Honeywell Launches AI Control Room Assistant to Predict Alarms 10 Minutes Early

Predicting the Unpredictable: New Experion Operations Assistant Forecasts Critical Incidents 10 Minutes Before They Occur

INDIA — March 20, 2026 — Honeywell has officially announced the commercial launch of the Experion Operations Assistant, a breakthrough AI-powered solution designed to revolutionize the industrial control room. By merging 50 years of process automation expertise with real-time site data, the assistant provides a predictive safety net for operators in complex plant environments.

Built directly into Honeywell’s flagship Experion PKS distributed control system, the tool acts as a bridge between autonomous technology and human decision-making, helping to mitigate production losses and unsafe operations before they escalate.

Proven Performance with Global Energy Leaders

The transition from pilot to commercial launch follows successful deployments with global partners, including Chevron and TotalEnergies. During these high-stakes trials, the AI assistant demonstrated its ability to significantly reduce unplanned downtime.

• Early Warning System: In pilot phases, the assistant successfully predicted alarm incidents an average of 5 to 10 minutes before they occurred.

• Actionable Intelligence: This predictive window allowed operators to implement corrective actions early, effectively preventing events that would have otherwise led to shutdowns or safety risks.

• Legacy Data Utilization: The system leverages historical site-specific knowledge, ensuring the AI's advice is grounded in the actual operational reality of the specific facility.

Solving the "Knowledge Gap" in Industrial Automation

One of the primary drivers behind the Experion Operations Assistant is the ongoing "knowledge transfer" challenge. As a veteran workforce nears retirement, industrial firms are looking for digital ways to preserve and apply institutional expertise.

“Industrials are under pressure to avoid unplanned downtime while navigating the massive knowledge transfer of a retiring workforce. Experion Operations Assistant helps operators anticipate issues earlier, respond with confidence, and operate more safely and effectively.” — Jim Masso, President and CEO, Honeywell Process Automation.

Key Capabilities for the Modern Control Room

The solution is designed for seamless integration, meaning it builds upon the sensors and systems already in place within the Experion PKS network.

• Real-Time Decision Support: Uses advanced language models to analyze operational data and proactively advise operators on impending issues.

• Predictive Insights: Forecasts potential critical scenarios associated with production losses.

• Seamless Integration: Designed to be a natural extension of the existing control room environment, requiring minimal infrastructure changes for current Honeywell users.

FAQ.

How does the AI "know" an alarm is coming?

The Experion Operations Assistant analyzes vast streams of historical and real-time data to identify subtle patterns—"pre-alarm" signatures—that humans might miss. By recognizing these patterns early, it can alert the operator to a developing trend 5-10 minutes before the actual safety thresholds are breached.

Is this meant to replace the control room operators?

No. Honeywell has designed this as an "assistant." Its primary goal is to empower human operators by providing them with more time and better data to make informed decisions. It bridges the gap between fully autonomous systems and human-led operations.

What industries can benefit from this technology?

While the pilot involved major oil and gas players like Chevron and TotalEnergies, the system is applicable to any complex process industry utilizing the Experion PKS DCS, including chemicals, pharmaceuticals, power generation, and refining.