Prototipe Instrumentasi Control Automatic dengan Distributed Control System (DCS) Berbasis ESP32 pada Process Truck Loading Minyak Bumi

Abstract

This study addresses small-scale crude oil truck loading systems that still rely on manual human control, which endangers the environment, equipment, and personnel. Unmonitored human error such as overfilling occurs because the flow is not observed in real time, fires may arise from crude oil exposed to ambient heat, and miscommunication frequently happens between the local operator running the process and the operator recording the loading data. The purpose of this study is to design a reliable automated control system for the crude oil truck loading operation, to implement instrumentation on that operation, and to build an actual-condition graphical HMI using Node-RED. The method used is experimental research, comprising problem-data collection, design analysis, and implementation. The monitored parameters are tank level, temperature, and crude oil flow, read by an ESP32-based controller and displayed on a local LCD panel as well as a Node-RED DCS HMI in real time. The automated control with the DCS system is equipped with protection mechanisms (overheat, low level, and overflow) that safeguard the equipment and its surroundings in the event of an operational failure. The results show that the ESP32-based automated control runs according to the actual operating design; the HC-SR04 level sensor is accurate but limited below 3 cm, the DS18B20 temperature sensor is accurate within ±1 C, while the YF-S201C flow sensor is less accurate below 1 L/min. The DCS HMI display makes it easier for operators to view the parameter history for data logging and troubleshooting analysis.