{"id":129467,"date":"2025-03-03T16:46:43","date_gmt":"2025-03-03T22:46:43","guid":{"rendered":"https:\/\/www.controleng.com\/?p=129467"},"modified":"2025-03-14T10:51:58","modified_gmt":"2025-03-14T15:51:58","slug":"new-insights-100-controller-exxonmobil-open-process-automation","status":"publish","type":"post","link":"https:\/\/www.controleng.com\/new-insights-100-controller-exxonmobil-open-process-automation\/","title":{"rendered":"New insights: 100-controller ExxonMobil Open Process Automation"},"content":{"rendered":"\n<h2 class=\"wp-block-heading\"><br>ExxonMobil OPA-S Lighthouse Project insights<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Open Process Automation (OPA) ExxonMobil Lighthouse Project, 100 controller, 1000 I\/O project, architecture, migration, startup and benefits were described at the ARC Industry Leadership Forum.<\/li>\n\n\n\n<li>OPA ExxonMobil Lighthouse Project participants discuss architecture, and compare to migrating a distributed control system (DCS).<\/li>\n\n\n\n<li>Additional OPA information, timelines and artificial intelligence (AI) integration was discussed.<\/li>\n<\/ul>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<p>A new ground-up process control system is operating with more than 100 controllers and 1000 input\/output (I\/O) points at the ExxonMobil Resins Finishing Plant in Baton Rouge, Louisiana, using the Open Process Automation Standard (O-PAS), as described at the 2025 ARC Industry Leadership Forum by <a href=\"http:\/\/www.arcweb.com\/\">ARC Advisory Group<\/a>. The <a href=\"applewebdata:\/\/1C7BE505-E068-4CB8-9349-667BFA0E0283\/open%20architecture,%20standards-based%20system%20and%20its%20hardware%20and%20software%20components%20are%20\">open architecture, standards-based system and its hardware and software components are \u201creplaceable, interchangeable and interoperable<\/a>,\u201d said David DeBari, R&amp;D team leader, ExxonMobil (Figure 1), followed by substantial spontaneous audience applause. Ideas for the effort emerged 16 years ago, and the first <a href=\"https:\/\/www.controleng.com\/up-next-more-open-process-automation\/\">OPA prototype and test bed was five years ago<\/a> (Figure 2). <\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig1-DaveDeBari-mHoske-1024x768.jpg\" alt=\"Figure 1: Audience applause followed the announcement that ExxonMobil Resins Finishing Plant in Baton Rouge, Louisiana, is operating using the Open Process Automation Standard (O-PAS), as described at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. The open architecture, standards-based system and its hardware and software components are \u201creplaceable, interchangeable and interoperable,\u201d said David DeBari, R&amp;D team leader, ExxonMobil. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129476\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig1-DaveDeBari-mHoske-1024x768.jpg 1024w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig1-DaveDeBari-mHoske-300x225.jpg 300w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig1-DaveDeBari-mHoske-768x576.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig1-DaveDeBari-mHoske-1536x1152.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig1-DaveDeBari-mHoske-2048x1536.jpg 2048w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\">Figure 1: Audience applause followed the announcement that ExxonMobil Resins Finishing Plant in Baton Rouge, Louisiana, is operating using the Open Process Automation Standard (O-PAS), as described at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. The open architecture, standards-based system and its hardware and software components are \u201creplaceable, interchangeable and interoperable,\u201d said David DeBari, R&amp;D team leader, ExxonMobil. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig2-OPA-standard-timeline-mHoske-1024x768.jpg\" alt=\"Figure 2: Open Process Automation, now in the commercial installation stage, began 16 years ago, said David DeBari, R&amp;D team leader, ExxonMobil, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129477\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig2-OPA-standard-timeline-mHoske-1024x768.jpg 1024w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig2-OPA-standard-timeline-mHoske-300x225.jpg 300w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig2-OPA-standard-timeline-mHoske-768x576.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig2-OPA-standard-timeline-mHoske-1536x1152.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig2-OPA-standard-timeline-mHoske-2048x1536.jpg 2048w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\">Figure 2: Open Process Automation, now in the commercial installation stage, began 16 years ago, said David DeBari, R&amp;D team leader, ExxonMobil, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">OPA ExxonMobil Lighthouse Project, architecture<\/h2>\n\n\n\n<p>In addition to interoperability, O-PAS separates hardware and software, so, like information technology (IT) systems, incremental upgrades can be made over time on the fly, rather than often only during a large-scale distributed control system (DCS) upgrade every 20 to 30 years. Last year, those involved cited a <a href=\"https:\/\/www.controleng.com\/new-cost-analysis-open-process-automation-saves-52-versus-dcs\/\">52% OPA hardware and software savings compared to traditional DCS<\/a>.