Design of industrial internet of things system on mini-plant oil separator level control based on industrial wireless sensor and actuator

One of the high-level risks of work accidents in the oil and gas industry is the separation process of the oil phase after the drilling process. Crude oil, which is flammable, become very dangerous to the field workers who are tasked to monitor the separation process. To monitor and control the oil separation process safely, IoT has become the solution. Furthermore, IoT can be a solution to reduce operational and maintenance costs in the petroleum exploration process. Research has been carried out on the implementation of IIoT-based control and monitor systems and optimization of level control systems using fuzzy PID controllers on a three-phase separator mini plant. The results showed the Industrial Wireless Sensor and Actuator Networks (IWSAN) communication system using the Zigbee IEEE 802.15.4 protocol at the mini plant communicated in real-time at a distance of 100m with a delay time of 16ms. The PID-based fuzzy level control system can produce a better dynamic response than PI and PID control systems. The mixed level control shows a maximum overshoot of 2%, a settling time of 587 seconds, a steady-state error of 1%, a rise time of 466 seconds, and IAE 2546. Meanwhile, the control of an oil level shows a maximum overshoot of 3%, a settling time of 362 seconds, a steady-state error of 1 %, a rise time of 226 seconds, and IAE 1429.4.