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

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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.