<\/p>\n\n\n\n<p>The architecture for the ExxonMobil Lighthouse Project resin plant (Figure 3) has a control room operator console, advanced computing platform (infrastructure services, historian, advanced control and optimization, engineering tools, IEX 61499 runtime application and server for the human-machine interface [HMI]), multiple distributed control nodes (DCN) compute resources with IEC 61499 runtime applications all connected to an OPA connectivity framework. A DCN with a local I\/O device connects to the OPA connectivity framework and marshaling to field devices. Other network I\/O connect to the OPA connectivity framework and to marshaling and field devices also. In the process area, instead of connecting through marshaling, a DCN local I\/O device and network I\/O each connect to field devices through junction boxes.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig3-architecture-mHoske-1024x768.jpg\" alt=\"Figure 3: The diagram shows the Open Process Automation architecture (advanced computing, distributed control nodes, networking, I\/O and field device connections) for the ExxonMobil Lighthouse Project resin plant at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129478\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig3-architecture-mHoske-1024x768.jpg 1024w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig3-architecture-mHoske-300x225.jpg 300w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig3-architecture-mHoske-768x576.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig3-architecture-mHoske-1536x1152.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig3-architecture-mHoske-2048x1536.jpg 2048w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\">Figure 3: The diagram shows the Open Process Automation architecture (advanced computing, distributed control nodes, networking, I\/O and field device connections) for the ExxonMobil Lighthouse Project resin plant at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<p>Enabling Open Process Automation technologies include deployment of virtualized controllers for DCS and programmable logic controller (PLC) automation systems. Harry Forbes, research director, ARC Advisory Group (Figure 4), discussed 2024 open automation survey results, showing about half of respondents expect to widely deploy virtualized PLC and DCS controllers by 2030. Forbes praised the OPA efforts and called on more end users to require Open Process Automation in requests for proposals (RFPs).<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig4-HarryForbes-ARC-mHoske-768x1024.jpg\" alt=\"Figure 4: Harry Forbes, research director, ARC Advisory Group, discussed 2024 open automation survey results, showing about half of respondents expect to widely deploy virtualized PLC and DCS controllers by 2030. Forbes praised the OPA efforts and asked more end users to require Open Process Automation in requests for proposals (RFPs) at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129479\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig4-HarryForbes-ARC-mHoske-768x1024.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig4-HarryForbes-ARC-mHoske-225x300.jpg 225w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig4-HarryForbes-ARC-mHoske-1152x1536.jpg 1152w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig4-HarryForbes-ARC-mHoske-1536x2048.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig4-HarryForbes-ARC-mHoske-scaled.jpg 1920w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><figcaption class=\"wp-element-caption\">Figure 4: Harry Forbes, research director, ARC Advisory Group, discussed 2024 open automation survey results, showing about half of respondents expect to widely deploy virtualized PLC and DCS controllers by 2030. Forbes praised the OPA efforts and asked more end users to require Open Process Automation in requests for proposals (RFPs) at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">OPA ExxonMobil Lighthouse Project, architecture<\/h2>\n\n\n\n<p>The Lighthouse Project clears the way for more commercial installations of O-PAS, DeBari said, who called it a group effort beyond ExxonMobil because of involvement from <a href=\"https:\/\/www.opengroup.org\/forum\/open-process-automation-forum\">Open Process Automation Forum<\/a> (<a href=\"https:\/\/reports.opengroup.org\/opa_forum.shtml\">OPAF; more than 100 members, part of The Open Group<\/a>), including Shell, DuPont, Yokogawa and Supcon, among others.<\/p>\n\n\n\n<p>The implementation timeline and results (Figure 5) was rigorous, but not perfect, DeBari said.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig5-implementation-timeline-mHoske-1024x768.jpg\" alt=\"Figure 5: The Open Process Automation Forum Lighthouse Project implementation timeline was rigorous, but not perfect, said David DeBari, R&amp;D team leader, ExxonMobil, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129480\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig5-implementation-timeline-mHoske-1024x768.jpg 1024w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig5-implementation-timeline-mHoske-300x225.jpg 300w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig5-implementation-timeline-mHoske-768x576.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig5-implementation-timeline-mHoske-1536x1152.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig5-implementation-timeline-mHoske-2048x1536.jpg 2048w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\">Figure 5: The Open Process Automation Forum Lighthouse Project implementation timeline was rigorous, but not perfect, said David DeBari, R&amp;D team leader, ExxonMobil, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Aug. 28, 2024: During an extensive factory acceptance test, it took operators all of six minutes to find the first mistake.<\/li>\n\n\n\n<li>Sept. 26: Changes were made, and the system was shipped and installed.<\/li>\n\n\n\n<li>Nov. 8: It was powered up and checked, and hot cutover was Nov. 8.