Kuliah Kapita Selekta

Kuliah Kapita Selekta
Teknik Elektro – Institut Teknologi Indonesia

Sabtu - 13 Juni 2020
Implementasi Sistem Otomasi dalam Industri

Perkenalan
Pendidikan & Pengalaman Kerja:
Teknik Elektro – Institut Teknologi Indonesia (1992 - 1998)
PT. Kota Minyak Automation (1998 – 2001)
PT. Schneider Indonesia (2001 – 2005) Anthony Josia
GEIOC - GE Intelligent Platforms (2005 – 2010) anthony@grcteknik.com
PT. Tiara Prima Solusi (2010 – 2012)
PT. Genta Raya Cemerlang (2012 – sekarang)
0811875218
@anthonyjosia
Skill & Kompetensi:
Automation & Control System: PLC & HMI/SCADA
Network
Basic Instrumentation
Software Application & Database
Aplikasi:
Auxiliary and Engine Control, Boiler Control, Well Test, Gathering Station, Water Injection System, Electrical Transmission,
Gas Facilities, Gas Metering System, Integrated Office System, Remote Monitoring System, Building Automation System, Ash
Handling/Coal Handling System, Continuous Emission Monitoring System, Water/Waste Water Treatment Plant
Industri:
Oil & Gas, Palm Oil, Power, Food & Beverages, Pharma, Pulp & Paper, Mining
©2020 PT. Genta Raya Cemerlang 2

Latar Belakang:
Kemajuan teknologi instrumentasi, kontrol dan IT telah membawa perubahan besar
dalam berbagai sektor industri dan saat ini telah mengarah pada sistem otomasi
terintegrasi yang secara umum sering disebut Industri 4.0.

Tujuan:
Sharing session dengan mahasiswa Teknik Elektro ITI untuk berbagi pengalaman
dan pandangan terkait topik ini, supaya engineer Teknik Elektro ITI memiliki
semangat untuk terus berkreasi, berinovasi dan melengkapi diri dengan kompetensi
teknologi yang up to date.

Abstrak:
Pengenalan umum mengenai sistem otomasi industri terkait sistem instrumentasi,
kontrol dan IT.
Pembahasan secara umum sistem kontrol berbasis PLC (Programmable Logic
Controller) dan DCS (Distributed Control System), HMI/SCADA (Human Machine
Interface / Supervisory Control & Data Acquisition), serta berbagai protokol
komunikasi industri dan integrasi dengan sistem IT, baik secara hardware maupun
software dengan beberapa contoh nyata dari aplikasi industri.
Sebagai penutup terbuka sesi interaktif untuk diskusi dan tanya jawab seputar topik
dan pengalaman lapangan.

Industrial Automation System
As an integrated system, the entire industrial automation system is built of the

following components:
 Instrumentation System
Collection of instruments used to measure, monitor, and control a process.
 Control System
Manages, commands, directs, or regulates the behavior of other devices
or systems using control loops.
 Communication System
Collection of communications equipment that is integrated to link

Objective of Industrial Automation System
1. Protect People
2. Protect Environment
3. Protect Equipment
4. Maintain Smooth Operation
5. Achieve Product Rates & Quality
6. Optimizing First Five Above = Profit
7. Monitoring, Analysis & Diagnostic

Automation System Components Remote Monitoring
Client
 Instrumentation System
 Control System
 Communication System Corporate
Network SCADA Server
HMI
Control
Network
INPUT
OUTPUT
Controller
Gas Turbine

Instrumentation System
• Instrumentation system consist of measuring devices, sensor and actuator which serve as an
input or output of control system
Inputs Devices • Switches and Pushbuttons Outputs Devices • Valves

• Sensing Devices • Motor Starters
• Limit Switches • Solenoids
• Photoelectric Sensors • Actuators
• Proximity Sensors • Control Relays
• Condition Sensors • Horns & Alarms
• Pressure • Stack Lights
• Level • Fans
• Temperature • Counter/Totalizer
• Flow • Pumps
• Vacuum Switches • Printers
• Float Switches
• Encoders

Instrumentation Symbol

Process Flow Diagram
Process flow diagram is a simple illustration that uses process symbols to
describe the primary flow path through a unit

Piping & Instrumentation Diagram (P&ID)
A process and instrument drawing is more complex, it includes a graphic
representation of the equipment, piping, and instrumentation

Control System
A control system is a system of devices that manages, commands, directs or regulates the behavior
of other devices or systems using control loops.
A control loop is the fundamental building block of industrial control systems. It consists of all the
physical components and control functions necessary to automatically adjust the value of a
measured process variable (PV) to equal the value of a desired set-point (SP). It includes the
process sensor, the controller function, and the final control element (FCE) which are all required for
automatic control.

