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Experion simulation and pilot plant maintenance

Meiri, Timothy (2015) Experion simulation and pilot plant maintenance. Other thesis, Murdoch University.

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The Honeywell Experion Process Knowledge System (PKS) and Pilot Plant are both unique and invaluable teaching tools used in Instrumentation and Control Engineering at Murdoch University. The Pilot Plant is one of the most industry relevant practical components, which can be used to apply and develop theoretical control knowledge. Therefore it is essential to maintain and upgrade the Pilot Plant’s operability and performance. The main purpose of this thesis is to extensively analyse the current condition of the Pilot Plant, propose and organise an agenda to fix faulty components, install new components or new coding to ensure safer operations to protect users as well as equipment, and improve its working condition. To successfully achieve these goals, the project holder should have a moderate knowledge about the Pilot Plant server, Experion supervisory control system and the Pilot Plant’s C300 controller. This knowledge is usually obtained from working and practicing on the Experion Teaching System, which is the first aim to start the project.

As the Experion Training system was available for 3 months the work done to this system was limited. To improve some of the tutorial exercises and the documentation prepared by previous students, a simulated Experion system using a C300 controller and a Human-Machine Interface (HMI) page for the controlled system was developed and properly documented. The simulated system can use Object Linking and Embedding for Process Control (OPC) to link to a LabVIEW program. This is a fundamental step providing another linkage between Experion and a MATLAB program through OPC in the future.

The Pilot Plant Experion system has been extensively investigated in both hardware and software. By gaining an in-depth understanding of the system it was possible to identify the current problems regarding the plant and devise practical solutions for them. Numerous issues were resolved both physically and in the code. To prevent new issues from occurring, multiple interlocks have been designed, implemented and tested. Additionally the system’s code has also undergone restructuring, mainly in the form of removing redundant code. New sensors and actuators have also been installed and integrated into the system.

Through the comprehensive research and development that was undertaken over the course of this thesis, it has become apparent that there is a vast range of projects and opportunities that can build upon this knowledge base and continue to improve the Murdoch University Pilot Plant and ultimately the Instrumentation and Control Engineering degree.

Publication Type: Thesis (Other)
Murdoch Affiliation: School of Engineering and Information Technology
Supervisor: Vu, Linh and Cole, Graeme
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