<\/li>\n\n\n\n<li>Nov. 17, early: During a scheduled plant outage, the O-PAS system was commissioned and turned over to operation.<\/li>\n\n\n\n<li>Nov. 18, early: First sold production.<\/li>\n\n\n\n<li>Feb. 12, 2025: Stable operation has continued since, and operators are happy: (Toriano) Tito Jackson, ExxonMobil, operator (Figure 6) using OPA in Baton Rouge, was confident enough to leave the plant and get out of town after years of being close by in case a DCS on-site needed help.<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig6-TitoJackson-768x1024.jpg\" alt=\"Figure 6: Since the Nov. 18 first sold production at the OPA-powered Baton Rouge, Louisiana, Resins Finishing Plant, stable operation has continued said (Toriano) Tito Jackson, ExxonMobil, operator, who was confident enough to leave the plant and get out of town after years of being close by in case one of three DCSs on-site needed his help. Jackson spoke and answered questions at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129481\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig6-TitoJackson-768x1024.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig6-TitoJackson-225x300.jpg 225w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig6-TitoJackson-1152x1536.jpg 1152w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig6-TitoJackson-1536x2048.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig6-TitoJackson-scaled.jpg 1920w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><figcaption class=\"wp-element-caption\">Figure 6: Since the Nov. 18 first sold production at the OPA-powered Baton Rouge, Louisiana, Resins Finishing Plant, stable operation has continued said (Toriano) Tito Jackson, ExxonMobil, operator, who was confident enough to leave the plant and get out of town after years of being close by in case one of three DCSs on-site needed his help. Jackson spoke and answered questions at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">OPA differences compared to migrating a DCS<\/h2>\n\n\n\n<p>Dave Hedge, ExxonMobil technology and engineering, (Figure 7) who\u2019s worked through 21 process control system conversions, said the project phases using O-PAS v2.1 include preparation, engineering and manufacturing operations experiences (Figure 8). The plant returned to typical process improvements and operations changes via automation system modifications like normal. Hedge said the difference between migrating a traditional DCS system compared to migrating to OPA is like the difference between using pencil and paper and a tablet computer.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig7-DaveHedge-mHoske-768x1024.jpg\" alt=\"Figure 7: Dave Hedge, ExxonMobil technology and engineering, has worked through 21 process control system conversions; he provided prospectives on the switch from a DCS to an OPA system at a 100-controller plant, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129482\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig7-DaveHedge-mHoske-768x1024.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig7-DaveHedge-mHoske-225x300.jpg 225w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig7-DaveHedge-mHoske-1152x1536.jpg 1152w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig7-DaveHedge-mHoske-1536x2048.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig7-DaveHedge-mHoske-scaled.jpg 1920w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><figcaption class=\"wp-element-caption\">Figure 7: Dave Hedge, ExxonMobil technology and engineering, has worked through 21 process control system conversions; he provided prospectives on the switch from a DCS to an OPA system at a 100-controller plant, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig8-Experiences-mHoske-1024x768.jpg\" alt=\"Figure 8: ExxonMobil Lighthouse Project phases using O-PAS v2.1 include preparation, engineering and manufacturing operations experiences, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129483\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig8-Experiences-mHoske-1024x768.jpg 1024w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig8-Experiences-mHoske-300x225.jpg 300w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig8-Experiences-mHoske-768x576.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig8-Experiences-mHoske-1536x1152.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig8-Experiences-mHoske-2048x1536.jpg 2048w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\">Figure 8: ExxonMobil Lighthouse Project phases using O-PAS v2.1 include preparation, engineering and manufacturing operations experiences, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<p>Hedge said operators have asked to make enhancements and changes to the system. They show each other tricks. Also, he said, not a piece of the prior DCS is left. Often DCS transitions are so involved that parts of the old system (I\/O, for instance) are left in place for replacement another time. Or the prior system may be left on-site in case the new one wouldn\u2019t operate as needed.<\/p>\n\n\n\n<p>Other OPA transition benefits include:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Skill building for internal and ecosystem capability<\/li>\n\n\n\n<li>Cybersecurity \u2013 IEC\/ISA 62442, role-based access control (RBAC)<\/li>\n\n\n\n<li>Automating the automation system<\/li>\n\n\n\n<li>OPC UA for control communications<\/li>\n\n\n\n<li>Advanced computing platform, an operational technology (OT) data center, small to extra-large, with good, better and best, containerized software.<\/li>\n\n\n\n<li>IT technology in the OT space \u2013 Linux, mesh networks, firewall rules, virtual local area networks (VLANS), and more.