By
Einser Nahiman Turjono 11601027
BACHELOR’S DEGREE in
MECHANICAL ENGINEERING – MECHATRONICS CONCENTRATION FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia
June 2020
Revision after Thesis Defense on [8 July 2020]
Einser Nahiman Turjono STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Einser Nahiman Turjono
_____________________________________________
Student Date
Approved by:
Edward Boris P. Manurung, M.Eng
_____________________________________________
Thesis Advisor Date
Leonard P. Rusli, B.Sc., M.Sc., Ph.D.
_____________________________________________
Thesis Co-Advisor
Date
Dr. Maulahikmah Galinium, S.Kom., M.Sc.
_____________________________________________
Dean Date
Einser Nahiman Turjono ABSTRACT
GAS BURNER SYSTEM IMPROVEMENT
By
Einser Nahiman Turjono
Edward Boris P. Manurung, M.Eng , Advisor Leonard P. Rusli, B.Sc., M.Sc., Ph.D.
Co-Advisor
SWISS GERMAN UNIVERSITY
The purpose of this thesis is to find the possibility to lower the LPG consumption on PT. KSM four-lane wafer-stick machine. Wafer-stick machine uses LPG fueled gas burner to bake the batter on the baking wheel. Currently the gas system on wafer-stick machine use two level of flame, big flame and small flame. The Implementation of multi-level flame will be researched to increase the temperature stability, thus lower the LPG consumption. The multi-level flame can be achieved with controlling the blower frequency and using proportional solenoid valve to control the gas flow. The wafer- stick machine that use multi-level flame prototype system will be tested and compared to the current gas system.
Keywords: Proportional Valve, Multi-level Flame, PLC, LPG, Temperature control
Einser Nahiman Turjono
© Copyright 2020 by Einser Nahiman Turjono
All rights reserved
Einser Nahiman Turjono DEDICATION
I dedicate this thesis for God, my family, my friends and Indonesia.
Einser Nahiman Turjono ACKNOWLEDGEMENTS
I would like to thank God for His blessings and grace, without Him this research would not have been possible.
I also thank my parents for their support, love, and sacrifices for me, also for my grandfather and my sister for their presence and support.
I am also grateful to have Mr. Edward Boris Manurung as my advisor and Mr. Leonard Rusli as my co-advisor, they provide guidance, support and valuable comment to help me finish this research.
For all my friends in university especially Audrey, Andrian, Alvin K, Alvin T, Agus, Billy, Deo, Ivan, Heverett, Radya, Edrick, Wilvan, Thomas, Rich, Gio, Oliver, Fendy, Kevin, Garry, Dion, Gene, Gabrielle, William, Dwi, Jason, Ari, and Quincy. Thank you for making my university life more colourful, fun, and exciting.
I would like to express my gratitude to all lecturer and staffs who taught me for all the guidance and lessons.
Finally, I want to thank PT. Kreasi Solusi Mandiri and PT. Sanco for allowing me to do my research there, and Mr. Weten, Mr. Erik, Mr. Puji, Mr. Sutri, Mr. Endang, Mr.
Handoko and all PT. Kreasi Solusi Mandiri staffs for their guidance and warm welcome during my research time.
