Experion MX - Quality Control System
Delivers Lowest Total Cost of Ownership
Author: Thomas H. Steele, Senior Marketing Leader, Pulp and Paper
Honeywell Process Solutions
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Table of Contents
Introduction ...........................................................................................................3
Integrated user interface .......................................................................................3
Faster scans .........................................................................................................4
Modular sensors ...................................................................................................5
New measurement capabilities .............................................................................6
Multivariable control ..............................................................................................6
On-line diagnostics & service options ...................................................................7
Introduction
The papermaking business has undergone dramatic change over the past few years.
Honeywell has conducted many interviews with customers to understand how these changes are affecting
papermakers and what they are looking for in paper machine automation to help address these new
challenges. We found three themes dominating the wish lists of papermakers today.
•
They are looking for equipment that is easy to operate service and maintain
•
They want better visibility into the papermaking process in order to improve quality
•
They are looking to reduce total cost of ownership
Honeywell has addressed these needs with Experion MX, its next generation of paper machine automation.
Experion MX provides an integrated user interface that makes it easier for operators to view and control the
process. New and enhanced measurements and advanced multivariable controls improve product quality
and operational efficiency. The resulting reduction in service and maintenance costs, and unscheduled
downtime., along with increased production and less waste provides the lowest total cost of ownership.
Integrated user interface
The new Experion MX human machine interface (HMI) is designed for ease of use and efficiency. It provides
a consistent look and feel for all operator tasks such as process measurements, machine direction (MD) and
cross direction (CD) controls, web monitoring, web inspection, quality reporting, production reporting and
field instrumentation. Integrated display capability provides profile data, camera data, programmable logic
controller (PLC) logic state data and distributed control system (DCS) loop data all on the same display so
the operator can see everything he or she needs to know about the process at a glance. All displays are
easy and intuitive to operate. Intelligent alarm handling quickly directs the user to the source of problems.
Example of integrated display screen
Faster scans
Experion MX features a new O-Frame scanner with many
unique design points. New beam designs have increased the
structural rigidity for improved reliability and accuracy on the
widest of machines. With a scan speed of up to 1200
mm/second, and a full scan taking 10 seconds or less, the
Experion MX scanner heads travel twice the speed of their
predecessor and several times faster than previous generation
systems. Fast scanning has always been important to reduce
recovery time after paper breaks and grade changes but it is
even more important now that scanning data is used in so
many places such as control, management information
systems (MIS), data historians, quality lab, shipping office, etc.
These different functions require consistent data collection for
their statistics to be valid to allow comparison between runs or
from day-to-day. To compensate for lower scan speeds,
competitive systems may switch from “normal scanning” to
“narrow scan” mode to support diagnostic modes but with the
speed of Experion MX even diagnostic data can be collected
in normal scanning mode. Of course, Experion MX scanners
can support narrow scan and single point modes on operator request, but fewer interruptions means more
complete, more consistent and more statistically accurate data with less time off control.
Modular sensors
Modular sensors can be interchanged quickly and easily
Experion MX sensors are modular so they can easily install via mounting rails that provide power, cooling,
air and network communications. You simply plug in a replacement module with factory calibration data for
the sensor already installed, and it connects to the network, self-identifies, downloads any operating
parameters, and is ready to operate. This approach enables fast removal and replacement of sensor
modules which reduces downtime. As papermakers move to more productive machines the cost of
downtime rises and it often makes sense to replace rather than repair the sensor to get the machine back
into operation faster. Sensors can also be serviced at the component level by experienced personnel from
Honeywell or in-house service teams as in the past.
New measurement capabilities
Unique new measurements are provided to improve measurement capabilities. A new coating measurement
provides direct infrared CaCO3 measurement and GelView on-line coating consolidation. Scanning camerabased sensors inspect paper formation, fiber orientation and anisotrophy, and surface topography, crepe
and smoothness. New strength property measurements include direct ESS for MD and CD controls, with
correlations for tensile energy absorption (TEA), compressive strength (STFI) and ring crush. Former
drainage measurements are based on online water weight measurement called SpectraFoil. A new porosity
measurement capability is also available.
