Desain dan Implementasi AGC Modular Berbasis OPC UA dan PLC RX3i pada Sistem Turbin Gas TM2500 di PLTG Suppa 2X25 MW

Wahyudi, Wahyudi (2026) Desain dan Implementasi AGC Modular Berbasis OPC UA dan PLC RX3i pada Sistem Turbin Gas TM2500 di PLTG Suppa 2X25 MW. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Penerapan Automatic Generation Control (AGC) pada unit pembangkit diperlukan untuk mendukung pengaturan frekuensi, pelaksanaan dispatch daya aktif, program anti-blackout, serta peningkatan keandalan sistem tenaga listrik. Namun, fasilitas AGC bawaan pada turbin gas GE TM2500 di PLTG Suppa 2×25 MW belum dapat diaktifkan secara langsung karena memerlukan konfigurasi ulang oleh Original Equipment Manufacturer (OEM), biaya tinggi, waktu implementasi panjang, dan akses logika kontrol yang terbatas. Kondisi tersebut menimbulkan kesenjangan antara kewajiban pemenuhan Grid Code dan kesiapan implementasi AGC di lapangan. Penelitian ini bertujuan merancang, mengimplementasikan, dan mengevaluasi sistem AGC modular sebagai plant-side dispatch-following supervisory layer tanpa memodifikasi protected OEM core logic. Arsitektur sistem mengintegrasikan Master SCADA RCC, gateway C264, KEPServerEX, komunikasi OPC UA dan Modbus, HMI serta logika berbasis Node-RED, dan PLC RX3i. Pengujian meliputi komunikasi baca-tulis, kesesuaian data waktu nyata, pemeriksaan permissive, pembatasan dan pembagian setpoint, penyaringan spike menggunakan filter Kalman, serta respons ramp-up dan ramp-down. Hasil pengujian menunjukkan bahwa 37 dari 37 tag berhasil berkomunikasi dengan tingkat keberhasilan 100%. Delay komunikasi lokal tercatat rata-rata 100 ms dan maksimum 200 ms, sedangkan delay end-to-end RCC–pembangkit sebesar 200 ms, sehingga memenuhi target kurang dari 500 ms. Logika Node-RED memastikan setpoint hanya diteruskan ketika persyaratan operasi terpenuhi. Filter Kalman mampu mereduksi spike ekstrem, tetapi tetap mengikuti perubahan setpoint yang valid. Pengujian lapangan menghasilkan ramp rate rata-rata 0,80 MW/menit pada ramp-up dan 1,52 MW/menit pada ramp-down. Dibandingkan pendekatan OEM, biaya implementasi dapat ditekan dari Rp1,60 miliar menjadi Rp109 juta atau hemat 93,19%, sedangkan waktu penerapan berkurang dari 3–6 bulan menjadi sekitar dua minggu. Dengan demikian, sistem yang dikembangkan lebih fleksibel, ekonomis, vendor-independent, dan berpotensi direplikasi pada unit TM2500 lain dengan penyesuaian konfigurasi komunikasi, pemetaan tag, dan batas operasi. Pendekatan ini juga meningkatkan kemandirian engineer lokal dalam pengembangan dan pemeliharaan sistem.
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The implementation of Automatic Generation Control (AGC) in generating units is required to support frequency regulation, active-power dispatch, anti-blackout programs, and power-system reliability. However, the built-in AGC facility of the GE TM2500 gas turbines at PLTG Suppa 2×25 MW cannot be activated directly because it requires OEM reconfiguration, high costs, long implementation time, and limited access to control logic. This creates a gap between Grid Code requirements and readiness for AGC implementation. This study aims to design, implement, and evaluate a modular AGC system as a plant-side dispatch following supervisory layer without modifying the protected OEM core logic. The system architecture integrates the RCC Master SCADA, C264 gateway, KEPServerEX, OPC UA and Modbus communication, a Node-RED based HMI and control logic, and the RX3i PLC. The tests covered read/write communication, real-time data consistency, permissive checking, setpoint limiting and allocation, spike filtering using a Kalman Filter, and ramp-up and ramp-down responses. The results showed that all 40 tags communicated successfully, achieving a 100% success rate. The average local communication delay was 100 ms, with a maximum of 200 ms, while the RCC-to-plant end-to-end delay was 200 ms, satisfying the target of less than 500 ms. The Node-RED logic ensured that setpoints were forwarded only when operating requirements were satisfied. The Kalman Filter reduced extreme spikes while following valid setpoint changes. Field testing produced average ramp rates of 0.80 MW/min during ramp-up and 1.52 MW/min during ramp-down. Compared with the OEM approach, the implementation cost decreased from IDR 1.60 billion to IDR 109 million, representing a saving of 93.19%, while the implementation period decreased from 3–6 months to two weeks. Therefore, the developed system is flexible, economical, vendor-independent, and potentially replicable on other TM2500 units with adjustments to communication configuration, tag mapping, and operating limits. This strengthens engineers’ independence in system development and maintenance.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	KEPServerEX, Modular AGC, Node-RED, OPC UA, PLC RX3i. KEPServerEX, Modular AGC, Node-RED, OPC UA, RX3i PLC.
Subjects:	T Technology > TK Electrical engineering. Electronics Nuclear engineering > TK1007 Electric power systems control T Technology > TK Electrical engineering. Electronics Nuclear engineering > TK1322.6 Electric power-plants
Divisions:	Faculty of Intelligent Electrical and Informatics Technology (ELECTICS) > Electrical Engineering > 20101-(S2) Master Thesis
Depositing User:	Wahyudi Wahyudi
Date Deposited:	03 Aug 2026 03:46
Last Modified:	03 Aug 2026 03:46
URI:	http://repository.its.ac.id/id/eprint/142884

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