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Ultimate Water System (Installation & Commissioning)

Janosz, Richard (2010) Ultimate Water System (Installation & Commissioning). Other thesis, Murdoch University.


The Ultimate Water System is destined to be a learning tool for engineering students to develop skills in control engineering. The system has been in design and various stages of construction for several years. However, before this thesis, the pumps had never been run and the instruments had never been mounted.

The plan for this thesis was to complete the installation of the instrumentation and electrical components of the Ultimate Water System to the point where the system could be run under automatic control. The control system and user schematics developed for this thesis would not be complex, but adequate to provide a commissioning interface for the system and prove the operation of the completed system in automatic control.

The control system hardware originally installed was no longer supported by National Instruments, so its replacement with a modern National Instruments controller was included in the thesis. This involved replacing the existing National Instruments Field-Point FP-2010 Real Time controller with a National Instruments CompactRIO 9012 controller. Retrofitting the CompactRIO controller required extensive control panel rework, including relocation of the control system on the panel, re-wiring and terminal modifications.

At the start of this thesis the Ultimate Water System had pipe-work mounted equipment such as pumps, flow meters, flow valves and flow control valves installed. However no level transmitters or level switches were fitted to the tanks. The instrument control panel had been wired for the original NI controller but not installed in the cabinet. No power wiring, instrument wiring or pneumatics had been installed between the cabinet and the system.

The plan to complete the required works under-estimated the time required for the controller and field equipment installation. This resulted in a reduction in the scope of the thesis. The revised thesis delivered a complete and operational system with calibrated instrumentation and a LabVIEW commissioning program with proven control capability.

James Kurz, a fellow student, was completing his thesis based on the CompactRIO controller and HMI for the UWS in parallel with this thesis. The content of our work was discussed with Graeme Cole to ensure this course of action did not compromise our completed works.

Future enhancements for the system are included in this thesis. Some of the suggestions are considered necessary to enable the system to continue to operate such as the inclusion of filters to protect valves and flow meters.

Item Type: Thesis (Other)
Murdoch Affiliation(s): School of Engineering and Energy
Supervisor(s): Cole, Graeme
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