“Honeywell as the base supplier for automation systems at Sappi Gratkorn has offered us a customer-oriented solution that reuses installed equipment combined with the newest DCS and QCS functions and technology.”
– Karl Weiss, Sappi Gratkorn
Paper has been produced at Gratkorn (Austria) for more than four centuries. Sappi totally revolutionized the mill by building the largest and most advanced coated fine paper production line in the world. Gratkorn has an annual capacity of one million tons of triple-coated fine paper on just two paper machines and 250,000 tons of totally chlorine free (TCF) chemical pulp. After extension of Gratkorn’s sheeting plant, it now has an annual sheet finishing capacity of 860,000 tons.
Coated papers from Gratkorn Mill are used mainly in high gloss advertising for brochures and leaflets as well as for art cata-logues, books, magazines, annual reports, calendars etc.
These papers are the preferred choice where highest print quality and outstanding color reproduction is needed and where best results are expected in die cutting, embossing, dispersion-, oil based- resp. UV-varnishing or laminating..
The main reason for this project was quality improvements and reduction of off-spec production.
In addition, plant management needed to improve operator effec-tiveness with a modernized automation platform and still while continuing to communicate with other legacy Honeywell products in the same production line.
The migration of the legacy Honeywell DCS, with over 12,000 IO points, was required to complete in a very short time frame in order to minimize shutdown time and support functions for further rebuilds.
As legacy DCS and QCS systems become more difficult and costly to support, Honeywell’s Experion Upgrades enable a step-by-step transition for the most critical components. The upgrade options allow users to take advantage of the latest technological innovations in a simple, cost-effective manner.
Selected capabilities for Sappi Gratkorn include:
- Experion MX,
- Experion with PMD controller,
- Uniformance™ PHD and
- Safety Manager
The site’s MXOpen QCS systems migrated to Experion MX and the TP Alcont DCS to Experion PKS. PMD and PHD are up-graded to the latest versions. Also, with Safety Manager, the site will have a fully integrated solution based on the Experion plat-form for their Paper Machine 11.
| Gratkorn Mill, Austria |
Coated woodfree paper
Upgrading Sappi’s systems will increase process visibility and provide better operator efficiency, leading to higher product quali-ty at lower production cost.
Experion PMD and MX provide the full advantages of a single automation platform for Paper Machine 11 with less hardware, cost savings on spares, and reduced maintenance services.
The new Experion platform delivers new tools and diagnostic functions for comprehensive remote support.
Using the Honeywell TPA-PMD Migration tools, it was possible to upgrade all applications and displays 100% error free, resulting in immense time savings.
The large legacy DCS application migration at PM11 was ac-complished in just three days.
Sappi reports that the Gratkorn DCS and QCS upgrade invest-ment has achieved the scheduled targets in time and within planned production capacity.