master proposal · 2019-02-07 · [ethernet tcp/ip, modbus rtu rs485, rs232, can profibus, etc]...

PT. TRI AGUNG SINERGIElectrical,Instruments & Automation Specialist

Presented By : Mochammad FuadiResearch & Development : SyaifulDesign System Integration : Hafidhudin & WaluyoTechnical Service Support : Yudi Aries & Ade Noviyanto

MASTER PROPOSAL

MASTER PROPOSALPT. TRI AGUNG SINERGI

Presented By : Mochammad FuadiResearch & Development : SyaifulDesign System Integration : Hafidhudin & WaluyoTechnical Service Support : Yudi Aries & Ade Noviyanto

Electrical,Instruments & Automation Specialist

We use the data to trace and analyze any error in the production,weighing, critical process parameter, quality integrity, utility,energy comsumption and power quality

TOTAL SMART SOLUTION FOR UTILITY, PROCESS,PRODUCTION AND PLANT MANUFACTURING Connected to each machine, intouch is able to monitor

production in real time and deliver live, up to date information to any part of your factory.

PROCESS & PRODUCTION MONITORING

We use the data to trace, isolate critical issues andanalyze any error in the utility for process aspect, Then we can

develope and measure performance andsystem to improve utility system

CRITICAL PARAMETER – UTILITY MONITORING

To calculate & identify electrical power consumption & measure critical parameter

ENERGY MANAGEMENT SYSTEM

ELECTRICAL INTEGRITY INSPECTION / ASSESMENT ELECTRICALPOWER SYSTEM STUDY

INDUSTRIAL REVOLUTIONSRevolutions Industry 4.0

1st 2nd 3rd 4thMechanization,

water power, steam power

1st Revolution

Mass production, assembly line,

electricity

2nd Revolution

Computer and automation

3rd Revolution

Cyber Physical System

4th Revolution


Why do you need the real & actual data?

We can analyze the collected data to improveutility optimalization

We use the data to trace, isolate critical issues andanalyze any error in the utility for process aspect

Then we can develope and measure performance andsystem to improve utility system


TRIAS Smart Panel Control (SPC) Customized & Multi FunctionCustomized I/O

1. PLC, HMI any brands as customer request

2. Custom Sequence Digital Input/Output, HS Pulse & Counter

3. Multi network device (as requirement )

[4-20 mA, 0-10V, Rtd, TC, RH/Sensors, Load cell & all instruments]

4. Multi network device (as requirement)

[Ethernet TCP/IP, ModBus RTU RS485, RS232, Can profibus, etc]

Customized Technical Function1. Oil & Gas, Marine, Chemical, Petrochemical, Pharmachy, Cosmetic, Food & Beverage, Automotive, Textile, Blow molding, Injection molding, etc

2. Processing, Filling, Packaging, Conveying, Boilers, Chillers, AHU, WWTP, Pumping, Compressor Control, (Upgrade & Retrofit)

Customized Technical Function

Real View, Record Trending/Data Logging, Barcoding, IoT Real Time Monitoring & GSM Module (Support to Industrial Revolution 4.0)

Target : Real low cost Automation to increasing efficiency, productivity, quality and safety

Type: Economical, Medium & Advanced

PRODUK UNGGULANPT. TRI AGUNG SINERGI


PRODUCTION MONITORING SYSTEM (PMS)

KPls, Takt, OEE/TEEP

Complete performance metrics

CREATE YOUR OWN FULL-FEATURED, REAL-TIME PRODUCTIVITY SCOREBOARDS

Production monitoring system lets you create own interface, real-time productivity scoreboard in minutes, using any consumer model LED/LCD or Plasma TV.

Save thousands over packaged industrial displays and get unprecedented capabilities, fast and easy connectivity to your machines.

PMS

Line status, calls maintenance

Flow monitoring

Events, alerts, downtime timers

Andon

Heijunka, Kanban

Production smooting

Packing, assembly

Operator guidance

Scorecards, messaging news, break timers

Safety


PRODUK UNGGULAN

Tingkatkan produktivitas melalui pemantauan real time

REAL TIME MONITORINGMengeliminasi pekerjaan manual yang

tidak diperlukan

ABNORMALITY NOTIFICATION


Apa itu Production Monitoring System?

