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Secara arsitektur umum, sistem kontrol utama pada industri, terutama di industri oil & gas terbagi menjadi 3:

1. PCS (Process Control System): digunakan untuk pengontrolan besaran-besaran proses (flow, temperature, pressure, level, etc)

Implementasi dari PCS biasanya dengan menggunakan DCS (Distributed Control System). Contoh merek2 DCS yang cukup populer adalah: Yokogawa Centum, Foxboro I/A, Honeywell Experion/TPS/TDC, Siemens S7/PCS7, etc

2. ESD (Emergency Shutdown System): digunakan untuk proteksi pabrik, dimana dalam keadaan emergency equipment dapat dibawa ke kondisi safe (shutdown)

Implementasi dari ESD adalah dengan menggunakan PLC yang berkapabilitas sebagai Safety System. Contoh merek2 Safety System yang cukup populer adalah: Invensys Triconex, Honeywell FSC, Siemens S7/PCS7, Yokogawa ProSafe, ICS Triplex Regent/Trusted, etc

3. FGS (Fire & Gas System): digunakan untuk proteksi pabrik, dengan mendeteksi adanya api & gas sehingga memberikan alarm atau dapat membawa equipment ke kondisi safe (shutdown)

Implementasi dari FGS adalah dengan menggunakan PLC yang berkapabilitas sebagai Safety System. Contoh merek2 Safety System yang cukup populer adalah: Invensys Triconex, Honeywell FSC, Siemens S7/PCS7, Yokogawa ProSafe, ICS Triplex Regent/Trusted, etc

Sistem kontrol diatas kemudian dapat dikombinasikan menjadi suatu sistem yang lebih kompleks sbb:

- Dikoneksikan satu sama lain dengan link komunikasi (ethernet, fiber optic, etc)

- Dikoneksikan dengan HMI (Human Machine Interface) berupa workstation (PC, keyboard, mouse, monitor) sebagai media komunikasi dengan operator. Ada beberapa software HMI yang populer: ada yang sudah terintegrasi paket dengan sistem kontrolnya, ada yang open dengan macam-macam sistem. Contohnya adalah: Invensys Wonderware.

- Dikoneksikan dengan PIMS (Plant Information Management System), untuk mengkomunikasikan, menyimpan (history), memproses dan mempresentasikan data2 proses dari plant ke level managerial atau penyimpanan. Contohnya adalah: Yokogawa Exaquantum, Foxboro AIM, etc

Sebagai summary, ketiga sistem ini membentuk arsistektur umum dalam disain dan perancanan sistem kontrol industri, dan ditemukan baik di petrochemical plant, oil & gas plant, LNG plant, offshore processing platform, offshore FPSO, dan lainnya.

Today, I finally finish my job to conduct training at Temasek Polytechnic. The participants are some mechatronics students from  School of Engineering. The objective of this training is to prepare the students on entering the workforce in process control industry, and in particular to prepare some students to take 5 months internship program in my company.

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The training program takes 2 weeks to complete, and covers practical topics such as: basic hardware in process control, PLC logic and HMI software. The first lecture has been conducted by my manager, Mr. David Ong on the topic of offshore industry. The next session has been conducted by my colleague, Jiang Qi on the overview of the hardware involved in a process control project.

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After topics on hardware, then it was my turn to explain on PLC architecture and logic programming. The students have an opportunity to do hands-on experiment on real PLC, assembly the PLC modules and wiring and writing the ladder logic program.

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The next session has been done by my colleague, Xia Bo Feng on HMI software. The students also have opportunity to do hands-on experiment for HMI, and also how to connect the HMI into PLC.

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At the last day, the students have the opportunity to do small project, and finally present their project. This is very an rewarding moment to see them explaining their project in front of the lecturer, students and of course, my dear boss :) Really nice to see these youngsters make their gigs on stage performance. I also can see their enthusiasm during training, their eagerness to understand something and their sense of responsibility to get the things done.

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After the training, I am also receiving many feedback from lecturers and students to improve this training in the future.  This is very important, because for technical training; our objective is to give a hands-on experience in a short period, as a basis for the audience to develop a more advanced application in the future. A few days; or one week shall be enough to give such a foundation. Starting with a short introduction, and continuing to gives handout consists of step-by-step experimentation. A lecturer can give the guidence, while the students do their experiment. Starting from simple logic, and build more advanced application. Starting from simple HMI drawing and combine the logic with HMI so complete the overall training project.

The other thing is how to make the training more fun. Because learning with fun is more effective, can increase students interest and easily to teach new concept to them.

Hmm … something that I shall try and improve it later if I have an opportunity to conduct training in the future. Hopefully I also could have chance to do it in Indonesia …

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*Thanks to Mrs Yuan Min, Mr. Lim Hock Chuan and students for the event and feedback!

While searching for some references to write new articles in my blog, I was visiting some nice blogs written by Indonesian’s professional and expatriate on Automation. The topic covers PLC, SCADA, instrumentation and other interesting stuff. Some of the writer are currently working as an automation area in Indonesia and overseas. Here are some of the links:

PLC and SCADA

Instrumentation & Process Control

 Those were to name a few, and we will see the growing number of automation experts from Indonesia and their contribution.

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