perancangan sistem control level dan pressure … · jurusan teknik fisika. ... proses and flow...
TRANSCRIPT
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Oleh :Awal Mu’amar 2404 100 030
Pembimbing :Hendra Cordova ST, MT
Fitri Adi Iskandarianto ST, MT
JURUSAN TEKNIK FISIKAFAKULTAS TEKNOLOGI INDUSTRI
INSTITUT TEKNOLOGI SEPULUH NOPEMBERSURABAYA
PERANCANGAN SISTEM CONTROL LEVEL DAN PRESSURE
PADA BOILER DI WORKSHOP INSTRUMENTASI
BERBASIS DCS CENTUM CS3000 YOKOGAWA
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Latar Belakang
Boiler adalah sebuah bejana tertutup yang digunakan untuk memisahkan fluida antara fase gas (steam) dan fase cair (air).
Distributed Control System (DCS) adalah sistem kontrol yang terdistribusi atau terbagi-bagi. Pada penggunaan DCS sebagai sistem kontrol, fungsi kontrol proses didistribusikan pada beberapa lokal kontrol yang menangani proses yang berbeda-beda.
CENTUM CS 3000 adalah salah satu DCS yang terbaru keluaran dari PT.Yokogawa Indonesia.
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Permasalahan
Bagaimana merancang sebuah sistem control level dan pressure pada boiler
di workshop intrumentasi berbasis DCS CENTUM CS3000 Yokogawa
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Batasan Masalah
Boiler yang digunakan adalah boiler pada miniplant di Workshop Instrumentasi
Variable yang dikontrol adalah level dan pressure dari steam drum boiler
Sinyal input berasal dari sensor yang ada pada plant
Software yang digunakan adalah CENTUM CS3000 Yokogawa
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Tujuan Penelitian
Merancang sebuah sistem control level dan pressure pada boiler di Workshop Instrumentasi berbasis DCS CENTUM CS3000 Yokogawa
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Metodologi Penelitian
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Proses and Flow Diagram Miniplant Boiler di Workshop Intrumentasi
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Miniplant Boiler di Workshop Intrumentasi
Wall Tube
Steam DrumEconomizer
Superheater
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Distributed Control System (DCS)
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DCS CENTUM CS 3000 Yokogawa
FCS FCS : Field Control Station: Field Control StationFIO FIO : Field Network Input/Output: Field Network Input/OutputRIO RIO : Remote Input/Output: Remote Input/OutputENG ENG : Engineering PC: Engineering PC
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ControllerP
I
D
++++-E(s)R(s)
Feed
Bac
k
m(s)
sKs
KKsGc d
ip )(
sT
sTKpsGc d
i
11)(
)()(1)()( te
dtdTdtte
TteKtGc d
ip
Transfer Function PID controller dalam domain S dapat dinyatakan sebagai berikut :
Dengan Kp , Ki , dan Kd masing – masing adalah gain P, I, dan D. Bentuk diatas dapat pula ditulis dalam bentuk lain, sebagai berikut :
Bila dinyatakan dalam domain waktu (t), PID controller dapat ditulis :
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Diagram Blok SistemController
FinalControlElement
Plant
Level
text
SP OutputInput
ControllerFinalControlElement
Planttext
SP OutputInput
Presure
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Sistem Pengendalian LevelF2
F1
PI Dh(t)
L T
Steam
Water
F1 : Flow Air masuk (m3/s)F2 : Flow Steam Keluar (m3/s)h(t) : Tinggi permukaan air (meter)LT : Level TransmiterPID : Controller
)(1
)(1
)(1
)( 2321 sQ
sAsP
sAsF
sAsH
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Pemodelan Sensor Level
