to proactively managing process operations. With advanced process management, we get the right information at the right time and act on it as appropriate. Honeywell’s Experion combines the strengths of the automation platform, advanced applications and expert services to help us make better decisions and improve overall business performance."
Arnold Oliver, Process Control Superintendent, Worsley Alumina
In order to maintain its competitive advantage, Worsley needed to provide its operators with a more effective way to manage the various processes employed at the refinery. Worsley turned to Honeywell’s advanced applications based on the proven Experion® Process Knowledge System (PKS) platform to achieve its objectives. As a result, the refinery experienced the following benefits:
Located in Western Australia, Worsley Alumina is a joint venture between BHP Billiton, Japan Alumina Associates (Australia) Pty. Ltd. and Sojitz Alumina Pty. Ltd. A world-class research and development laboratory, administration center, maintenance workshops, warehouse and advanced alumina transport and storage facilities make it the one of the world's most modern and efficient refineries. The refinery’s 3.5 million tonnes of alumina per year capacity makes it one of the world’s largest alumina refineries. About 1,500 people are employed at the mine site and refinery.
Elevating production performance in an alumina refinery is a challenge because it hinges on an operator’s ability to be proactive and act on information appropriately. Worsley Alumina realized that one catalyst to improving performance was to use advanced automation to replace some of the operators’ current tasks, allowing them to focus on production goals.
"Following an extensive review of our process management, we knew we wanted to implement advanced applications and improve our production control," said Angelo D’Agostino, Senior Process Control Engineer at Worsley Alumina. "Our operators were key to this transformation and seen as the biggest lever to improve production and quality, and to decrease costs."
Part of the transformation included implementing a centralized control room and upgrading Worsley’s Honeywell TDC 2000® control system. It also included finding ways to make operators more proactive through advanced automation technology.
With a longstanding partnership, the company turned to Honeywell for advanced automation technology applications. Two years into its four-year timeline, Worsley can point to some early successes and a rapid return on investment.
"We have a history of forming joint project teams with Honeywell. After completing the first phase, we saw rapid payback and return on our investment," said D’Agostino. "We were able to see the potential for Honeywell’s products and services to deliver value."
Following an extensive study of its process management, Worsley Alumina obtained approval for the Advanced Process Management (APM) project. The project put Worsley on the upgrade path to Experion. With early success in alarm management , advanced control using Honeywell’s Profit® Controller and operator training using Honeywell’s UniSim® Operations, Worsley control room operators continue to meet their goals of proactive process management.
The project also included upgrading the existing GUS and US operator stations to the Experion Station TPS (ES-T) to allow plant staff the benefit of using HMIWeb graphics while still maintaining the connection to the existing local control network. "Our operators are looking forward to using their leading-edge, new central control room utilizing an Experion HMI to consolidate old and new control systems and monitor advanced process control," said D’Agostino.
Upgrading from legacy Honeywell technology was easy with the support of Honeywell’s services team. With continuous evolution and backward compatibility, Worsley was able to migrate its TDC 2000 control system (dating back over 25 years) to the latest Experion platform without any problems.
"Honeywell’s commitment to protecting customers’ automation investments is clearly evident in its continued support for control technology developed almost 30 years ago," said D’Agostino.
As part of the APM project, the Worsley facility has also upgraded all of its TDC 2000 controllers to the latest Experion controller technology through an easy upgrade path completely supported by Honeywell.
"Honeywell makes advanced automation and control easy through its superior products, integration with existing infrastructure and advanced training methodologies. Our team felt in control and right at home with their Honeywell counterparts. Honeywell did a great job of knowledge transfer to our team and have helped us achieve a benchmark in advanced automation control," D’Agostino said.
Experion®, TDC 3000®, Profit® and UniSim® are registered trademarks of Honeywell International Inc.