Programmable Logic Controller (PLC)
• Programmable Logic Controller (PLC) is a computer-type device used to control equipment in
an industrial facility. It accepts inputs from switches and sensors, evaluates these in
accordance with a stored program, and generates outputs to control machines and processes.
• Programmable Logic Controller (PLC) were created to replace conventional relay controls with
solid state equipment.
Typical PLC Components
1. Rack 5. Comm. Module 6. Programming Tools
4. I/O Modules
Digital, Analog,Thermocouple,
RTD, Hi Speed Counter, etc
7. Programming Cable
2. Power Supply 3. CPU with embedded
Comm. Module

PLC Cycle During each operating cycle, the processor reads all inputs, takes these values, and
energizes or de-energizes the outputs according to the user program. This process is
Housekeeping known as a scan
Input Scan
Scan time of PLC
Program
Execution
Output Scan
Comm. Service
The scan time indicates how fast the controller can react to changes in inputs. Scan
Diagnostics times vary with computer model and program content, and length. If a controller has to
react to an input signal that changes states twice during the scan time, it is possible that
the PLC will never be able to detect this change.

Typical Motor Control Circuit
PB1 PB2
MASTER STOP START MOTORS
PS-1 FLS-1
5 SEC
T R1 W ARNING DELAY
1M1 TR1
WARNING HORN
H Y D R A U LIC P U M P
1M
M O TO R STARTER

Relational Diagram Of Field I/O & Ladder Logic
INPUT OUTPUT
MODULE
2 3
MODULE 4
1
I1 = PB1 Q1 = M1_HORN
I2 = PB2 Q2 = M1_RUN 1M
I3 = FLS-1
I4 = PS-1
PB1 PB2 FLS-1 PS-1

M1_RUN
5s Q2
I1 I2 I3 I4
TIMER M1_HORN
Q2 R1
M1_RUN Q1

Sensor & Signal for Process Control
Pressure Transmitter PLC

Analog Input
4-20 mA
Measurement range Analog Input Register

0 – 10 Bar Analog Input wiring example 0 – 32767

IEC 61131-3 Programming Language
Function Block Diagram
Ladder Diagram
Sequential Function Chart
Structure Text
Instruction List
HMI / SCADA
What is the difference between HMI and SCADA?
The main difference between HMI and SCADA is their scope. HMI is actually just a part of the
SCADA system.
HMI = Human Machine Interface

HMI functionality: Visualizing the Process
SCADA = Supervisory Control And Data Acquisition
SCADA functionality: Managing and Controlling the Process
HMI could be only a small touchscreen mounted on the panel or even an annunciator or simple
flow process diagram with numbers of indicator lamps

HMI / SCADA
Supervisory control and data acquisition (SCADA) is a system of software and hardware elements
that widely used in various industry to help operator to monitor and control the process in real-time
locally or even at remote location.
SCADA system allows the operator to get direct interaction with the devices, such as sensors,
valves, pumps, motors, etc. through the HMI (Human Machine Interface) visualization. SCADA
system also have historical data for further analysis.

HMI / SCADA
HMI/SCADA Screens Alarms Scripts Trends HMI Screen

Points
Point Database
Devices
Native
OPC
Ports
PLC Industrial HMI Driver
Protocols OPC
Industrial Controllers

Distributed Control System (DCS)
DCS systems have for many years provided multi-disciplined controllers for logic, sequential and
process control, HMIs, custom applications, and business integration on one platform.
Although PLCs have become more powerful, they are still based on “loose” component
architectures allowing functions to be easily added with hardware and software. For example, a
historian may be added to many PLC products by plugging a module into the backplane that
acquires data from the controllers, but history communications is done over a separate Ethernet
connection.