Production Monitoring System adalah sistem yang dirancang untuk mencatat proseskinerja keseluruhan jalur produksi secara real time. Sistem ini mengumpulkan datadari berbagai bagian jalur produksi dan diteruskan ke karyawan dan manajer yangbekerja di jalur tersebut. Data yang dikumpulkan oleh sistem pemantauan digunakandalam meningkatkan efisiensi lini produksi.

PT. TRI AGUNG SINERGI

Mengurangi masalahdowntime mesin pada saat

produksi

PRODUCTIVITY ANALYSIS



Salah satu sistem terbaik yang digunakan oleh berbagai industri saat ini adalahIndustrial Dashboard (IDB) untuk Industri 4.0. Sistem ini menggunakan teknologi IoT(internet of Things), memungkinkan Anda memonitoring produksi menggunakanwireless atau koneksi internet. Dengan IDB, Anda bisa memantau proses produksi danperformance mesin dimanapun Anda berada melalui smartphone, tablet, PC maupunleptop Anda yang terhubung dengan koneksi Internet.


Weighing Hardware Configuration & System Architecture

We create an integration system to control and monitor every event on the system. Aim to simplify and bring the machine closer to the owner. The data is processed to ms.excel and monitored through the local network.

PT. TRI AGUNG SINERGI PRODUK UNGGULAN

What is iQ Monozukuri ANDON?

This simple ANDON* package easily enables visualization of production sites using GOT2000 and a general-purpose web browser. Information obtained from production equipment is displayed on the monitor for ANDON via GOT2000, allowing sharing of the production site information to enable visualization.* ANDON system visualizes information (production status, alarms) that is obtained from production equipment, sharing the information among site workers, a manager, and a maintenance personnel.


PRODUK UNGGULAN

Monozukuri ANDON

System configuration exampleIf you have equipment that can be connected to GOT2000, an ANDON system can be configured easily.

PT. TRI AGUNG SINERGI PRODUK UNGGULAN

Visualization is realized throughout the production site!


The GOT Mobile function of GOT2000 realizes visualization at production sites and offices. By grasping the occurrence of a problem timely and performing smooth troubleshooting, you can improve the operation rate of equipment and productivity.

PRODUK UNGGULAN


We use the data to trace, isolate critical issues and analyze any error in the utility for processaspect, Then we can develope and measure performance and system to improve utilitysystem


Basic Hardware Cofiguration & System Architecture

Boiler Effeciency – Energy Saving


PRODUK UNGGULANElectrical,Instruments & Automation Specialist

ENERGY MANAGEMENT SYSTEM (EMS)To calculate & identify electrical power consumption & measure critical parameter

Energy management systems are also often commonly used by individual commercial entities to monitor, measure, and control their electrical building loads. Energy management systems can be used to centrally control devices like HVAC units and lighting systems across multiple locations, such as retail, grocery and restaurant sites. Energy management systems can also provide metering, submetering, and monitoring functions that allow facility and building managers to gather data and insight that allows them to make more informed decisions about energy activities across their sites.Save thousands over packaged industrial displays and get unprecedented capabilities, fast and easy connectivity to your machines.

EMS

Comparatively high specific consumption (waste of energy, negative influence on productivity)Ex) $ kWh of electricity per day can be savedwith improvement.


Energy-saving method

• Facilities start-up too fast• After investigation and deciding appropriatestart-up time, implement countermeasure

Compare data before and after implementing countermeasure($ kWh reduced per day)

Implement similar countermeasures for other facilities

PRODUK UNGGULAN


Energy Management System

Support factory, building and school energy-saving activities. Build visualized environments and manage energy effectively. Support to energy conditions at all times and quickly resolve energy loss problems.Finaly reduce energy loss, increaseproductivity and cut production costs.

Energy and Electric Systems

A wide range of power and electrical products from generators to large-scale displays.

Electronic Devices

A wide portfolio of cutting-edge semiconductor devices for systems and products.

Home Appliance

Dependable consumer products like air conditioners and home entertain-

ment systems.

Information and Communication Systems

Commercial and consumer-centric equipment, products and systems.

Industrial Automation Systems

Maximizing productivity and efficiency with cutting-edge automation technology.

PRODUK UNGGULAN



EMS Hardware Configuration & System Architecture






Electronic Devices


Home Appliance


ment systems.





