Pengalaman Pekerjaan Sebelumnya: - Instrument Commissioning Engineer - Software & Control Engineer - Electrical Production Engineer

3/15/2016

Topik Khusus Kendali Juni Ardi Irawan 14 Maret 2016

Nama

: Juni Ardi Irawan Alumni FTUI, Angkatan 1997, Kendali (Control)

Pekerjaan : Instrumentation Engineer (termasuk Control Engineer & Metering Engineer) di Dept. Maintenance, VICO Indonesia

Pengalaman Pekerjaan Sebelumnya: - Instrument Commissioning Engineer - Software & Control Engineer - Electrical Production Engineer

Blog

:

https://juare97.wordpress.com

disusun oleh Juni A. Irawan

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sumber: Circor Energy


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sumber: www.vico.co.id

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Arthit (AWP, APP, AQP), Gulf of Thailand, Arthit PTTEP

sumber: dokumen pribadi

sumber: http://www.yokogawa.com/iab/suc/oilgas/iab-suc-pptep-en.htm disusun oleh Juni A. Irawan

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FPSO (Floating, Production, Storage & Offloading) Belanak, Belanak, Natuna, Natuna, Indonesia, ConocoPhillips

Sumber: http://www.inpex.co.jp/english/ business/indonesia.html

Sumber: http://www.flickr.com/photos/ 7368810@N03/423817857/

Sumber: http://www.aukevisser.nl/supertankers/FPSO-FSO/id515.htm disusun oleh Juni A. Irawan

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RTU

Control Room

Ilustrasi …

RTU

MTU

PCS – Process Control System

Field

(DCS/PLC)

PCS Field Instr. (PT, LT, PCV, LCV, dll)

F&G Devices (Flame Det, Gas Det, dll)

F&G System (PLC/EQP, dll)

SIS (SIF LS) / ESD System

SIF atau ESD (Sensor (PT, LT, dll) / Final Element (SDV, BDV, dll))

Unit/Package -Feed Gas/Sales Gas Compressor -Generator -Heater -Air Compressor -dll

Slide in berisi ANIMASI

(TMR / PLC) CP (PLC+HMI) CP (PLC+HMI)


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Pabrik Elektronika Pabrik Otomotif Pabrik Petrochemical Pabrik Food and Beverages Dan lain sebagainya…


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Programmable Logic Controller

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PLC adalah singkatan dari Programmable Logic Controller, Controller dalam Bahasa Indonesianya: Pengendali Logika Terprogram

(PLT).

Pengendali artinya menunjukkan kemampuan dalam mengontrol dan mengatur proses sehingga menghasilkan output yang diinginkan. Logika menunjukkan kemampuan dalam memproses input secara aritmatik dan logic, yakni melakukan operasi membandingkan, menjumlahkan, mengalikan, membagi, mengurangi, negasi, AND, OR, dan lain sebagainya Terprogram maksudnya adalah bisa diprogram dengan komputer sehingga mudah diubah-ubah bila perlu.


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PLC diperkenalkan akhir tahun 60-an Alasan utamanya adalah untuk menghilangkan harga yang mahal untuk Sistem Relay Konvesional yang rumit. Bedford Associates (Bedford, MA) mengajukan alat dengan nama Modular Digital Controller (MODICON) ke perusahaan mobil di US. MODICON 084 adalah PLC yang pertama kali dikomersilkan di dunia.


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Hanya diperlihatkan saat Presentasi….


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Sekuensial Control PLC memproses input sinyal biner menjadi output yang digunakan untuk keperluan pemrosesan teknik secara berurutan (sekuensial), disini PLC menjaga agar semua step atau langkah dalam proses sekuensial berlangsung dalam urutan yang tepat. Contoh: Vacuum Lifter, Lampu lalu lintas. Monitoring Plant PLC secara terus menerus memonitor status suatu sistem (misalnya temperatur, tekanan, tingkat ketinggian) dan mengambil tindakan yang diperlukan sehubungan dengan proses yang dikontrol (misalnya memonitor level tangki) Shutdown System PLC berfungsi sebagai electrical shutdown system bersamaan dengan mechanical shutdown system. PLC juga digunakan paralel dengan DCS sebagai Start permition system, package local control, dll.


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Mudah diganti-ganti rangkaian Logikanya (programming). Mudah menyelesaikan troubleshooting di lapangan karena power Linenya kelihatan. Sangat menghemat tempat karena menyederhanakan komponen-komponen sistem kontrol. Flexsibel. Dokumentasi lebih baik dll


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Fixed ◦ Power Supply, Processor, I/O module sebagai satu unit. Tidak bisa dipisahkan

Modular

Chassis sebagai Base dari PLC Module.