12.072.72
)()(
ssIsL
L
L
Pemodelan Control Valve
113.11024.1
sGCV
Pemodelan Level
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Sistem Pengendalian Pressure
q2
PID
SteamWater
PT
h(t)
pembakaranq1
q1 : Flow kerosin/bahan bakar masuk (m3/s)q2 : Flow air masuk (m3/s)h(t) : Tinggi permukaan air (meter)PT : Pressure TransmiterPID: Controller
)()()( 22
12
sQQkCs
PKsQQkCs
sP w
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Pemodelan Sensor Pressure
12.0067.1
)()(
ssIsL
L
LPemodelan Control Valve
185.2306.0
s
GCV
Pemodelan Pressure
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PemodelanSistem PengendalianLevel dan Pressure
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Control Drawing Sistem
Tampilan Human Interface Station
PI Ziegler Nichols PID Ziegler Nichols
Tuning Trial Eror
Tuning Controller
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Tampilan HMI Control PID
Uji Step Sistem Pengendalian
Uji Tracking setpoint Uji Tracking setpoint
Uji Penambahan Load
Level Pressure
Uji Penambahan Load
Uji Pengurangan Load Uji Pengurangan Load
Pengujian
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KESIMPULAN1. Telah Dirancang sebuah sistem pengendalian level dan pressure
pada boiler di workshop Instrumentasi menggunakan DCS CENTUM CS3000 Yokogawa
2. Perancangan Sistem control pada boiler mendapatkan nilai Gain dari hasil Trial Eror :KP = 0,33 , TI = 9 , dan TD = 4 untuk LevelKP = 0,5 , TI = 10 , dan TD = 0 untuk pressure
3. Pengendalian Level :
Uji Step waktu 58
detik dan overshoot 7,7%
Uji Tracking setpoint waktu 37 detik
Uji Penambahan Load waktu 86 detik
Uji Pengurangan Load waktu 45 detik4. Pengendalian Pressure :
Uji Step waktu 52 detik dan overshoot 6,25%
Uji Tracking setpoint waktu 30 detik
Uji Penambahan Load waktu 69 detik
Uji Pengurangan Load waktu 65 detik
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Sistem pengendalian Temperatur dan Flow dari boiler dapat dijadikan topik pada penelitian berikutnya.Untuk Mahasiswa Teknik Fisika khususnya
dapat dikembangkan dengan melakukan interfacing langsung (online) dengan real plant.
SARAN
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Terima Kasih
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PB TiLevel 15,1 % 20 s
Pressure 2,4 % 20 s
Tuning PI Ziegler Nichols
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PB Ti TdLevel 11,3 % 12 s 3 s
Pressure 1,8 % 12 s 3 s
Tuning PID Ziegler Nichols
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PB Ti TdLevel 300 % 9 s 4 s
Pressure 200 % 10 s -
Tuning Trial Eror
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Uji Step Sistem Pengendalian
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Uji Traking Set Point Level
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Uji Traking Set Point Pressure
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Uji Penambahan Load 2% level
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Uji Pengurangan Load 2% level
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Uji Penambahan Load 0,7% Pressure
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Uji Pengurangan Load 0,7% Pressure
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Level PressurePu 24 24
Pbu 6.8 1.1
LevelC P I DPI 15.11111 20 -
PID 11.33333 12 3
PressureP I D
PI 2.444444 20 -PID 1.833333 12 3
Tuning ControllerPI PBU/0.45 Pu/1.2 -