PRODUK UNGGULAN

Energy-saving Points

PENTINGNYA memvisualisasikan energi

Masalah Esensial untuk Menghemat Energi

Target Value Management

Managing objectives is a very important issue when practicing energy savings.“Target value management” is the process of transforming actual conditions into ideal conditions, and thereby requires understanding the actual situation and how much “unseen” waste there is. For this reason, target value management involves performing detailed management of operations, moving from months to days and lines to equipment, and evolving from “seeing” waste to “understanding” it.

Additionally, when using target value management, it is necessary to construct and put into practice an organization thatvalues “people who set objectives (manage),” “people who find things” and “people capable of thinking of improvementsand implementing them.”

Value Management






Electronic Devices


Home Appliance


ment systems.





PRODUK UNGGULAN



Masalah Esensial untuk Menghemat Energi

Specific consumption management

In lines where there is a large difference in production volume, it is difficult to save energy and improve productivity u singenergy management alone.By understanding specific consumption —energy consumed per product— waste in energy and production processes can be clarified, and it becomes easier to implement countermeasures.Rather than simply not using energy, it’s important to use energy efficiently when, where and how much needed.

Specif ic consumption management






Electronic Devices


Home Appliance


ment systems.





PRODUK UNGGULAN



Penghematan Energi dengan memvisualisasikan permintaan

Demand is average electric power at a specified period. This period for demand differs for each country and the way of

management method.

Electric fee is basically determined based on the highest demand in one year( contract demand).

The highter the contract demand is, the more expensive the electric basic charge is.

There are two types of basic demand management method as below.

(2) Fixed block demand management method

The demand period consists of only an interval.

(2) Rolling block demand management method

The demand period consists of interval and sub interval. Interval is the period for caluclation of average electric. Sub interval is the period for updata the calculation.

Rolling block demand management method

Ex) Interva l 15min Sub interval 5min

Fixed block demand management

Ex) Interva l 30min

EcoWebServerm with demand monitoring function comply with the Fixed block

demand management method. Interval can be selected from 15min or 30min.

What is "Demand"....






Electronic Devices


Home Appliance


ment systems.





PRODUK UNGGULAN



Penghematan Energi dengan memvisualisasikan permintaan

Demand is average electric power at a specified period. This period for demand differs for each country and the way of

management method.

Electric fee is basically determined based on the highest demand in one year( contract demand).

The highter the contract demand is, the more expensive the electric basic charge is.

There are two types of basic demand management method as below.

What is "Demand"....






Electronic Devices


Home Appliance


ment systems.





PRODUK UNGGULAN

Features

˔ T h e d i s p l a y p r o c e d u r e i s s e l ec tʠ ᶃ M e a s u r i n g p o i n t g r o u p / n am e ˠ ᶄ G r a p h d i s p l ay d a t e a n d s e l e c t

3 Di sp lay only.

˔ A c o m p a r i s o n o f t h e s p e c i f i e d d a t e a n d i t e m s c a n b e d i s p l a y e d .

1 Date compar i son g raph

1. Add new comparison screens according to the scenario. Strong support provided for analyzing activities.






Electronic Devices


Home Appliance


ment systems.





PRODUK UNGGULAN

Features

˔ T h e d i s p l a y p r o c e d u r e i s t o s e l e c t ʠ ᶃ M e a s u r i n g p o i n t g r o u p / n a m e ˠ ᶄ G r a p h d i s p l a y f o r m a t ˠ ᶅ G r a p h N o . ˠ ᶆ G r a p h d i s p l a y i n t e r v a l s e t c . a n d s e l e c t ʠ ᶇ D i s p l a y o n l y .

˔ I t s p o s s i b l e t o s e l e c t g r a p h s a n d d i s p l a y v a r i o u s g r a p h s i n t h e f o r m a t o f y o u r c h o i c e . I t s a l s o p o s s i b l e t o d i s p l a y t h e s a m e g r a p h , m a k i n g i t e a s y t o u n d e r s t a n d g r a p h c o r r e l a t i o n s .

2 Measur ing po in t compar i son g raph







Electronic Devices


Home Appliance


ment systems.