<\/li>\n\n\n\n<li>Ability to install and run controller in less than 20 minutes.<\/li>\n\n\n\n<li>Plug-and-play reality.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Next OPA project for ExxonMobil<\/h2>\n\n\n\n<p>Kelly Li, ExxonMobil, commercial lead (Figure 9), with the company for 19 years, said ExxonMobil is working on more commercial deployments of open, secure and standard-based systems. The company is seeking to use commercially available products for the OPA vision. She expects PLC and supervisory control and data acquisition (SCADA) projects next.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig9-KellyLi-mHoske-768x1024.jpg\" alt=\"Figure 9: Kelly Li, ExxonMobil, commercial lead, with the company for 19 years, said ExxonMobil is working on more commercial deployments of open, secure and standard-based systems, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129484\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig9-KellyLi-mHoske-768x1024.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig9-KellyLi-mHoske-225x300.jpg 225w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig9-KellyLi-mHoske-1152x1536.jpg 1152w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig9-KellyLi-mHoske-1536x2048.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig9-KellyLi-mHoske-scaled.jpg 1920w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><figcaption class=\"wp-element-caption\">Figure 9: Kelly Li, ExxonMobil, commercial lead, with the company for 19 years, said ExxonMobil is working on more commercial deployments of open, secure and standard-based systems, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<p>Those involved are collaborating with end users and system integrators in ecosystem development (beyond energy). The effort supports standards from OPA Forum and also UniversalAutomation.org, <a href=\"https:\/\/www.controleng.com\/new-picmg-interedge-standard-helps-open-modular-process-control-systems\/\">PICMG<\/a>, <a href=\"https:\/\/www.controleng.com\/universalautomation-org-welcomes-oil-and-gas-giant\/\">NAMUR<\/a> and International Association of Oil &amp; Gas Producers (IOGP).<\/p>\n\n\n\n<p>Li said a <a href=\"https:\/\/corporate.exxonmobil.com\/news\/corporate-news\/pioneering-a-new-automation-technology\">Feb. 10 OPA ExxonMobil article tells more<\/a>.<\/p>\n\n\n\n<p>The open, secure and standards-based efforts continue with a vision for a scale-up plan and OPA ecosystem. Open Process Automation is a mature ecosystem (Figure 10) that supports OPA deployments with interoperable options, intrinsic cybersecurity, scalability, portability and transferability, Li said. This year will expand multiple steppingstone projects, with opportunity for more SCADA\/DCS implementations, she continued.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig10-ecosystem-mHoske-1024x768.jpg\" alt=\"Figure 10: Open Process Automation is a mature ecosystem that supports OPA deployments with interoperable options, intrinsic cybersecurity, scalability, portability and transferability, said Kelly Li, ExxonMobil, commercial lead, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129485\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig10-ecosystem-mHoske-1024x768.jpg 1024w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig10-ecosystem-mHoske-300x225.jpg 300w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig10-ecosystem-mHoske-768x576.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig10-ecosystem-mHoske-1536x1152.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig10-ecosystem-mHoske-2048x1536.jpg 2048w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\">Figure 10: Open Process Automation is a mature ecosystem that supports OPA deployments with interoperable options, intrinsic cybersecurity, scalability, portability and transferability, said Kelly Li, ExxonMobil, commercial lead, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<p>The OPA project midstream terminal PLC-type project, request for proposal (RFP) resulted in multiple proposals for commercially available solutions.<\/p>\n\n\n\n<p>Later this year in a chemical business, engineering, procurement and construction (EPC) begins with a medium-sized DCS greenfield implementation; an RFP is expected later this year.<\/p>\n\n\n\n<p>OPAF launched the O-PAS certification program for v2.1, useful for automation vendors, components suppliers and system integrators to create more commercially available offerings and solutions using the open-standards based, secure interoperable standards.<\/p>\n\n\n\n<p>Li added: \u201cI\u2019m excited to see the future impacts. I call on other end users, suppliers and system integrators to move into the future to realize the benefits of lower TCO for deployment in field. We need more deployments.\u201d<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">OPA Forum roadmap<\/h2>\n\n\n\n<p>Jacco Opmeer, Shell, (Figure 11) representing the OPA Forum, outlined other 2024 major achievements in a roadmap. O-PAS V2.1 is working in a large commercial installation. Connectivity provides glue between distributed control nodes (DCN) and the advanced computing platform (Figure 12).<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig11-Shell-Jacco-Opmeer-mHoske-768x1024.jpg\" alt=\"Figure 11: Jacco Opmeer, Shell, representing the OPA Forum, outlined other 2024 major achievements in a roadmap, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129486\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig11-Shell-Jacco-Opmeer-mHoske-768x1024.