Distributed Control System (DCS)

Industrial Communication Protocols
There are many Industrial Communication Protocols was developed, some protocols was
proprietary in earlier time, some protocols was for specific application such as for Building
Automation, Lighting Control, HVAC, etc.
Some of protocols widely used:
 Modbus (RTU / TCP / UDP)
 Profibus PA / DP
 Profinet
 Devicenet
 HART … and.. still many more….

http://www.modbus.org
 Modbus is a serial communications protocol originally published by Modicon in 1979 for use with its PLC.
 Simple and robust, it has since become a de facto standard communication protocol, and it is now a
commonly available means of connecting industrial electronic devices.
 The main reasons for the use of Modbus in the industrial environment are:
 developed with industrial applications in mind
 openly published and royalty-free
 easy to deploy and maintain
 moves raw bits or words without placing many restrictions on vendors
 Modbus enables communication among many (approximately 240) devices connected to the same network
 The development and update of Modbus protocols has been managed by the Modbus Organization since
April 2004, when Schneider Electric transferred rights to that organization. The Modbus Organization is an
association of users and suppliers of Modbus compliant devices that seeks to drive the adoption and
evolution of Modbus.

http://www.modbus.org
 Modbus is the simplest protocol that widely used because no need special cable, no need
additional communication card or converter, and available in serial and ethernet
 There are many Modbus tester software available in market and many devices have built-in
Modbus protocol for integration with other devices.

 PROFIBUS (acronym for Process Field Bus) is a standard for fieldbus communication in
automation technology and was first promoted in 1989 by BMBF (German department of
education and research) and then used by Siemens. It should not be confused with the
PROFINET standard for Industrial Ethernet.
https://www.profibus.com/technology/profibus/
 PROFINET (acronym for Process Field Net) is an industry technical standard for data
communication over Industrial Ethernet, designed for collecting data from, and controlling,
equipment in industrial systems, with a particular strength in delivering data under tight time
constraints (on the order of 1ms or less).
https://www.profibus.com/technology/profinet/

https://opcfoundation.org/
OPC (Open Platform Communications) is a software interface standard that allows Windows programs to
communicate with industrial hardware devices.
OPC is implemented in server/client pairs. The OPC server is a software program that converts the hardware
communication protocol used by a PLC into the OPC protocol. The OPC client software is any program that
needs to connect to the hardware, such as an HMI. The OPC client uses the OPC server to get data from or
send commands to the hardware.
https://opcdatahub.com/WhatIsOPC.html

Introduction to Industrial Communication
Information
Control
PLC DCS CNC Robot
Field

Typical Configuration – GE LM2000
Operator Workstation
Ethernet
Woodward Sequencer Vibration Monitor

Atlas PC GE Fanuc 90-70 BN3500
VersaMax I/O
Genius Bus

Typical Configuration – GE TM2500 GEN8
HMI/SCADA HMI/SCADA
Cimplicity Cimplicity
Ethernet 192.168.15.x 192.168.15.x

192.168.15.x 192.168.15.1 VSV SPC CDP SPC
Slave ID 2 Slave ID 3
Woodward Servo
AVR DMMF Position Controller
BN3500 –
Vibration RX3i – Devicenet
Sequencer CAN Open
DVP DVP
niu1.gcp niu2.gcp niu3.tcp niu4.mgtb niu5.mgtb niu6.tcp niu7.tcp niu8.tcp

192.168.0.2 192.168.0.3 192.168.0.4 192.168.0.5 192.168.0.6 192.168.0.7 192.168.0.8 192.168.0.9
VersaMax IO

Typical Configuration – Gas Compressor Station
OWS-01 OWS-02 Vibration EWS-01 EWS-02
LAN A
GE Bently Nevada
PCS IS PCS NIS

ESD FGS
ProLinx ProLinx
ICS Triplex / Rockwell Automation MTL / GE Intelligent Platforms GTCP A GTCP B
Solar Turbine - Rockwell Automation
Serial to FO
Converter
To existing SCADA Metering System
GEG-A GEG-B
Power Meter DEG
Power Meter
F&G Power Meter
F&G