Einser Nahiman Turjono TABLE OF CONTENTS
Page
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
LIST OF FIGURES ... 10
LIST OF TABLES ... 12
CHAPTER 1 - INTRODUCTION ... 13
1.1 Background ... 13
1.2 Thesis Objective ... 14
1.3 Thesis Problem ... 14
1.4 Thesis Scopes ... 14
1.5 Thesis Limitation ... 14
1.6 Hypothesis ... 14
1.7 Significant of Study ... 15
1.8 Thesis Organizations ... 15
CHAPTER 2 - LITERATURE REVIEW ... 17
2.1 Introduction ... 17
2.2 Liquified Petroleum Gas ... 17
2.3 Regulator ... 17
2.4 Diaphragm Gas Meter ... 18
2.5 Industrial Temperature Sensor ... 19
2.5.1 Temperature Controller ... 20
2.6 Air and Fuel Ratio for Perfect Combustion ... 21
2.7 Venturi Gas Mixer ... 23
2.8 Proportional Solenoid Valve ... 23
2.9 PID Controller ... 25
2.10 Programmable Logic Controller (PLC) ... 26
2.11 AC Servo Motor ... 27
CHAPTER 3 – RESEARCH METHODS ... 28
Einser Nahiman Turjono
3.2 General Methodology ... 28
3.3 Current Fire System ... 29
3.3.1 Current Fire System LPG Usage Data ... 30
3.3.2 Current Fire System Rise Time ... 32
3.4 System Identification ... 34
3.5 Material and Equipment ... 35
3.5.1 Four-lane Wafer-stick Machine ... 35
3.5.2 Wafer-stick Machine Gas System ... 37
3.5.3 Baking Wheel ... 37
3.5.4 Gas Burner ... 38
3.6 Electrical Component ... 39
3.6.1 Infrared Thermosensor ... 39
3.6.2 Proportional Valve ... 39
3.6.3 AC Servo Motor ... 42
3.7 Ball Valve Position ... 43
3.8 PLC Component ... 45
3.8.1 Analog to Digital Converter ... 45
3.8.2 Digital to Analog Converter ... 46
3.9 Program ... 47
3.10 Fire System Using Multiple Flame Size Setting ... 47
3.11 Testing Method ... 48
CHAPTER 4 – RESULTS AND DISCUSSIONS ... 49
4.1 Introduction ... 49
4.2 PID Tuning ... 49
4.3 Proportional Valve Testing ... 54
4.4 Servo Actuated Ball Valve ... 54
4.4.1 AC Motor Setup ... 56
4.5 Analog Module Installation ... 59
4.5.1 Analog to Digital Converter ... 59
4.5.2 Digital to Analog Converter ... 62
4.6 Multiple Flame Size Simulation ... 66
4.7 Device Connection ... 70
4.8 Testing Result ... 70
4.8.1 Sensor and Thermogun Comparison ... 70
4.8.2 LPG Usage Data ... 72
4.8.3 Production Testing Result ... 74
CHAPTER 5 – CONCLUSIONS AND RECOMMENDATIONS ... 75
5.1 Conclusions ... 75
Einser Nahiman Turjono GLOSSARY ... 76 REFERENCES ... 77
Einser Nahiman Turjono LIST OF FIGURES
Figures Page
Figure 2-1: LPG ... 17
Figure 2-2: Regulator ... 18
Figure 2-3: Diaphragm Gas Meter ... 18
Figure 2-4: Diaphragm Gas Meter Components ... 19
Figure 2-5: Infrared Thermosensor ... 19
Figure 2-6: Infrared Thermometer Diagram ... 20
Figure 2-7: Temperature Controller ... 20
Figure 2-8: AFR 12:1 ... 22
Figure 2-9: AFR 13:1 ... 22
Figure 2-10: AFR 14:1 ... 22
Figure 2-11: AFR 15:1 ... 22
Figure 2-12: AFR 16:1 ... 22
Figure 2-13: Venturi Gas Mixer... 23
Figure 2-14: Principle of Proportional Solenoid Valve ... 23
Figure 2-15: PID Controller Block Diagram ... 25
Figure 2-16: PLC ... 26
Figure 2-17: AC Servo Motor ... 27
Figure 3-1: General Methodology ... 28
Figure 3-2: Wafer-stick Machine Fire System Flowchart ... 29
Figure 3-3: Human Machine Interface (HMI) ... 32