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig11-Shell-Jacco-Opmeer-mHoske-225x300.jpg 225w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig11-Shell-Jacco-Opmeer-mHoske-1152x1536.jpg 1152w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig11-Shell-Jacco-Opmeer-mHoske-1536x2048.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig11-Shell-Jacco-Opmeer-mHoske-scaled.jpg 1920w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><figcaption class=\"wp-element-caption\">Figure 11: Jacco Opmeer, Shell, representing the OPA Forum, outlined other 2024 major achievements in a roadmap, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig12-DCN-hardware-software-mHoske-1024x768.jpg\" alt=\"Figure 12: Connectivity provides glue between distributed control nodes (DCN) and the advanced computing platform. Among 100 Open Process Automation Forum (OPAF) members are most major automation hardware and software suppliers, most major process automation system suppliers, many large end users and system integrators, explained at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129487\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig12-DCN-hardware-software-mHoske-1024x768.jpg 1024w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig12-DCN-hardware-software-mHoske-300x225.jpg 300w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig12-DCN-hardware-software-mHoske-768x576.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig12-DCN-hardware-software-mHoske-1536x1152.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig12-DCN-hardware-software-mHoske-2048x1536.jpg 2048w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\">Figure 12: Connectivity provides glue between distributed control nodes (DCN) and the advanced computing platform. Among 100 Open Process Automation Forum (OPAF) members are most major automation hardware and software suppliers, most major process automation system suppliers, many large end users and system integrators, explained at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<p>Among 100 OPAF members are most major automation hardware and software suppliers, most major process automation system suppliers, many large end users and system integrators, Opmeer said.<\/p>\n\n\n\n<p><a href=\"http:\/\/www.opengroup.org\/certications\/o-pas\">O-PAS Certification<\/a> has launched; next is verification lab recognition for physical platform certification and network capabilities. The idea for the standard is that automation should be plug and play, like USB, Opmeer said.<\/p>\n\n\n\n<p>The O-PAS interoperability event in the Shell offices in Amsterdam, was a plug fest with a week of interoperability testing among vendor products prototypes and proof-of-concept applications.<\/p>\n\n\n\n<p>Semantic versioning includes content to be added incrementally to O-PAS when ready; incremental updates will be in edition 2, V2.1, Opmeer said, such as:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Security, OPC FX<\/li>\n\n\n\n<li>Architecture and hardware updates<\/li>\n\n\n\n<li>AutomationML portability<\/li>\n\n\n\n<li>Orchestration \u2013 management of O-PAS components.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">How end-users benefit from the ExxonMobil Lighthouse Project<\/h2>\n\n\n\n<p>Dave Emerson, Yokogawa, and co-chair of enterprise architecture of the OPA-S working group (Figure 13), said end-users from around the world have been interested in Lighthouse Project benefits because of many commonalities at their facilities, including:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Brownfield obsolescence, end of life issues, obtaining new technology value.<\/li>\n\n\n\n<li>Greenfield: New facilities and new processes need new architectures. Many seek ways to feed artificial intelligence (AI) applications with more content. Applications can create new value with O-PAS to get attention quicker.<\/li>\n\n\n\n<li>Lowest total cost of ownership (TCO): There\u2019s lot of interest in gaining value over longer time scales.<\/li>\n\n\n\n<li>Interoperability, interchangeability, modularity and flexibility are key drivers for rethinking process automation applications.<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig13-DaveEmerson-mHoske-768x1024.jpg\" alt=\"Figure 13: Dave Emerson, Yokogawa, and co-chair of enterprise architecture of the OPA-S working group, said end-users from around the world have been interested in Lighthouse Project benefits because of many commonalities at their facilities, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129488\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig13-DaveEmerson-mHoske-768x1024.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig13-DaveEmerson-mHoske-225x300.jpg 225w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig13-DaveEmerson-mHoske-1152x1536.jpg 1152w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig13-DaveEmerson-mHoske-1536x2048.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig13-DaveEmerson-mHoske-scaled.jpg 1920w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><figcaption class=\"wp-element-caption\">Figure 13: Dave Emerson, Yokogawa, and co-chair of enterprise architecture of the OPA-S working group, said end-users from around the world have been interested in Lighthouse Project benefits because of many commonalities at their facilities, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">OPA System components explanation, hardware, software examples<\/h2>\n\n\n\n<p>Process automation hardware is important, Emerson said, but hardware is a place to deploy software to, explaining how an Open Process Automation system works (Figure 14). OPA provides ability to move and orchestrate where to move software and when. OPA has two categories of software functionality, where the processes and applications run and how to manage HMI for operators.