Implementation of Automatic Dust Detector on Dust Suppression System on Transfer Tower 0 In Paiton 9 Power Plants

The operation of dust suppressor and dust collector was operating semi-manually by pressing the power button on the local panel during the initial unloading of coal material from the barge or stockpile, where local operators manage several large areas. This research is carried out on the implementation of Automatic Dust Detector for Dust Suppression operational at Paiton Unit 9 power plants with the aim of increasing the efficiency of operator and equipment performance. We use House of Quality (HOQ) as a determinant of the priority scale for technical response to be implemented, namely the addition of an Automatic Dust Detector. The results obtained showed a decrease in the calculation of the dust suppression operating time, i.e. from 5 hour 54 minutes to 5 hour 6 minutes, from 1005,36L/barge to 869,04L/barge  for water consumption, and 1L/barge to 0,86L/barge for chemical use. Furthermore, the implementation of the Automatic Dust Detector can significantly increase efficiency at least 15% from operating time difference.  


Introduction
The application of the Hi-Pressure Fog Spray Dust Suppression System can control the dust formed during the coal handling process. This is proven by the reduction of dust levels in the air from 50.14 mg/m 3 to 1.35 mg/m 3 .This is correspond to the standard of 10 mg/m 3 and that one of the programs that support Operation Excellent, especially Coal Handling Safety because dust control can minimize the incidence of fire and environmental pollution. can reduce maintenance costs, especially in the scope of cleaning [1].
In the operation of the dust suppressor and dust collector operators should be operate semi-manually by pressing the power button on a local panel when the initial unloading of coal from the barge or stockpile is started. From the condition above, we proposed the Volume 20 (1) 2021 implementation of automatic dust detector to dust suppression system. This is aimed to reduce the operating time and water consumption and to improve the efficiency of dust suppression system operational.

Data Collection
In this research, we use three data resoruces, which are : 1. Observation data is data taken from samples in the field and then summarized in descriptive sentences and tables. 2. Operational data is any operating activities recorded in the logbook forms, excel sheets and reported via email. 3. The simulation data is data obtained from the process of designing and experimental tools to get the final result.

Experiment and Simulation Methods
Raw data from the data collection process are processed into operating data to define operating limits for the basis of tool design and simulation. We use HOQ as a reference for innovation where the greatest weight is applied to the existing system. After the implementation stage, an evaluation of the operator's assessment is carried out to improve the efficiency of the operational process.

Research Flowchart
The following is the sequence process of data collection and data processing so that the final result for the design of the tool can be seen in Figure 1

House of Quality (HOQ) Product
House of Quality (HOQ) is part of Quality Function Development (QFD) which identifies the needs or product features from the costumers/users. Identification is done in the field of design, sub-system characteristics, manufacturing processes, production activities, and also quality assurance. The HOQ takes the form of a matrix of development and planning through the process of comparing the characteristics of critical components and key operations in production [3].

Initial Technical Assessment
In the preliminary research, a technical study was carried out on the operation of the equipment system before implementation. The use of material consumption during the operation of the dust suppression system can be seen in Table 1.  The design of the equipment has been converted in the form of block diagram to explain briefly some groups of components that will be compiled in a single prototype. The following illustration on the  The next step is to design a programming language on a prototype that has been adjusted to the results of observational data collection and operational data. The following is a series of commands that have been programmed into the tool on

Tool Work System
Equipment that has been designed and assembled has several types of programming commands as follows: • When the dust density variable is at a value < 0.46 then the green LED (standby indicator) on, red LED (indicator running) off, yellow LED (dust suppression systems) off. • When the dust density variable is at a value >= 0.46 then the green LED (standby indicator) is off, the red LED (running indicator) on, yellow LED (dust suppression systems) on.

Volume 20 (1) 2021
• When the dust density variable is at a value > 0.53 then the buzzer (alarm indicator) on up with the rhythm on and off 0.1 seconds. • When the dust density variable is at a value < 0.53 then the buzzer (alarm indicator) off.
The results of the prototype experimental simulation by being triggered using a random sample of coal dust 3 times are shown in the following Figure 5.  The layout from Figure 6 is a description of the block diagram that has been designed before and the coding is programmed to make a prototype of the applied layout function as designed. In the simulation process, it is stated that the equipment functions in accordance with the coding that has been programmed on the prototype and with the success of the simulation of the equipment, the calculation of operational efficiency can be carried out. The following is the calculation of efficiency after implementation which is presented in table form. After the implementation of the tool, the results obtained can be seen in the comparison in Table there is a decrease between working hours, operator travel time and water and chemical consumption

Research HOQ
HOQ research is determined by calculating the priority scale shown by a ranking system for the selection of innovations to be produced and there is a comparative survey between the systems before and after the implementation of the tool which can be seen in Determining the priority scale of the customer requirements, namely operator requests and functional requirements or technical responses [6] generates basic ideas for designing an automatic dust detector device and after the implementation process there is an increase in the value of the author's survey for each operator's request so that it is stated that the implementation of automatic dust detector equipment can increase work efficiency [7] and improve the performance of the dust suppression system equipment and the performance of the operator in operational activities.
In rate data retrieval importance and level of satisfaction (perception) using a Likert scale namely (1) very insignificant, (2) not important, (3) quite important, (4) important and (5) very important. Meanwhile data for the level of satisfaction (perception) service is (1) very bad, (2) bad, (3) bad enough, (4) good and (5) very good. Testing data in this questionnaire is conducted through validity and reliability test [8].
QFD is widely used in product development and production fields [9]. The Quality Function Deployment (QFD) framework is used to understand the product requirements Volume 20 (1) 2021 defined by the user [10]. QFD focuses on transforming customer needs into engineering product characteristics. House of Quality (HOQ) is the tool used at QFD [11].

Discussion
The results obtained from the implementation of automatic dust detector is decrease the time for the shortest travel time operator for 1 hour 36 minutes per barge cause operator no longer need to travel form patrol post building to transfer tower 0 building for activating dust suppressor. The decrease of the time dust suppression systems operational for a minimum of 48 minutes per barge, water consumption of at least 136.2 litres per barge and chemical consumption of at least 0.14 litres per barge cause operational of dust suppressor was cut off for no longer waiting the operator operate dust suppressor semi manually. Chart of comparasion can be seen on Figure 8 and Figure 9.

Conclusion
The final result of designing an automatic dust detector fulfils the objectives of the preparation of the proposal, namely minimizing the work of the dust suppression system equipment and operators and increasing the performance of the entire system operation.
The result of automatic dust detector modification can be developed with a more complete design in the Coal Handling System area of the Paiton 9 power plant and can be reviewed for implementation in other coal power plant units according to field conditions. The system can be developed also in industries that have concerns about the handling of dust to reduce the risk generated by the dust that can be generated industry with high performance and environmental friendly.