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Prototype of a PLC-Based Automatic Switch System for Pump Protection in a Palm Oil Mill
 
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Mechatronics Department, Politeknik Caltex Riau, Pekanbaru 28265, Indonesia
 
 
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hendriko hendriko   

Mechatronics Department, Politeknik Caltex Riau, Pekanbaru 28265, Indonesia
 
 
 
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ABSTRACT
Palm oil mill pumping systems rely on a VSD, a motor, and a centrifugal pump to continuously transfer crude palm oil (CPO) between processing units. Disturbances such as overcurrent, overvoltage, undervoltage, or overheating can halt production. The mill without an automatic backup system experience prolonged downtime and losses. This study developed a prototype of the Automatic Switch System (ASS) that detects VSD and motor faults in real time and automatically transfers operation to a backup system without manual intervention. The prototype integrates a current sensor, a voltage relay, and a TOR sensor, coordinated through PLC-based control logic. Testing was performed to check current sensor accuracy, overvoltage/undervoltage detection, overload response, and switching back to the main system. Results show that the maximum current measurement deviation was 4.71%. At the 5% setpoint, the main system remained active at the tested values from 212 to 227 V and switched to the backup system at 209 V and 231 V. At the 10% setpoint, it remained active from 200 to 239 V and switched at 197 V and 242 V. During the overload test, currents above the 3.5 A threshold caused transfer after the overcurrent condition persisted for the predefined 8-minute period. The time-delay switching strategy followed with the predefined 8-minute sustained overcurrent duration, avoiding nuisance tripping. Overall, the prototype demonstrates the capability of ASS technology to improve the reliability and operational continuity of CPO pumping systems; however, full-scale performance and the actual reduction in downtime and losses require validation in an operating palm oil mill.
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