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"756\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig14-OPAF-fundamentals-mHoske-1024x756.jpg\" alt=\"Figure 14: Process automation hardware is important, but hardware is a place where software is deployed in an Open Process Automation system works, as Dave Emerson, Yokogawa, and co-chair of enterprise architecture of the OPA-S working group, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129489\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig14-OPAF-fundamentals-mHoske-1024x756.jpg 1024w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig14-OPAF-fundamentals-mHoske-300x222.jpg 300w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig14-OPAF-fundamentals-mHoske-768x567.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig14-OPAF-fundamentals-mHoske-1536x1134.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig14-OPAF-fundamentals-mHoske-2048x1512.jpg 2048w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\">Figure 14: Process automation hardware is important, but hardware is a place where software is deployed in an Open Process Automation system works, as Dave Emerson, Yokogawa, and co-chair of enterprise architecture of the OPA-S working group, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<p>While components are interoperable like in the IT world, the installed system looks like a familiar DCS for the OT world, Emerson explained: It\u2019s what\u2019s operators are used to. Historization capability provides quality data to historians to collect more efficiently and move data around faster as needed without a full system upgrade. You don\u2019t have to rip out everything to upgrade to more open capabilities, he said. At least 50 OPA-compliant packages have been installed at one customer in connect and build system. Virtualization and containerization help manage controller workloads. Cybersecurity management is built in, and onboarding is easier. Distributed control nodes put capabilities where needed. It opens up the question: What will software do for me?<\/p>\n\n\n\n<p>At the ARC Leadership Forum, in the Yokogawa booth, Yokogawa web-based software (CI Server HMI) showed a Phoenix Contact Control Plus DCN, an R. Stahl I\/O DCN and an ASRock Industrial Control DCN operating on one screen.<\/p>\n\n\n\n<p>In addition, two OPA hardware configurations with different plug-and-play components were shown, one at the Collaborative Systems Integration (CSI) booth (with a COPA500 Controller, Phoenix Contact for power and I\/O, an ASRock Industrial controller, Supermicro HMI and a Cisco gateway, Figure 15) and another system at the Wood booth using R. Stahl I\/O.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig16-COPA-hardware-configuration-mHoske-768x1024.jpg\" alt=\"Figure 15: The Yokogawa booth shows Open Process Automation, with a COPA500 Controller from Collaborative Systems Integration (CSI), Phoenix Contact for power and I\/O, an ASRock Industrial controller, Supermicro HMI and a Cisco gateway, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129491\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig16-COPA-hardware-configuration-mHoske-768x1024.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig16-COPA-hardware-configuration-mHoske-225x300.jpg 225w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig16-COPA-hardware-configuration-mHoske-1152x1536.jpg 1152w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig16-COPA-hardware-configuration-mHoske-1536x2048.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig16-COPA-hardware-configuration-mHoske-scaled.jpg 1920w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><figcaption class=\"wp-element-caption\">Figure 15: The Yokogawa booth shows Open Process Automation, with a COPA500 Controller from Collaborative Systems Integration (CSI), Phoenix Contact for power and I\/O, an ASRock Industrial controller, Supermicro HMI and a Cisco gateway, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\n<\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Process control experts discuss OPA benefits, opportunities<\/h2>\n\n\n\n<p>Asked about the size of the implementation, DeBari said the ExxonMobil Lighthouse Project resin plant is a commercial installation with 1000 I\/O and 100 controllers, a project focused on Open Process Automation systems, not for all surrounding devices and systems, which he called \u201curban renewal.\u201d<\/p>\n\n\n\n<p>Li said the next ExxonMobil project using OPA has 200 I\/O.<\/p>\n\n\n\n<p>Asked about OPA progress, DeBari said the Lighthouse Project marks the end of the OPA R&amp;D stages, as many commercially available products are available. \u201cNow every project can decide if will use OPA.\u201d<\/p>\n\n\n\n<p>Regarding training and support, DeBari said ExxonMobil group its people to the Woodland Texas facility before and during the factory acceptance test to progress. Keeping the same HMI screens helped reduce training time to a week. The system has more cybersecurity than any other system, and has a contract with a system integrator for software and hardware support, instead of with a DCS vendor. While the system and operators need some support, common skills are used; special operator knowledge was not required.<\/p>\n\n\n\n<p>Michael Hotaling, ExxonMobil, innovation and strategy digital manager, leading the digital twin working group, said it\u2019s important to envision a world where automation users stop buying dumb equipment and demand open and agnostic equipment. When do we stop buying things that do not communicate with open standards? So much has been an afterthought.