PID PBU/0.6 Pu/2 Pu/8
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Pemodelan matematis pengendalian level
dm : Perubahan Massa air (m3)dt : Perubahan waktu (sekon)ρw
: Massa jenis air (kg/m3)ρv
: Massa jenis uap air (kg/m3)q1 : Flow air masuk (m3/s) q2 : Flow Uap Air keluar (m3/s)
)()()(21 tqtq
dttdm
vw
)()()(21 tqtq
dttLdA
vww
Jika m= ρ
Vw
dan d Vw
= L dA
maka menjadi :
Gv S
tPtfCtq )()()(1
Aliran air yang lewat control valve :
……..(3)
…..(2)
……..(1)
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)()()()( 221 tq
SPtghtPtfC
dtdALD v
G
wvww
Substitusi persamaan menjadi :
2321 QAPAFAHdtdH
Disederhanakan menjadi :
gKLD
w
2
82.0Dimana :
gKK
Aw2
11 g
Aw1
2 gK
Aw2
3024.0
)(1
)(1
)(1
)( 2321 sQ
sAsP
sAsF
sAsH
Hasil transformasi Laplace menjadi :
……..(5)
……..(4)
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Pemodelan Sensor LevelSensor Menggunakan DP Transmitter.Inputan = 22 cm / 0,22 MOutputan elektrik = 4-20 mA
)(
)(
metermasukanSpan
mAkeluaranSpanGL MetermA
MetermA 72,72
22,0420
1)()()(
sTG
sIsL
c
L
L
LGL : gain transmitteTc : time constant transmitter
Fungsi transfer Transmitter
12.072.72
)()(
ssIsL
L
L
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Pemodelan Control Valve
1
sTK
Gcv
Ccv
Karena boiler yang digunakan Orde satu maka fungsi transfer adalah :
Kcv : gain control valveTcv : time constant control valve (11,13 detik)
scm
masukantekananperubahanmaksimumaliranlajuKCV
2
46.5
mAcmKg
mAinputSpancmkgoutputSpanGT 2
2
1875.0)(
)/(
mAsKgxKGK CVTC .
024.146.51875.0.
113.11024.1
sGCV
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Pemodelan Level
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Pemodelan matematis pengendalian pressure
C
: kapasitansi tangkidP
: Perubahan Tekanan steam (kg/m2)
dt : Perubahan waktu (sekon)q1
: Flow air masuk (m3/s)q2
: Flow uap air keluar (m3/s)ρw
: Massa jenis air (kg/m3)ρv
: Massa jenis uap air (kg/m3)
)()()(21 tqtq
dttdPC vw
RTMP
v Dimana :
)()()(21 tq
RTMPtq
dttdPC w
……..(8)
……..(7)
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))()(()()(221 tPqtqP
RTMtq
dttdPC w
Persamaan (8) dilinierkan menjadi :
RTMK Misalkan :
)()()( 22
12
sQQkCs
PKsQQkCs
sP w
Hasil transformasi Laplace menjadi :
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Pemodelan Sensor PressureInputan = 15 bar / 15 Kg/cm2
Outputan elektrik = 4-20 mA
1)()()(
sTG
sIsL
c
L
L
LGL : gain transmitteTc : time constant transmitter
Fungsi transfer Transmitter
12.0067.1
)()(
ssIsL
L
L
2/067.12/)15(
)420(cmkg
mA
cmkg
mAGP
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Pemodelan Control Valve
1
sTK
Gcv
Ccv
Karena boiler yang digunakan Orde satu maka fungsi transfer adalah :
Kcv : gain control valveTcv : time constant control valve (23.85 detik)
scm
masukantekananperubahanmaksimumaliranlajuKCV
2
323.0
mAcmKg
mAinputSpancmkgoutputSpanGT 2
2
1875.0)(
)/(
mAsKgxKGK CVTC .
06.0323.01875.0.
185.2306.0
s
GCV
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Pemodelan Pressure
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178.26.1
178.2613.0
119.0035.0
119.01533.0
113.11024.1
)()(
1
1
s
sssssM
sC
Sistem Pengendalian Level
6.1752.4848.002.0056.0
119.01533.0
113.11024.1
)()(
21
1
sss
sssMsC
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Sistem Pengendalian Pressure
119.01533.0
119.0035.0
178.2613.0
178.26.1
185.23122.0
)()(
2
2
s
sssssM
sC
1533.046.008.0002.00038.0
178.26.1
185.23122.0
)()(
22
2
sss
sssMsC