PRODUK UNGGULAN

Energy-saving

˔ D e m a n d c o n t r o l p o s s i b l e b y i n t e r c o n n e c t i n g w i t h M i t s u b i s h i E l e c t r i c W e b - c o m p a t i b l e i n t e g r a t e dc o n t r o l l e r - A E - 2 0 0 J , G - 1 S 0 A D , e t c .A d d i t i o n a l l y , a u t o m a t i c c o n t r o l o f l o a d p o s s i b l e t h r o u g h c o n t a c t p o i n t o u t p u t v i a m a i n u n i t o fE c o W e b S e r v e r ᶙ a n d C C - L i n k .

3 Energy- sav ing a i r cond i t ion ing ope ra t ion r ea l i zed by

in t e rconnec t ing wi th in t eg ra t ed a i r - cond i t ion ing con t ro l l e r.


ELECTRICAL INTEGRITY INSPECTION

Today's intensely competitive business environment forces plant or building management personnel to be very aware of the total owning cost of the power distribution system.

ASSESMENT ELECTRICAL POWER SYSTEM STUDY

Power Quality issues cause business problems

such as:

• Lost productivity, idle people and

equipment

• Lost orders, good will, customers and

profits

• Lost transactions and orders not being

processed

• Revenue and accounting problems

• Customer and/or management

dissatisfaction

• Overtime required to make up for lost

work time

EII


PRODUK UNGGULAN

They demand assurances of maximum return on all capital investments in the power system.

The use of digital computers makes it possible to study the performance of proposed and actual systems under many operating conditions. (to simulate the system)

Answers to many questions regarding impact of expansion on the system, short-circuit capacity, stability, load distribution, etc.,

ELECTRICAL INTEGRITY ASSESMENT AND POWER SYSTEM STUDIES



Flash Studies Studies

Studies Coordination Studies SystemAnalysis

Scope Of Power System Studies

Load Flow Studies Short-Circuit &Arc Stability Studies Motor-Starting

HarmonicAnalysis Reliablility Studies Protection DCAuxiliary Power




PQ Problems and Possible CausesTypical problems Disturbance Type Possible Causes

Overheated neutralIntermittent lock-upsFrequency deviations

Steady-state Shared neutralsImproper or inadequate wiringHigh source impedanceSCR/Rectifiers and notchingHarmonics

Interruption

Garbled data

Random increase in harmonics levels

Utility faults

Inrush currents

Inadequate wiring

Intermittent lock-ups

Lights flicker

Garbled data

Sags/Swell Source voltage variations

Inrush/surge currents

Inadequate wiring

Component failure

Dielectric breakdown

Lock-ups

Garbled data

Wavy CRTs

Impulses

EMI/RFI

Lightning

Load switching

Capacitor switching

Static discharge

Hand-held radios

Loose wiring/arcing

Overheated transformers and motors

Voltage and current distortions

Garbled data

Lock-ups

Harmonics Electronic loads

SCR/rectifier

Power Quality Analyzer

• suatu peralatan ukur yang digunakanuntuk mengetahui kualitas daya daritenaga listrik. Alat ini sangat kompleks,karena dapat mengukur tegangan, aruslisrik, frekuensi, daya kompleks, daya aktif,daya reaktif dan factor daya.








SKEMA PENGUKURAN POWER QUALITY ANALYZER





Lutron Power Quality Analyzer DW-6095

screen 2 ( 5-12 )

PF1:

65

V12:V23:V31:

0.0 V0.0 V0.0 V

V1:V2:V3:

0.0 V0.0 V0.0 V

A1:A2:A3:

0.00 A0.00 A0.00 A

P1: P2:P3:

- 0.000 KW S1: 0.000 KVA Q1: - 0.000 KVAR- 0.000 KW S2: 0.000 KVA Q2: - 0.000 KVAR- 0.000 KW S3: 0.000 KVA Q3: - 0.000 KVAR

PΣ

PFΣ Φ 1:

- 0.000 KW SΣ : 0.000 KVA QΣ : - 0.000 KVAR

:- 0.00 PF2: - 0.00 PF3: - 0.00

0.00 PFH: 0.00- 0.0° Φ2: - 0.0° Φ3: - 0.0°

WH: QH:

0.000 KWH SH: 0.000 KVAH0.000 KVARH FREQ: 0.0 Hz

CP120120A 3Φ 4W SEC: 2 CT: 1 PT: 1





Data Excel PQA

REPORT POWER QUALITY




METODE PENGAMBILAN DATA

DC Auxiliary Power System Analysis

Harmonic analysis Studies

Reliability StudiesProtection

Coordination Studies

Motor-starting analysis

Stability analysisShort Circuit Analysis

ARC Flash StidesLoad Flow Study

AB

Metode Trending

Metode trending digunakan untuk mengetahui karakteristik dan besarbeban/ power yang diserap dalam satu sistem dalam durasi waktu tertentu.

