Implementasi Sistem Pigging pada Proses Transfer Cat dengan Metode Finite State Machine untuk Product Recovery

Putra, Surya Pratama (2026) Implementasi Sistem Pigging pada Proses Transfer Cat dengan Metode Finite State Machine untuk Product Recovery. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Jalur distribusi konvensional (non-pigging) di salah satu perusahaan cat mencatat Loss Rate dengan rata-rata 13,42% pada Produk A berdasarkan data operasional periode Januari hingga Maret 2026. Untuk mengatasi hal ini, perusahaan membangun sistem pigging pada 9 jalur distribusi baru yang beroperasi paralel dengan jalur lama. Puluhan instrumen lapangan di tiap jalur menghasilkan ratusan titik Input/Output (I/O) yang dikendalikan oleh satu unit kontroler. Penelitian ini mengimplementasikan algoritma kendali pada infrastruktur pigging yang sudah terpasang, bertujuan meningkatkan product recovery dan mengevaluasi kinerjanya dibandingkan jalur konvensional (non-pigging). Sistem dibangun pada PLC Modicon M580 dan HMI HMIET6500x (Schneider Electric), dengan menerapkan metode Finite State Machine (FSM) untuk mencegah race condition yang berisiko muncul akibat kompleksitas 28 state operasional sistem. Sistem divalidasi melalui tiga tahap, yaitu I/O check, Dry run, dan Wet run. Hasil komparatif menunjukkan penurunan Loss Rate dari 13,42% pada jalur non-pigging menjadi -1,82% pada jalur pigging (nilai negatif menunjukkan pemulihan residu carry-over dari siklus sebelumnya melalui mekanisme pig clearance, bukan kerugian material).
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The conventional (non-pigging) distribution line at a paint company recorded an average Loss Rate of 13.42% for Product A, based on operational data from January to March 2026. To address this, the company built a pigging system across 9 new distribution lines operating in parallel with the existing line. Dozens of field instruments per line result in hundreds of Input/Output (I/O) points controlled by a single controller unit. This research implements a control algorithm on the already-installed pigging infrastructure, aiming to improve product recovery and evaluate its performance against the conventional (non-pigging) line. The system was built on a Modicon M580 PLC and HMIET6500x HMI (Schneider Electric), applying the Finite State Machine (FSM) method to prevent race conditions that could arise from the complexity of the system's 28 operational states. The system was validated through three stages, namely I/O check, Dry run, and Wet run. Comparative results show a Loss Rate reduction from 13.42% on the non-pigging line to -1.82% on the pigging line (the negative value reflects the recovery of carry-over residue from the previous cycle through the pig clearance mechanism, rather than material loss).

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Finite State Machine, Human Machine Interface, Product recovery, Programmable Logic Controller, Sistem Pigging. Finite State Machine, Human Machine Interface, Pigging System, Product recovery, Programmable Logic Controller.
Subjects:	T Technology > TK Electrical engineering. Electronics Nuclear engineering > TK3070 Automatic control
Divisions:	Faculty of Vocational > 36304-Automation Electronic Engineering
Depositing User:	Surya Pratama Putra
Date Deposited:	05 Aug 2026 08:54
Last Modified:	05 Aug 2026 08:54
URI:	http://repository.its.ac.id/id/eprint/144070

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