◦ Power Supply, Processor, I/O module adalah modul terpisah. Mudah diubah berdasarkan kebutuhan. Lebih flexible in menambah dan merubah I/O-I/O nya

Module

… Installed


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1 2 3 1. 2. 3. 4.

5.

Power Supply Processor Modul Komunikasi Basic I/O Module - Analog - Discrete Modul Spesial - High Speed Counter Module - dll

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INPUT Flow transmitters Pressure transmitters Temperature transmitters Position transmitters Level transmitters

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OUTPUT Electric motor drives Analog meters Chart data recorders Process controllers Variable Speed Drives Control Valves


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INPUT Selector Switch Temperature Switch Flow Switch Level Switch Pushbutton Motor starter contacts (running, tripped) Limit Switch Pressure Switch Relay Contact

OUTPUT Annunciator Alarm light Electric fan Indicating light Electric valve Alarm horn Selenoid valve Motor starters


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Memeriksa status dari Input Control proses dengan menjalankan program lalu meng-Update Output-outputnya Program akan dijalankan secara periodic berdasarkan waktu tertentu (tergantung dari setting dan seberapa besar programnya) Pengguna dapat merubah program dan mendownload ke PLC kapan saja. Untuk perubahan yang kecil tidak akan mempengaruhi kinerja Sistem (tidak perlu untuk shutdown)


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Contact adalah kode program yang memonitor Status Input nya

… check input …

… eksekusi program …

… update output…

Coil adalah kode program untuk merepresentasikan Output yang merupakan hasil dari operasi logic Ini menjadi acuan untuk mengupdate physical Output disusun oleh Juni A. Irawan

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Rancangan Sistem Kendali Penentuan I/O Perancangan Program Pemrograman Menjalankan Sistem (Testing)

Apabila masih ada kekurangan kembali ke langkah 3

1. 2. 3. 4.


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IEC-61131-3 - Ladder Diagram (LD) - Function Block Diagram (FBD) - Instruction List (IL) - Structure Text (ST) - Sequential Function Chart (SFC)

IEC = International Electrotechnical Commission


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Merepresentasi relay ladder diagram listrik Paling banyak digunakan


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Program dalam bentuk diagram block

Mendeskripsikan hubungan atau fungsi antara beberapa input dan output

Sangat cocok dengan banyak aplikasi yang berhubungan dengan arus informasi dan data di antara komponen kontrol.

programmer dapat membuat prosedur kontrol yang kompleks

Extensive function blocks library disediakan


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Merepresentasikan set dari step-step yang dihubungkan oleh transisi-transisi. Aksi dalam step ini menggunakan Bahasa Structured Text (ST)


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Sangat efektif untuk aplikasi yang kecil atau optimisasi bagian dari aplikasi list dari instruksi level rendah (low level instructions) Terdiri dari operasi-operasi yang distandardkan ◦ Data manipulation ◦ Arithmetic ◦ Branch instruction Contoh: Start : LD pushbutton *) ANDN ST motor *)

IX1

(* load input IX1, start

MX5

(* AND with NOT of MX5)

QX2

(* store output QX2 to start disusun oleh Juni A. Irawan

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Umumnya digunakan untuk prosedur yang kompleks Bahasa Baku untuk mendeskripsikan aksi didalam step dan kondisi di transisi dari SFC Tipe-tipe Statement: ◦ assignment imax:=max_ite; cond:=X12; ◦ subprogram or function call if not(cond(*alarm*)) ◦ “C” function block call then return; end_if; ◦ Selection (if, then, else, case, etc) for i:=1 to max_ite do if i<>2 then ◦ Iteration (for, while, repeat, etc) SPcall(); ◦ Control (return, exit, etc) end_if; end_for; ◦ Special disusun oleh Juni A. Irawan

Rockwell - Allen Bradley Schneider Electric Siemens Mitsubishi GE Fanuc Omron LG dll


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Allen Bradley Controllogix

Schneider – Modicon Quantum

Siemens – S7-400

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CompactLogix

Controllogix

MicroLogix SLC

PLC-5 disusun oleh Juni A. Irawan

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SCHNEIDER SIEMENS S5 Family S7-200 S7-300 S7-400 S7-1200 S7-1500 … Modicon Quantum Modicon TSX Micro SCADA Pack …


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Allen Bradley RSLogix5/500/5000 Schneider Electric Concept, dll Siemens Step5, Step 7, dll Mitsubishi Melsec dll

Beda Manufacture, beda Software !!