<\/p>\n\n\n\n<p>Hedge said automation is necessarily changing from closed to open architectures in industrial automation, as he outlined the past, present and future evolution of process automation toward open architectures (Figure 16). \u201cStop saying no. Say yes.\u201d<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig15-Automation-changes-mHoske-1024x768.jpg\" alt=\"Figure 16: Dave Hedge, ExxonMobil technology and engineering, said automation is necessarily changing from closed to open architectures in industrial automation, as he outlined the past, present and future evolution of process automation toward open architectures, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129490\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig15-Automation-changes-mHoske-1024x768.jpg 1024w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig15-Automation-changes-mHoske-300x225.jpg 300w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig15-Automation-changes-mHoske-768x576.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig15-Automation-changes-mHoske-1536x1152.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig15-Automation-changes-mHoske-2048x1536.jpg 2048w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\">Figure 16: Dave Hedge, ExxonMobil technology and engineering, said automation is necessarily changing from closed to open architectures in industrial automation, as he outlined the past, present and future evolution of process automation toward open architectures, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<p>Using the OPA Lighthouse Project software-defined architecture as an example, when a new widget comes out with better capabilities, it\u2019s possible to change system as it sits in the facility today.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">More operator perspective about Open Process Automation<\/h2>\n\n\n\n<p>Jackson provided additional operator experiences with the new system, paraphrased below.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>I supported three DCSs in Baton Rouge for 14.5 years, and thought, \u201cWow. Something new.\u201d It seemed like a lot to support, at first. I was skeptical. When I learned more about it, I wondered why IT technology was stepping into my OT area. Working with it, I started to enjoy it. It works. It\u2019s running. And now I see endless possibilities.<\/li>\n\n\n\n<li>I love to get back into IT learning.<\/li>\n\n\n\n<li>It has a small footprint.<\/li>\n\n\n\n<li>Saw the finish line sooner than with a DCS transition.<\/li>\n\n\n\n<li>I don\u2019t have to be there physically. I took my first vacation in two years.<\/li>\n\n\n\n<li>This is a big toy store for me.<\/li>\n\n\n\n<li>It\u2019s nice not to have phone calls throughout the day.<\/li>\n\n\n\n<li>It\u2019s new technology and people, an exciting journey. I know artificial intelligence (AI) is coming, and I\u2019m enjoying it.<\/li>\n\n\n\n<li>While I don\u2019t like change, I\u2019ll stick with this.<\/li>\n\n\n\n<li>I hope more users will adopt OPA. It\u2019s really cool. I could run 100 DCNs on the platform. You have to reimagine what you can do.<\/li>\n<\/ul>\n\n\n\n<p>Hedge said those involved have to be good at the fundamentals; that\u2019s the same. Standards make it easier. Among lessons relearned (Figure 17), we were reminded that innovation is a journey. Some want to participate and others do not. Software upgrades can be done at a component and system levels, online and offline.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig17-LessonsLearned-mHoske-1024x768.jpg\" alt=\"Figure 17: Among lessons relearned during the Open Process Automation Lighthouse project was the reminder that innovation is a journey. Some want to participate and others do not. Software upgrades can be done at a component and system levels, online and offline, Dave Hedge, ExxonMobil technology and engineering, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering\" class=\"wp-image-129492\" srcset=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig17-LessonsLearned-mHoske-1024x768.jpg 1024w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig17-LessonsLearned-mHoske-300x225.jpg 300w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig17-LessonsLearned-mHoske-768x576.jpg 768w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig17-LessonsLearned-mHoske-1536x1152.jpg 1536w, https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/03\/CTL2504_WEB_F1_OpenAutomation_ExxonMobil-ARC-Fig17-LessonsLearned-mHoske-2048x1536.jpg 2048w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\">Figure 17: Among lessons relearned during the Open Process Automation Lighthouse project was the reminder that innovation is a journey. Some want to participate and others do not. Software upgrades can be done at a component and system levels, online and offline, Dave Hedge, ExxonMobil technology and engineering, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. Courtesy: Mark T. Hoske, Control Engineering<\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Applying artificial intelligence to Open Process Automation<\/h2>\n\n\n\n<p>Addressing what\u2019s needed to make systems more autonomous with AI use, Mark Hammer, global account manager, Yokogawa, said a rich data model, with consistent integration and common data sets will help rather than data conversions and gateways used for data in many of today\u2019s systems.<\/p>\n\n\n\n<p>Don Bartusiak, president, Collaborative Systems Integration, said sensors and their application need to be reliable with correct sampling. You cannot paper over instrumentation with AI math. Proper training is needed, also.