Typical Configuration – Gas Metering Station
Engineering Station Operator Station
Ethernet
RS-485
Gas Chromatograph Siemens S7-300

Controller Unit
Daniel 2350 Omni FlowCom

Typical Configuration – Sub Station Automation
SCADA Master
DCC
IEC104
Engineering Station Operator Station
Control Room
Modbus / IEC 61850
Switch Yard
Bay Controller IED Bay Controller IED IED IED PLC

Typical Configuration – SCADA Distribusi
GI DCC

Typical Configuration – Refinery Plant Client
Corporate
Production
Operator Workstation Operator Workstation Weighing System Report Server Engineering Workstation
Control
Serial Device Server

GE RX3i AB SLC500
Chronos SpeedAC
Weighing Controller

System Configuration – Fraksinasi Plant
Operator Workstation Operator Workstation
Siemens
Ethernet
Siemens S7-300
CPU 317-2 PN/DP
IM 360 IM 361 IM 361 IM 361

Profibus
IM 153

Typical Configuration – Margarine Plant
Operator Workstation Engineering Workstation
Ethernet
RX3i
Profibus Slaves 1 2 3 4 5
Mettler Toledo
Danfoss Danfoss Festo Beckhoff I/O
Weighing
Drive Soft Starter

Typical Configuration – Power & Energy Monitoring Remote
Web Client
Internet
Gateway
Corporate Network
Power Monitoring Server

• Energy Usage Monitoring
• Power Quality Monitoring
Power Monitoring
Network
Ethernet
Gateway
RS-485 Network RS-485 Network

Intermediate Metering
Advanced Metering
Basic Metering Basic Metering

Typical Configuration – CEMS Online
Unit Pembangkitan KLHK Office

Stack Gas Analyzer CEMS Shelter
ENDA‐5610
NOx
Opacity SO2
Durag D‐R290 / CO
Horiba EM‐D5100 O2
Opacity
Flow
Flowmeter Temperature
Durag D‐FL100 PGS DAS
PGS Via Corporate /
Stack #1 Data Logger 3rd Party Provider
Stack Gas Analyzer
ENDA‐5610
SISPEK Server
NOx
Opacity SO2
Durag D‐R290 / CO
Horiba EM‐D5100
O2
Opacity
Flow
Temperature
Flowmeter
Durag D‐FL100
Stack #2

Typical Configuration – CEMS Online
DAS CEMS Server
DCS DCS
Opacity Opacity
Opasity Analog Gas Analyzer Opasity Analog Gas Analyzer
Particulate Splitter Particulate Splitter
NOx NOx
Flow Gas MCR-FL-C-UI-2UI-DCI-NC Flow Gas MCR-FL-C-UI-2UI-DCI-NC
4-20mA SO2 4-20mA SO2
Stack Stack
CO CO
HORIBA HORIBA
4-20mA ENDA 5000
CO2 4-20mA ENDA 5000
CO2
O2 O2
HRSG #2.1 HRSG #2.2

Typical Configuration – AQMS Mobile Station
Mobile Station BPPT
60” LED Smart TV

Data Logger Panel PC
- Dashboard
- Trend, Report
- Alarm & Event Server
Ethernet
Parameters: Client Workstation & Display

PM10 - Dashboard
PM2.5 - Trend, Report
SO2 Analyzer - Alarm & Event
NO2 Workstation
O3
CO
*Internet via GSM modem *Internet Ready

Typical Configuration – IPAL Online
IPAL KLHK
Shelter Control Room
Server
HP200 pH meter
Via 3rd Party
OPSA 150 Internet Provider
4-20mA Data Logger A
pH
COD
Systea Ammonia
NH3-N
Flowmeter Debit
Temp.
Server SPARING

Plant Monitoring & Performance Analysis
Office
Web Apps Client

- Dashboard Cloud
- Trending Gateway
- Report Server
- Alarm Notification
Unit 1-2
Unit 3-4
FO
Remote Converter
Access Remote
Server Access
OWS #1 OWS #2 OWS #3 OWS #4 Server
Arcnet Arcnet
Ethernet Ethernet
FT-110 FT-110 FT-110 FT-110

