Analisis Kinerja Sistem Otomatis Pengisian Tangki BBM Genset Berbasis PLC Dan IoT

Manual fuel refilling systems in generator sets often suffer from inefficiencies such as inaccurate volume estimation, delayed refueling, and the absence of real-time tank level monitoring. This study aims to analyze and test an automatic fuel tank refilling system based on a Programmable Logic Controller (PLC) integrated with Internet of Things (IoT) technology. The system employs an ultrasonic sensor (HC-SR04) to detect fuel levels, a flow switch to verify the presence of fuel flow, and an ESP32 microcontroller to transmit data to a remote monitoring application (Blynk). Two operation modes were tested: manual and automatic. The research results show that the manual fuel filling system for generators has weaknesses in volume accuracy, delayed filling, and a lack of real-time level monitoring. This study developed an automated system based on PLC and IoT using HC-SR04 sensors and a flow switch, controlled by ESP32 and connected to the Blynk application. Testing showed that the automated system can fill fuel twice as fast compared to manual (with a filling time of only 2 minutes compared to 4 minutes). The filling volume reached 70.8 liters with a sensor accuracy of 98.3% and a power consumption of only ±0.75189 kWh/hour. The IoT system showed data delays of less than 1 second over 24 hours. This system proved to be more energy-efficient than the existing manual system and can support the digitalization of energy management.