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Engineering Internship Final Report: Process Control Engineering

Edwards, Kyle (2010) Engineering Internship Final Report: Process Control Engineering. Internship Report, Murdoch University.

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In 2010, two final year students studying Instrumentation and Control Engineering at Murdoch University were given the opportunity to undertake a six month Process Control Engineering internship program at BHP Billiton’s Worsley Alumina Refinery located in the south west of WA. The purpose of this document is to present the work carried out on a number of projects by an intern employed as a Murdoch University Contractor at the Worsley Alumina Refinery.

Prior to commencing project work the intern needed to gain an understanding of the refinery’s operations, control system architecture and some of the software tools utilised by Process Control Engineers. A summary of these are provided in this document preceding discussion of the intern’s project work.

Projects covered in detail in this document related directly to the field of Process Control Engineering and allowed the intern to experience a broad range of tasks from control loop tuning through to configuration of software and hardware relating to the Refinery’s Distributed Control System (DCS). Background information, methodologies for implementation and a summary of findings or future recommendations are presented for each of the four projects covered in detail. The four projects detailed in this report are as follows;

• Network Configuration for a Foundation Fieldbus (FFB) Training Exercise
• DCS to PLC Communications Interface Project
• Gas Calculation Migration to an ACE Control Module
• Offline SISO Control Loop Tuning Utilising Tune Wizard

Also covered in this report are brief summaries of other work undertaken by the intern including projects ascertaining to the building of Human Machine Interface (HMI) graphical pages, migration of DCS point information and training courses undertaken to improve the intern’s technical and professional development as an engineer.
The Process Control Engineering internship program offered by BHP Billiton Worsley Alumina Pty Ltd and Murdoch University allowed the intern to gain relevant industry experience through the application of knowledge gained in his university studies and was thoroughly worthwhile.

Item Type: Internship Report (Bachelor of Engineering)
Murdoch Affiliation: School of Engineering and Energy
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