Sistem Otomatisasi Pengisian Air Pada Vertical Fire Tube Boiler Berbasis OPC (Open Platform Communication)

Nanta, Tepy Lindia (2026) Sistem Otomatisasi Pengisian Air Pada Vertical Fire Tube Boiler Berbasis OPC (Open Platform Communication). Diploma thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Sistem otomatisasi pengisian air pada Vertical Fire Tube Boiler berbasis OPC (Open Platform Communication) dirancang untuk meningkatkan keandalan dan keselamatan operasional boiler dengan menjaga kestabilan level air secara otomatis. Sistem ini mengatasi masalah fluktuasi level air yang dapat menyebabkan dry run atau overfill, yang berpotensi merusak komponen boiler dan menurunkan efisiensi termal. Pengendalian manual yang konvensional dinilai kurang responsif dan akurat, sehingga sistem ini mengintegrasikan Level Switch Float Magnetic, aktuator (pompa dan solenoid valve), dan Programmable Logic Controller (PLC) Schneider M221 untuk mengatur pengisian air berdasarkan logika ON/OFF. Protokol OPC digunakan untuk memfasilitasi komunikasi real time antara PLC dan perangkat pemantauan seperti Mini PC, memungkinkan pengawasan tanpa antarmuka HMI fisik. Sistem ini dirancang dengan kapasitas boiler 45,5 liter dan volume pengisian minimal 19,1 liter, menggunakan material stainless steel grade 304 sesuai standar ASME. Pengujian meliputi validasi komponen, simulasi proses dengan perangkat lunak HYSYS dan ANSYS, serta evaluasi kinerja sistem dalam menjaga level air. Hasil yang didapatkan adalah sistem berhasil menjaga level air dalam rentang aman dengan akurasi validasi komponen ≥ 96%. Integrasi OPC melalui KEPServerEX dan komunikasi real-time dengan Mini PC berfungsi optimal. Analisis ANSYS menunjukkan head loss pada inlet 0,062 m dan outlet 0,021 m, keduanya dalam batas yang dapat diterima. Sistem otomatisasi berbasis PLC dan OPC dapat meningkatkan keandalan, keselamatan, dan efisiensi operasional boiler. Hasil ini memberikan referensi teknis untuk implementasi sistem kontrol serupa dalam skala industri kecil dan menengah, serta menjadi sarana pembelajaran pentingnya sistem kontrol dalam proses industri.
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The OPC (Open Platform Communication) based water filling automation system for Vertical Fire Tube Boilers is designed to improve boiler operational reliability and safety by automatically maintaining stable water levels. This system addresses the issue of water level fluctuations that can cause dry runs or overfills, which can potentially damage boiler components and reduce thermal efficiency. Conventional manual control is considered less responsive and accurate, so this system integrates a Magnetic Float Level Switch, actuators (pumps and solenoid valves), and a Schneider M221 Programmable Logic Controller (PLC) to regulate water filling based on ON/OFF logic. The OPC protocol is used to facilitate real-time communication between the PLC and monitoring devices such as Mini PC, enabling monitoring without a physical HMI interface. This system is designed with a boiler capacity of 45.5 liters and a minimum filling volume of 19.1 liters, using 304 grade stainless steel material in accordance with ASME standards. Testing included component validation, process simulation with HYSYS and ANSYS software, and evaluation of the system's performance in maintaining water levels. The results showed that the system successfully maintained water levels within a safe range with component validation accuracy ≥ 96%. OPC integration via KEPServerEX and real-time communication with the Mini PC functioned optimally. ANSYS analysis showed head loss at the inlet of 0.062 m and at the outlet of 0.021 m, both within the acceptable range.

Item Type:	Thesis (Diploma)
Uncontrolled Keywords:	Vertical Fire Tube Boiler, Otomatisasi, OPC, PLC, Level Air Vertical Fire Tube Boiler, Automation, OPC, PLC, Water Level
Subjects:	T Technology > TK Electrical engineering. Electronics Nuclear engineering > TK3070 Automatic control
Divisions:	Faculty of Vocational > Instrumentation Engineering
Depositing User:	Tepy Lindia Nanta
Date Deposited:	24 Jul 2026 07:42
Last Modified:	24 Jul 2026 07:42
URI:	http://repository.its.ac.id/id/eprint/137313

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