<\/p>\n\n\n\n<p>Hedge said compute power is needed for networking, data communications and \u201cfor fancy things in future efforts.\u201d<\/p>\n\n\n\n<p>Are younger operators needed for OPA and AI implementations?<\/p>\n\n\n\n<p>Jackson acknowledged that everyone\u2019s different. If I see it a few times, I pick it up. It\u2019s not hard. With my experience, I can fix things without calling for help.<\/p>\n\n\n\n<p>Hedge said virtualization was a hot topic in colleges during the decade ending in 2010. hot topic. Today\u2019s universities are very cloud-centric.<\/p>\n\n\n\n<p>Addressing if AI could be applied to a problematic temperature control loop tuning challenge, Bartusiak said AI isn\u2019t going to replace control anytime soon. There will be a mix of technologies. AI might help if an application has sticky valves that cannot be fixed right away; reinforcement learning may help in the meantime. Open platforms will enable companies to innovate faster than they could have previously.<\/p>\n\n\n\n<p>Comparing traditional DCS migration to OPA upgrades, Bartusiak said one creates a massive disruption and the other is as easy as replacing a laptop has become. \u201cYou can incrementally upgrade. It\u2019s much less costly and less disruptive than looking backward.\u201d<\/p>\n\n\n\n<p>A more capable, more upgradeable system, applied to a small modular power plant, for instance, might be capable of autonomous operations, in perhaps 10 years, said Timothy Triplett, control consultant, Texas A&amp;M University.<\/p>\n\n\n\n<p>Bartusiak said for routine operations, plants can be autonomous, but manual attention is required to handle a small number of infrequent circumstances that arise. It\u2019s like autopilot on airplanes; computers cannot handle low-frequency events; well-trained pilots take over.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">OPA is how to avoid the pain and expense of DCS migrations<\/h2>\n\n\n\n<p>Whit McConnell, chief engineer, automation and process control, ExxonMobil, said the OPA effort results from explaining to management the costs and time required to modernize a fleet of DCSs. \u201cThere were really big numbers, producing facial expressions we didn\u2019t want to see. They asked us to rethink the problem. OPA prevents the DCS upgrade scenario every 15 to 20 years.<\/p>\n\n\n\n<p>Obsolescence is a way of life in our industry, with operating systems still around since the late 1970s, 1980s and 1990s. In the meantime, can retrofits and upgrades be more open? Yes.<\/p>\n\n\n\n<p>Vien Nguyen, principal software architect, Yokogawa, told <em>Control Engineering<\/em> that an OPA system is never done, always improving and providing additional benefits.<\/p>\n\n\n\n<p><strong>Mark T. Hoske<\/strong>, editor-in-chief, <em>Control Engineering, <\/em>WTWH Media<em>,<\/em> mhoske@wtwhmedia.com.<\/p>\n\n\n\n<p>CONSIDER THIS<\/p>\n\n\n\n<p>Are you requiring Open Process Automation in your next request for proposal?<\/p>\n\n\n\n<p>ONLINE<\/p>\n\n\n\n<p>See a <em>Control Engineering<\/em> 2024 series about open automation starting with:<\/p>\n\n\n\n<figure class=\"wp-block-embed is-type-wp-embed is-provider-control-engineering wp-block-embed-control-engineering\"><div class=\"wp-block-embed__wrapper\">\n<blockquote class=\"wp-embedded-content\" data-secret=\"dNuSQvIime\"><a href=\"https:\/\/www.controleng.com\/new-cost-analysis-open-process-automation-saves-52-versus-dcs\/\">New cost analysis: Open process automation saves 52% versus DCS<\/a><\/blockquote><iframe loading=\"lazy\" class=\"wp-embedded-content\" sandbox=\"allow-scripts\" security=\"restricted\" style=\"position: absolute; visibility: hidden;\" title=\"&#8220;New cost analysis: Open process automation saves 52% versus DCS&#8221; &#8212; Control Engineering\" src=\"https:\/\/www.controleng.com\/new-cost-analysis-open-process-automation-saves-52-versus-dcs\/embed\/#?secret=zBZBwwudQ2#?secret=dNuSQvIime\" data-secret=\"dNuSQvIime\" width=\"500\" height=\"282\" frameborder=\"0\" marginwidth=\"0\" marginheight=\"0\" scrolling=\"no\"><\/iframe>\n<\/div><\/figure>\n","protected":false},"excerpt":{"rendered":"<p>ExxonMobil OPA-S Lighthouse Project insights A new ground-up process control system is operating with more than 100 controllers and 1000 input\/output (I\/O) points at the ExxonMobil Resins Finishing Plant in Baton Rouge, Louisiana, using the Open Process Automation Standard (O-PAS), as described at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. The open [&hellip;]<\/p>\n","protected":false},"author":41,"featured_media":129476,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"pgc_sgb_lightbox_settings":"","footnotes":""},"categories":[104070],"tags":[109831,109828,109826,109929,109340,109937,109936,109928,109933,109931,109930,109934,109932,109935],"tracking-metrics":[],"display-location":[109353],"class_list":{"2":"type-post"},"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v25.9 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>New insights: 100-controller ExxonMobil Open Process Automation - Control Engineering<\/title>\n<meta name=\"description\" content=\"ARC Industry Leadership Forum, 2025: ExxonMobil runs Open Process Automation (OPA) system in a large-scale Lighthouse Project.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.controleng.com\/new-insights-100-controller-exxonmobil-open-process-automation\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"New insights: 100-controller ExxonMobil Open Process Automation - 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