Metode Sampling

Metode sampling digunakan untuk mengetahui besar dan sifat power yang diserap pada satu peralatan (sesaat). Karena proses pengambilan data sampling hanya bersifat pengukuran cepat (durasi waktu sedikit) dimungkinkan nilaipower yang terukur saat audit dilakukan dan waktu yang lain diperoleh data yang tidak sama akibat karakteristik peralatan yang mempunyai sifat bebanberubah- ubah.





METODE TRENDING EXAMPLE PROJECT

Terkait pekerjaan Energy Audit di MB-11 pengambilan data trending dilakukan pada 3 trafo, yaitu:

Trafo MB 856-T01 (4500 kVA)Beban yang ditanggung trafo MB 856-T01 merepresentasikan total power yang diserap padasistem MB-11. Power trafo MB 856-T01 diukur melalui pengambilan data pada panelincoming 856-B1 EHA 2000.12

Trafo MB 856-T02 (2000 kVA)Trafo MB 856-T02 merepresentasikan beban untuk sistem tegangan 380 V selain feedconveyor. Power trafo MB 856-T02 diukur melalui pengambilan data pada panel incoming856-B1 EHA 2000.15

Trafo MB 856-T08 (1600 kVA)Trafo MB 856-T08 merepresentasikan total beban 380V untuk sistem feed conveyor. Power

trafo MB 856-T08 diukur melalui pengambilan data pada panel incoming 856-T08





METODE SAMPLING EXAMPLE PROJECT

Terkait pekerjaan Energy Audit di MB-11 pengambilan data trending dilakukan pada 3 trafo, yaitu:

Metode sampling digunakan untuk mengetahui besar dan sifat power yang diserap pada satu peralatan(sesaat) . Karena proses pengambilan data sampling hanya bersifat pengukuran cepat (durasi waktu sedikit)dimungkinkan nilai power yang terukur saat audit dilakukan dan waktu yang lain diperoleh data yangtidak sama akibat karakteristik peralatan yang mempunyai sifat beban berubah- ubah.

Pengukuran secara sampling dilakukan pada beban-beban sisi tegangan 3,3kV dan 380V.





HASIL PENGUKURAN DAN ANALISA

Pegukuran Trending

B.1.1. Trafo MB 856-T01 (Total Power MB-11)

Data Trafo MB 856-T01 :

Rating KVA

Tegangan HV

Tegangan LV

Arus HV

Arus LV

Oil Temp rise

Winding Temp rise

:

:

:

:

:

:

:

o

o

o

o

o

o

o

4500 kVA

33000 V

3470 V

75 A

749 A

50 C

55 C

Pengambilan data trending trafo MB 856-T01 pada sisi LV trafo (panel incoming 856-B1 EHA 2000.12)• Data Tegangan

Data tegangan berdasarkan pengukuran diketahui bahwa tegangan stabil, perubahan nilai

tegangan sangat kecil sekali dengan range 3,42 -3,47 kV. Dengan rating tegangan LV3470 V

persentase maksimum dari deviasi tegangan (over/under voltage) :

|3470− 3420|Deviasi max (%) : x100%

3470

Deviasi max (%) : 1,44 %

Max unbalance tegangan selama pengukuran 0,2 %. Mengacu pada standarNFPA-70B (standart unbalance tegangan < 5% )Salah satu efek yang ditimbulkan dari unbalance tegangan adalah panas,semakin besar unbalance tegangan pada suatu peralatan maka temperatureyang dihasilkan semakin tinggi.






Pegukuran Trending

• Data Arus

Data arus berdasarkan pengukuran diketahui bahwa arus fluktuatif dari 344,4– 493,4 A

dengan maksimum unbalace arus 1,19%.