Experion MX also provides improvements to classic measurements. Basis weight measurements now
include a specialized 2 curie Promethium 147 (147Pm) for light weight sheets and a new infrared (IR) dry
tissue weight. Moisture measurement has been enhanced to include high power reflectance and
transmission IR for heavy weights, microwave IR sheet temperature measurement and press
section/through air dried (TAD) moisture with new ExPress fiber optic sensing. The caliper measurement
has been enhanced with light-touch UniFoil contacting and new laser non-contacting measurements. Ash
and opacity measurements are now insensitive to filler mix. Color, fluorescence and brightness
measurements now offer continuous opacity compensation. TAPPI gloss measurements have been
improved with continuous dust compensation and reduced sensitivity to misalignment.
Multivariable control
Multivariable MD control
The Experion MX Multivariable MD Control has been enhanced to make it easier to tune and maintain.
Improved nonlinear first principles automatic gain and delay retune capabilities are provided. Integrated tools
are offered for tuning and optimization. Support is delivered for multivariable controllers for process area
optimization. Multivariable model predictive control with hard constraints optimizes grade change trajectories
for a 50% reduction in grade change losses.
Multivariable CD control has the ability to optimize overall quality over and above what can be accomplished
with traditional CD control for each individual quality parameter. Unique scan-by-scan control output
provides faster grade changes and break recovery. The control understands constraints and improves
control performance when CD actuators are operating near their limits.
On-line diagnostics & service options
Experion MX provides new on-line diagnostics to provide logical and fast access to information to improve
serviceability and maintainability. Every system component is presented as a member of a logical tree
structure. Alarms and alerts are escalated to higher levels for visibility. Relevant documentation can be
accessed directly from the tree. Asset status is provided by means of detailed color-coded information that
easily identifies the source of the problem. Integrated tools make it easy to plan maintenance. Periodic
maintenance tasks automatically populate the schedule with parts and effort estimates associated with each
task. Unfinished tasks automatically roll over to the next day. Component use data determines when
periodic maintenance is scheduled.
Another trend we are seeing is that service personnel have much wider areas of responsibility these days
and / or geographical territories. Fewer people are dedicated to servicing each machine, and mills are often
combining production responsibilities with service and maintenance. The result is that detailed service
expertise is often either declining or being diluted.
Experion MX has built-in capability for remote system access, an increasingly important means to providing
backup support as an alternative to having a team of experts on site. With a secure data connection, the
Honeywell global service team can view operating parameters and diagnostic results remotely to help solve
the problem. All communication is outbound. An inbound connection can be opened only when the
papermaker’s management requests that the remote service center take control of a specific task. In short,
the experts can look over the local service engineer’s shoulder without having to be there.
In addition, to expedite scanning sensor repairs, new enhanced diagnostics help quickly pinpoint sensor
failures and performance issues. For self-maintained systems, this means more effective troubleshooting
and maintenance; for Honeywell-maintained systems, this can mean more time available for process
optimization and less time troubleshooting and repairing.
Overall, the Experion MX quality control system with fast scanning, additional measurement sensors and
new multivariable control strategies increases process visibility and provides superior control; it’s new
integreatd HMI results in easier operation, and the diagnostic and maintenance tools cut down service an
maintenance efforts - all adding up to the lowest total cost of ownership in a QCS.
Easy to operate, service and maintain… Experion MX
More Information
For more information on Experion MX QCS, visit our
website at www.honeywell.com/ps or contact your
Honeywell account manager.
Automation & Control Solutions
Process Solutions
Honeywell
1860 W. Rose Garden Lane.
Phoenix, AZ, 85027
www.honeywell.com/ps
WP-10-12-ENG
September 2010
Printed in USA
© 2010 Honeywell International Inc.