Alfarizy, Muchamad Yahya (2026) Rancang Bangun Alarm System dan Shutdown System Pada Simulator Pressure Tank di Laboratorium Instrumentation and Control Departemen Teknik Instrumentasi ITS. Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Penelitian ini bertujuan mengembangkan dan mengimplementasikan sistem alarm dan shutdown pada simulator pressure tank eksisting di Laboratorium IC Departemen Teknik Instrumentasi ITS dengan mengadaptasi konsep Layer of Protection Analysis (LoPA). Proteksi berlapis dilakukan dengan memisahkan fungsi Basic Process Control System (BPCS) dan Safety Instrumented System (SIS) secara independen menggunakan dua mikrokontroler ESP32-S3. Analisis dinamika proses menunjukkan bahwa pemanasan air volume konstan menuju setpoint 105 °C secara teoritis menghasilkan tekanan uap jenuh sebesar 1,21 bar absolut. Melalui pemodelan fisis tersebut, nilai akumulasi uap bersih sebesar 0,27 bar dijadikan acuan batas bawah operasi pengendalian. Sebagai langkah mitigasi overpressure, ambang batas Pressure Alarm High (PAH) ditetapkan pada 1 bar gauge karena secara absolut setara dengan 2 bar, yang menandakan tekanan internal telah mencapai dua kali lipat tekanan atmosfer bumi. Arsitektur keselamatan ini dirancang menggunakan katup redundan berbasis dua buah solenoid valve yang bekerja secara mandiri dari sistem kendali utama. Seluruh data proses dipantau secara real-time melalui local dashboard berbasis Windows Forms. Hasil pengujian menunjukkan akurasi sensor RTD PT100 sebesar 97,62% dengan rata-rata error 1,23 °C, sedangkan pressure transmitter memiliki akurasi 99,95% dengan rata-rata error 0,043 bar. Pengendalian temperatur terbaik diperoleh pada konstanta Kp 5 dengan rise time 960 detik, steady-state error 0,76%, dan overshoot 2,76%. Kinerja sistem keselamatan berhasil mengaktifkan alarm buzzer pada tekanan 1 bar sebagai early warning dan mengeksekusi shutdown aliran gas melalui solenoid valve pada tekanan kritis 1,21 bar. Hasil ini membuktikan bahwa sistem yang dikembangkan mampu menjalankan fungsi pengendalian proses dan proteksi bertahap terhadap risiko overpressure sesuai rancangan.
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This research aims to develop and implement an alarm and shutdown system on a existing pressure tank simulator at the IC Laboratory, Department of Instrumentation Engineering, ITS, by adapting the Layer of Protection Analysis (LoPA) concept. Layer protection is achieved by separating the Basic Process Control System (BPCS) and Safety Instrumented System (SIS) functions independently using two ESP32-S3 microcontrollers. Process dynamics analysis indicates that constant-volume water heating toward a 105 °C setpoint theoretically generates a saturated steam pressure of 1.21 bar absolute. Through this physical modeling, the net pressure gain of 0.27 bar is utilized as the lower-limit reference for control operations. As an overpressure mitigation measure, the Pressure Alarm High (PAH) threshold is set at 1 bar gauge, which is absolutely equivalent to 2 bars, signifying that the internal pressure has reached twice the atmospheric pressure. This safety architecture is designed with redundant valves using two solenoid valves that operate independently from the main control system. All process data are monitored in real time via a Windows Forms-based local dashboard. The experimental results show an accuracy of 97.62%, with an average error of 1,23 °C for the RTD PT100 sensor and 99.95% for the pressure transmitter, with an average error of 0.043 bar. The optimum temperature control performance is achieved at a proportional gain of Kp 5, yielding a rise time of 960 seconds, a steady-state error of 0.76%, and an overshoot of 2.76%. The safety system performance successfully in activating the buzzer alarm as early warning at 1 bar and executing a gas flow shutdown via the solenoid valves at an actual critical pressure of 1.21 bar. These results demonstrate that the developed system is capable of performing process control and sequential protection functions against overpressure hazards as intended.
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