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Human Machine Interface / Man Machine Interface

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HMI = Human Machine Interface MMI = Man Machine Interface HMI/MMI adalah sekumpulan hardware dan software yang digunakan operator atau user lainnya untuk memonitor dan berinteraksi dengan sistem kontrol dengansaat proses melalui sistem Hanya dan diperlihatkan Presentasi…. kontrol. *

* ANSI/ISA-101.01-2015, Human Machine Interfaces for Process Automation Systems

Monitoring Setting (dibatasi oleh Security Level) Take Action (dibatasi oleh Security Level) Troubleshooting:

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Alarm (History or Summary) Trending (History or Real Time)

Analisa dan lain sebagainya disusun oleh Juni A. Irawan

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* ANSI/ISA-101.01-2015, Human Machine Interfaces for Process Automation Systems disusun oleh Juni A. Irawan

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Operations-users Maintenance-users Engineering-users Administrators-users Management-users Analysts-users Others-users


1. 2. 3. 4. 5. 6. 7.

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Wonderware – Intouch Siemens - WinCC Schneider - Vijeo look Rockwell - RSView CiTect HMI Lab VIEW etc


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CitectHMI

Wonderware Intouch

RSView disusun oleh Juni A. Irawan

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Vijeo Look

GE Cimplicity disusun oleh Juni A. Irawan

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HMI OPC PLC disusun oleh Juni A. Irawan

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Object Linking and Embedding (OLE) for Process Control. Sebuah standard mekanisme software untuk sharing data antara process automation (SCADA) dari manufacturer yang berbeda OPC berdasarkan Microsoft OLE (Object Linking and Embedding) dan DCOM (Distributed Component Object Model) Keuntungan OPC: ◦ ◦ ◦ ◦

Simple to implement Flexible to accommodate multiple vendor needs Provide a high level of functionality Allow for efficient operation


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Allen Bradley (DF1, DH+, DH-485, DeviceNet, ControlNet, Ethernet)

Modicon Quatum (Modbus, Modbus+, Modbus TCP/IP, etc)

SIEMENS (MPI, Profibus DP, ethernet, etc)

Other Brand Other protocol …


Compact Logix

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PC


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Kabel Modbus Konfigurasi Pinout – PC ke PLC


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Control System Exampe


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Control System Exampe

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Contoh Aplikasi

field

Tank

PCV LSH PIT A

Horn

PIT B

LIT LSL Pump disusun oleh Juni A. Irawan

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Contoh Aplikasi (cont’d) Field Instrument

PLC

PIT B PS

Analog Output PCV

AI AO DI DO

PIT A

Komunikasi

LIT

Processor

Analog Input

Discrete Input LSH

LSL

Discrete Output Horn

Terminal Block


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Contoh Aplikasi (cont’d) PLC

MMI

DO

CPU AI AO DI

Komunikasi

PS Processor

Monitor

Program PLC Program HMI/MMI 58 disusun oleh Juni A. Irawan

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Turbine Control Panel Solar Turbines –Turbotronic


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TIPE NON ENCLOSURE

TIPE ENCLOSURE

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Solar uses Rockwell / Allen-Bradley hardware for the Turbotronic control system.

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Control Panel Compressor 16V 27ATGL


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EXHAUST STACK

T/ C

Stepper motor

FUEL GAS

INTERCOOLER

Heater OXYGEN SENSOR

BYPASS

BAP

CARBURATOR AIR INLET

GOVENOR

WASTEGATE

Temp Inlet

INTAKE MANIFOLD Hanya diperlihatkan saat Presentasi…. MAP

MAN PICKUP

ENGINE

Engine Speed

DSM Filter

AFM

WOODWARD 701A

Speed S/P

PLC

IM

DSM

TCM 71

Emergency Shutdown System


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Fire & Gas System


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Sensor: Flame Detector Gas Detector Smoke Detector Manual Alarm Call Point / Break Glass dll

Hanya diperlihatkan saat Presentasi…. Output: Alarm Fire Confirm dll


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Water Injection and Oil Shipping


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Kotabatak GS – overview 2002


disusun oleh Juni A. Irawan 77

PLC Modicon Quantum PLC Water Injection (WI)


PS

CPU NOE

AI

AO

DI

DO


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Kotabatak Gathering Station



Water Injection System – WI Pumps



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Oil Shipping System – OS Pumps



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Water Injection System – PLC Panel



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Oil Shipping System – PLC Panel