Figure 3-4: Rise Time ... 34
Figure 3-5: Wafer-stick Machine ... 36
Figure 3-6: Wafer-stick Machine Side View ... 36
Figure 3-7: Wafer-stick Machine Gas System ... 37
Figure 3-8: Gas Burner ... 38
Figure 3-9: Nozzle ... 38
Figure 3-10: Omron ES1C-A40 Thermosensor ... 39
Figure 3-11: Bürkert Two-way Solenoid Control Valve ... 39
Figure 3-12: TFM15-S2-C, 1/2" DN15 Proportional Valve ... 40
Figure 3-13: AC Motor Servo Actuates Ball Valve ... 42
Figure 3-14:Mitsubishi AC Servo HG-KN43 ... 43
Figure 3-15:Melservo JE Servo Driver for HG-KN43 ... 43
Figure 3-16: Servo and Ball Valve Connection ... 44
Figure 3-17: PLC Unit Melsec Q ... 45
Figure 3-18: Q64AD Module ... 46
Figure 3-19: Q62DAN Module ... 46
Figure 3-20: Multiple Flame Size Setting Flowchart... 47
Figure 4-1: Black Box Model ... 49
Figure 4-2: Step Response Graph ... 49
Figure 4-3: PID Simulation ... 50
Einser Nahiman Turjono
Figure 4-5: Simulation Using PI Controller ... 52
Figure 4-6: Second Simulation Using PI Controller ... 53
Figure 4-7: Simulation Using PID Controller ... 53
Figure 4-8:Proportional Valve Failure ... 54
Figure 4-9: Close-up Big Flame and Small Flame Pipe ... 55
Figure 4-10: Servo Controlled Ball Valve Arrangement ... 56
Figure 4-11: Position Mode and Torque Setting ... 56
Figure 4-12: Position Pulse Input and Testing ... 57
Figure 4-13: Initial Position, Valve 100% open ... 57
Figure 4-14: Position 10°, Valve 90% open ... 58
Figure 4-15: Position 25°, valve 75% open ... 58
Figure 4-16: Position 60°, valve 40% open ... 59
Figure 4-17: Q64AD Installed ... 60
Figure 4-18: Q64AD Switch Setting ... 60
Figure 4-19:Q64AD Parameter Setting ... 61
Figure 4-20: Q64AD Data Storage Setting ... 61
Figure 4-21: Q64AD Application ... 62
Figure 4-22:Q62DAN Installed ... 63
Figure 4-23: Q62DAN Switch Setting ... 63
Figure 4-24: Q62DAN Parameter Setting ... 64
Figure 4-25: Q62DAN Data Storage Setting ... 64
Figure 4-26:Q62DAN Application ... 65
Figure 4-27: Q62DAN Analog Signal ... 65
Figure 4-28: Program Simulation 100% Valve Open ... 66
Figure 4-29: 100% Valve Opening With 42 Hz Frequency... 66
Figure 4-30: 90% Valve Opening ... 67
Figure 4-31: 90% Valve Opening With 38 Hz Frequency... 67
Figure 4-32: 75% Valve Opening ... 68
Figure 4-33: 75% Valve Opening With 32 Hz Frequency... 68
Figure 4-34: 40% Valve Opening ... 69
Figure 4-35: 40% Valve Opening With 20 Hz ... 69
Figure 4-36: Device Connection ... 70
Figure 4-36: Sensor and Thermogun Reading Comparison ... 71
Figure 4-37: Big Flame Previous System Vs Improved System ... 72
Figure 4-38: Small Flame (Production flame) Previous System Vs Improved System ... 73
Einser Nahiman Turjono LIST OF TABLES
Table Page
The Effect of Increasing Each Parameter Independently... 26
Current Gas System Parameter ... 30
Big Flame LPG Consumption ... 30
Small Flame Gas Consumption ... 31
Temperature Rise Over Time ... 32
Bürkert type 2875 / article no. 236906 Specification ... 40
TFM15-S2-C Specification ... 41
Ziegler Nichols Rule ... 51
Kp, Ki, Kd Aproximation ... 51
Production Testing Result ... 74
