Arkema

Arkema, a global specialty chemicals manufacturer, faced mounting safety risks from aging control systems across its production facilities. In the chemicals sector, where process upsets can trigger hazardous releases, fires, or regulatory shutdowns, outdated automation infrastructure is not merely an operational inconvenience — it is a liability. Legacy control hardware with diminishing vendor support, limited diagnostics, and no integration with modern safety standards left the facility exposed to both incident risk and compliance gaps. Without visibility into real-time process deviations, operators relied on reactive responses rather than proactive intervention, increasing the potential for harm to personnel and the surrounding environment.

Arkema partnered with Rockwell Automation to modernize its control system infrastructure, replacing end-of-life equipment with contemporary safety-rated automation platforms suited to specialty chemical environments. The modernization encompassed updated programmable logic controllers, safety instrumented systems aligned with IEC 61511 functional safety standards, and integrated human-machine interfaces that provide operators with real-time process visibility. Rockwell Automation's PlantPAx distributed control system architecture was central to the deployment, enabling tighter integration between process control and safety layers. The implementation was structured to minimize production disruption, with phased cutover procedures that allowed the facility to maintain output continuity while transitioning from legacy to modern control architecture. The upgraded systems also improved auditability, supporting regulatory documentation and compliance reporting.

The control system modernization delivered measurable improvements in safety posture and regulatory standing at Arkema's chemical facility. Key outcomes included:

• Improved safety performance: Modern safety instrumented systems reduced the risk profile associated with process upsets, with tighter alarm management and faster automated response to abnormal conditions.
• Regulatory compliance: Updated systems aligned with current IEC and OSHA PSM (Process Safety Management) requirements, reducing audit exposure.
• Operator visibility: Real-time HMI dashboards replaced fragmented legacy interfaces, enabling more informed decision-making during critical process transitions.
• Reduced obsolescence risk: Elimination of unsupported hardware removed single points of failure that previously had no available replacement parts.

• Deferred modernization compounds risk — in specialty chemicals, aging control systems don't just create maintenance headaches; they create regulatory and safety exposure that grows with each passing year.
• Functional safety standards should drive scope — aligning upgrades to IEC 61511 or equivalent frameworks ensures the project addresses compliance requirements, not just hardware refresh.
• Phased cutover planning is critical — in continuous chemical processes, a poorly sequenced migration can be more dangerous than the aging system it replaces.
• Safety and control layer integration matters — modernizations that unify SIS and DCS under a common architecture deliver more value than point replacements.
• Vendor support lifecycle should inform timing — waiting until hardware reaches end-of-life limits options and increases project risk.