Water Injection System – MMI - Wonderware



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Wheat Cleaning System



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Safety Instrumented System


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Safety Instrumented System adalah istilah yang digunakan untuk: • Emergency Shutdown System (ESD), • Safety Shutdown System, • Interlock System, • Permissive System, • Safety System, • Emergency Trip System, etc


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ANSI/ISA 84.01 SIS didefinisikan sebagai: “ Sistem yang terdiri dari sensors, logic solvers, dan final elements yang bertujuan untuk mengembalikan proses ke safe state (kondisi aman) pada saat proses telah melewati kondisi yang ditentukan.” disusun oleh Juni A. Irawan

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IEC 61511, SIS didefinisikan sebagai: Sistem Instrumentasi yang diimplementasikan untuk satu atau lebih safety instrumented function (SIF). SIS terdiri dari kombinasi sensors, logic solvers, dan final elements. SIF sendiri didefinisikan sebagai: Fungsi safety dengan nilai Safety Integrity Level tertentu


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Nilai diskrit (1-4) untuk menspesifikasi safety integrity yg dibutuhkan oleh safety instrumented function (SIF) untuk dialokasikan dalam safety instrumented system (SIS)

Safety Integrity Level

Low Demand of Operation (Average probability of Failure to perform its design function on demand)

Risk Reduction Factor

4

≥ 10-5 to < 10-4

100,000-10,000

3

≥ 10-4 to < 10-3

10,000-1,000

2

≥ 10-3 to < 10-2

1,000-100

1

≥ 10-2 to < 10-1

100-10


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Community Emergency Response Plant Emergency Response Physical Protection ( Containment Dikes ) Mechanical Protection ( Relief Devices, Design ) Safety Instrumented System (SIS) Critical Alarm, Operator Intervention Basic Process Control System


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SIF = Safety Instrumented Function

One or more initiator(s)

One or more Final Element(s)

Logic Solver

Purpose: to prevent a hazard


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Undesirable event adalah kejadian tidak diinginkan pada komponen proses yg menimbulkan bahaya pada keselamatan. Undesirable event yg dapat memberikan efek pada proses adalah: • Overpressure

• • •

Tekanan pada proses yg melampaui nilai maksimum tekanan yg diperbolehkan (maximum allowable working pressure). Bocor (Leak) Kejadian keluarnya fluida (contohnya Hydrocarbon) dari proses ke atmosfir. Liquid Overflow Liquid di proses yg masuk ke sistem proses Gas/ Vapour. Gas Blowby Gas di proses yg masuk ke sistem proses liquid.


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•

•

•

Underpressure Tekanan pada proses yg lebih kecil dari desain tekanan jatuh (Collapse Pressure). Excess Temperature Temperatur pada proses yang melebihi desain operasi. Sumber Api langsung (Direct Ignition Source) Permukaan, api, percikan api pada temperatur dan kapasitas yg cukup untuk menimbulkan ledakan.


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Manufacture: ABB, Hi Controller Yokogawa, Prosafe RS Triconnex – Trident Rockwell – AADvance, Trident HIMA – HIMax Honeywell


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Distributed Control System

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Requiring many operators Operators continuously circulated around each processing unit

observing locally mounted large indicating instruments appropriate calculations to adjust valves dampers drives other end elements


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Large indicating instruments & controls were moved into one location Bringing the plant to the operator rather than requiring the operator to go out into the plant Reduce the time lag in their decisions on the process performance Easier and faster for the operators to spot interactions between different portions of process

All of this was done through local control and monitoring using direct wiring and analog signals not much wiring/tubing (+) not much control (-) not much monitoring (-) not much “alarming” (-)


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After World War II Electronic controls became more rugged and practical More measurement were becoming possible Cost of sensors was coming down There were newer types of sensors The size of controllers was smaller More of them could fit on a panel, in a smaller area

more complex control room disusun oleh Juni A. Irawan

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Business Management

Asset management Investment plan Production plan

Plant operation plan Stable plant operation Process monitoring

Device management Device monitoring Inspection & maintenance

DCS

Process Management

Field Management Device Management Tool


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Yokogawa: Centum CS3000 R3 / Centum VP (R5) Honeywell Foxboro ABB dll


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human machine interface Operator Operation and monitoring function

Display and operation function station Human – machine database Communication system

Other System Communication between other systems

Gateway

Engineer System configuration, System maintenance

Control Data-base Control station Control function DDC/SEQ

Process

engineering interface

interface to other systems

Operator

Process

process interface disusun oleh Juni A. Irawan

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Fungsi

FCS:

• Mengambil input yang masuk dari transmiter dan perintah operator • Perhitungan sinyal kontrol • Mengirimkan sinyal kontrol ke aktuator Komponen

• • • •

FCS:

Central Processor Unit (CPU) Catu daya (Power Supply Unit, PSU) VL net coupler Modul masukan/keluaran (I/O modules, IOM) disusun oleh Juni A. Irawan

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Process Flow Diagram (PFD) Piping/Process and Instrumentation Diagram (P&ID) Data Sheet Hook-up Drawing Schematic Drawing Interconnection Wiring Diagram Cable Schedule Cable Block Diagram Cable Layout

… lanjut slide berikutnya ..