Sequencer Sequencer Sequencer Sequencer
& & & &
Fuel Control Fuel Control Fuel Control Fuel Control
RTU #1 Vibration Monitor RTU #2 Vibration Monitor RTU #3 Vibration Monitor RTU #4 Vibration Monitor
RTU#11 BN 3500 RTU#22 BN 3500 RTU#31 BN 3500 RTU#42 BN 3500

Aplikasi Terintegrasi berbasis Cloud
Server Cloud
CCTV
Sensor / Analyzer
Aplikasi Mobile
Aplikasi Web
Server Lokal
Industry 4.0
Industry 4.0 is a name for the current trend of automation and data exchange in
manufacturing technologies. It includes cyber-physical systems, the Internet of
things, cloud computing and cognitive computing. Industry 4.0 is commonly
referred to as the fourth industrial revolution.

Internet of Things
Internet of Things (IoT) is the network of
physical devices, vehicles, home appliances,
and other items embedded
with electronics, software, sensors, actuators,
and connectivity which enables these things
to connect and exchange data, creating
opportunities for more direct integration of the
physical world into computer-based systems,
resulting in efficiency improvements,
economic benefits, and reduced human
exertions.

Cloud Computing
Cloud computing is an information

technology (IT) paradigm that enables ubiquitous
access to shared pools of configurable system
resources and higher-level services that can be
rapidly provisioned with minimal management
effort, often over the Internet. Cloud computing
relies on sharing of resources to achieve
coherence and economies of scale, similar to
a public utility.

Cognitive Computing
Cognitive computing is the simulation of human thought processes in a
computerized model. Cognitive computing involves self-learning systems that
use data mining, pattern recognition and natural language processing to mimic the
way the human brain works. The goal of cognitive computing is to create automated
systems that are capable of solving problems without requiring human assistance.

Big Data
Big data is data sets that are so voluminous

and complex that traditional data-
processing application software are
inadequate to deal with them. Big data
challenges include capturing data, data
storage, data analysis, search,
sharing, transfer, visualization, querying,
updating, information privacy and data source.
There are a number of concepts associated
with big data: originally there were 3
concepts volume, variety, velocity. Other
concepts later attributed with big data
are veracity (i.e., how much noise is in the
data) and value.

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Teknik Elektro – Institut Teknologi Indonesia

Implementasi Sistem Otomasi dalam Industri

©2020 PT. Genta Raya Cemerlang 2

©2020 PT. Genta Raya Cemerlang 3

©2020 PT. Genta Raya Cemerlang 4

As an integrated system, the entire industrial automation system is built of the

©2020 PT. Genta Raya Cemerlang 5

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Inputs Devices • Switches and Pushbuttons Outputs Devices • Valves

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Typical PLC Components

1. Rack 5. Comm. Module 6. Programming Tools

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PB1 PB2 FLS-1 PS-1

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Pressure Transmitter PLC

Measurement range Analog Input Register

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Sequential Function Chart

HMI = Human Machine Interface

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HMI/SCADA Screens Alarms Scripts Trends HMI Screen

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PLC DCS CNC Robot

©2020 PT. Genta Raya Cemerlang 30

Woodward Sequencer Vibration Monitor

©2020 PT. Genta Raya Cemerlang 31

Ethernet 192.168.15.x 192.168.15.x

niu1.gcp niu2.gcp niu3.tcp niu4.mgtb niu5.mgtb niu6.tcp niu7.tcp niu8.tcp

©2020 PT. Genta Raya Cemerlang 32

PCS IS PCS NIS

To existing SCADA Metering System

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Engineering Station Operator Station

Gas Chromatograph Siemens S7-300

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Engineering Station Operator Station

Modbus / IEC 61850

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Serial Device Server

©2020 PT. Genta Raya Cemerlang 37

Operator Workstation Operator Workstation

IM 360 IM 361 IM 361 IM 361

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Operator Workstation Engineering Workstation

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Power Monitoring Server