Fluktuatif arus mengindikasikan beban pada sistem MB-11 berubah-ubah, semakin besar

arus mengindikasikan seakin besar beban pada sistem MB-11.

Mengacu pada rating trafo, beban maksimum yang sistem MB-11 selama proses

pengambilan data dapat dihitung sbb:

Untuk menjaga life time trafo (terutama trafo tua) sebaiknya load maksimum trafo dijagadengan nilai dibawah 85% dari rating trafo.Mengacu pada standar NFPA-70B (standart unbalance arus < 5% )unbalance arus yang terukur masih berada dalam standar normal.Salah satu efek yang ditimbulkan dari unbalance tegangan/arus adalah panas, semakin besar unbalance tegangan/arus pada suatu peralatan maka temperature yang dihasilkan semakin tinggi.

Loadmax(%) : x100%749

Load max(%) : 65,87 %

493,4






Pegukuran Trending

• Data Frequency

Data frequency fluktuatif dengan range 49,24 – 50,27 Hz dengan deviasi frekuensi

maksimum sebesar 0,76Hz.

Beberapa manufaktur membatasi nilaimaksimum deviasi yang diijinkan adalah < 2%,sehingga frekuensi yang terukur masih masukdalam batas normal operasi.

0,76Deviasi max (%) : x100%

50

Deviasi max (%): 1,52%






Pegukuran Trending

o

o

o

o

• Data PowerDari data trending power dan power factor, diketahui power factor relatif stabil, dengan

nilai PF diatas standat minimum yang ditentukan PLN (PF>0.85). berdasar grafik, terlihat PF

rata dengan ketiga grafik power (P,Q, dan S) mempunyai bentuk yang relative sama, naik

dan turun besar power mengikuti naik dan turunnya beban (Arus).

Power yang terukur fluktuatif dengan nilai sebagai berikut:

Active Power

Reactive Power

Apperance Power

Power Factor

: 2,06 – 2,68 MW

: 0,02 – 0,46 MVAR

:2,06 – 2,82 MVA

: 0,96 – 1

Berdasar data power yang terukur dapatdiketahui persentase besar beban untuksistem MB-11 sebagai berikut :

Load TR 856 T01max (%) :x100%

Rating KVA

2,68Load TR 856 T01max (%) : 4,5 x100%

Load TR 856 T01max (%) : 59,56%

Actual KVAmax






Pegukuran Trending

• Standard HarmonisaSalah satu standar yang mengatur batasan harmonisa terukur yang masih diijinkan pada suatu peralatan adalahstandar IEEE 519-1992 Pada standart IEEE 519-1992, standar harmonisa dibedakan untuk harmonisa arus danharmonisa tegangan dengan memperhitungkan besar nilai individual harmonic distortion (IHD) dan nilai totalharmonic distortion(THD).

Standar harmonisa arus menurut IEEE 519-1992

Current DistortionLimits 120-69kV

Isc/IL < 11 11 ≤ n< 17 17 ≤ n< 23 23 ≤ n< 35 35 ≤ n THD

*<20 4 2 1,5 0,6 0,3 5

20 - 50 7 3,5 2,5 1 0,5 8

50-100 10 4,5 4 1,5 0,7 12

100-1000 12 5,5 5 2 1 15






Pegukuran Trending

• Data THDTegangan

Dari data trending harmonic tegangan diketahui THD fluktuatif dari 2,6 – 3,4 %.Mengacu pada standar IEEE 519-1992. Nilai THD tegangan yang terukur masih dalambatas standar (THD tegangan < 5%).

Voltage Distortion Limits

Total VoltageDistortion THD

(%)

Individual VoltageDistortion (%)

Bus Voltage

69 kV and Below 3 5

69,001 kV through 161kV 1,5 2,5

161,001 and above 1 1,5






Pegukuran Trending

• Data THD ArusBerdasar data spectrum harmonic untuk phase I1






Pegukuran Trending

THANKYOU

TRIAS GroupBest Partner in Electrical Power, Instrument Control and Automation Solution, Calibration Service, Mechanical Fabrication,UtilityMaintenance Service, Technical Supply

master proposal · 2019-02-07 · [ethernet tcp/ip, modbus rtu rs485, rs232, can profibus, etc]...

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