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Networking Diagram Process Control Narrative / Control Philosophy / Functional Design Spesification (FDS) Logic Diagram Loop Diagram Cause and Effect (C& E) Chart IO List FAT (Factory Acceptance Test) Report MC / PC Certificate SAT (Site Acceptance Test) Report Commissioning Procedure SOP (Standard Operating Procedure) Preventive Maintenance (PM) Certificate Dan lain sebagainya …


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process flow diagram is a diagram that defines a process schematically and shows how much of each product a plant might make.


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A typical oil refinery

Sumber: http://en.wikipedia.org/wiki/Process_flow_diagram


A piping and instrumentation diagram/drawing (P&ID P&ID) P&ID is a diagram in the process industry which shows the piping of the process flow together with the installed equipment and instrumentation.

A piping and instrumentation diagram/drawing (P&ID) is defined by the Institute of Instrumentation and Control as follows: 1. A diagram which shows the interconnection of process equipment and the instrumentation used to control the process. In the process industry, a standard set of symbols is used to prepare drawings of processes. The instrument symbols used in these drawings are generally based on International Society of Automation (ISA) Standard S5. 1. 2. The primary schematic drawing used for laying out a process control installation. P&IDs play a significant role in the maintenance and modification of the process that it describes. It is critical to demonstrate the physical sequence of equipment and systems, as well as how these systems connect. During the design stage, the diagram also provides the basis for the development of system control schemes, allowing for further safety and operational investigations, such as the hazard and operability study (HAZOP).


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For processing facilities, it is a pictorial representation of Key piping and instrument details Control and shutdown schemes Safety and regulatory requirements Basic start up and operational information

Sumber: http://en.wikipedia.org/wiki/P%26ID


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Typical P&ID arrangement for 3 phase separator vessels Sumber: http://www.enggcyclopedia.com/2011/04/typical-pid-arrangement-3phase-separator-vessels/ disusun oleh Juni A. Irawan

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Loop diagram shows complete details of a hydraulic, electric, magnetic, or pneumatic circuit, showing all of the interconnections, components, and devices that participate in that circuit.


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Silahkan cari di mbah google yah .. ☺



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Instrumentation Engineer di Engineering Company (contoh: J Ray McDermott, KBR, Rekayasa Engineering, dll)

Instrumentation di Fabrication/Contruction Company (Contoh: J Ray McDermott Batam, Saipem , Nisconi, Hyundai, Gunanusa, dll) ◦ Instrument Production Engineer di Dept. Prod. ◦ Instrument Inspector di Dept. QC ◦ Instrument Commissioning Engineer di Dept. Completion/Commissioning Software & Control Engineer di System Integrator (Kota Minyak, Wifgas, Milway Eng., RES, Somit, dll) Instrument & Control Engineer di OEM (Solar Turbines, Yokogawa, Control System dll) Instrument Engineer di Oil&Gas Company ◦ Dept. E&C, plus Instrument Inspector ◦ Dept. Maintenance Control Engineer (PLC dan atau DCS Engineer) di Oil&Gas Company Pejabat pemerintahan di Ditjen Migas / Pejabat SKK Migas (misal dalam urusan sertifikasi Meter, Audit, dll)

dan lain sebagainya ….


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Maret 2016


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Allen Bradley Website, www.ab.com Siemens Website Schneider Website Wonderware Website, www.wonderware.com Solar Turbines Product Information Letter 180 Training Process Control Using Distributed Control System, Bandung, 2012 – ITB Training DCS CS3000 Engineering, Jakarta, 2012 – Yokogawa Training Basic PLC & HMI – Juni A. Irawan. Kuliah Umum, Instrumentation & Control in Oil & Gas Industry (Pengenalan), IEEE SB UI & OFFSHORE-SKILLS.COM, UI Depok, 9 Nov 2013 – Juni A. Irawan. dan lain sebagainya … (Apabila sumber belum tercantum mohon dimaklumi dan dimaafkan )… ☺


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Pengalaman Pekerjaan Sebelumnya: - Instrument Commissioning Engineer - Software & Control Engineer - Electrical Production Engineer

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