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FACTORY FACILITY DEPARMENT

PEB Energy saving project


No Activity FY’19 Saving (kWh) Investment Payback
cost (SGD) period
(month)
1 Air con system and humidity improvement June 13,853 8,900 3.1
at Device Production (CISM area) kWh/month
2 Energy saving activity with Combine High June 6,480 4,000 1.4
Vacuum pipe Device to IK kWh/month
3 Energy saving activity water chiller pump June 1,210 9,000 7
molding kWh/month
4 Control Hi Bay lamp operation at Annex June 1,192 4,872 18
building lot 509 & 510 kWh/month
5 Energy saving activity air con system at COB July 9,869 N/A
production kWh/month
6 Change of air inlet height of molding clean TDB - - -
room. Lowering the air supply to 2 m, air
conditioning only in the production area,
reducing running costs
7 Reduce temperature room 2nd floor July N/A
Confidential
molding storage with adjust air con system
PT. EPSON BATAM
1 Air con system and humidity improvement at Device Prod’n (CISM area)

1.1 Background and temp humidity at EOL and FOL area FY’ 2019
Current Specification
AIR CON SPECIFICATION
1. HITACHI AIR COOLER 20 HP x 7 Units
CISM (FOL) ~ 1 units for Fresh air
PRODUCTION
FOL ~ 6 units for supply cooling air to Production
(COF, FOL, EOL)
2. Fresh Air blower Capacity 8,000 CFM
Inverter set 35 Hz
3. Room pressure ~ 15 Pa

Problem : From data monitoring temperature and


COF
humidity monitoring at EOL and FOL area out
specification.
EOL Table result summary :
COF LINE
PRODUCTION
Area Temp Humidity Result Judgement
(20 – 25.5) (40 – 60)
CORRIDOR

PT. EPSON BATAM


JL. RAMBUTAN LOT 504-508A

FOL
JL. DELIMA LOT 509-510
MUKA KUNING,
BATAM-INDONESIA
23 38 Humidity out NG
CHANGING ROOM CISM (EOL)
DRAWING TITLE
MAPPING AIR CONDITIONER
specification
PRODUCTION
DUCTING
COF & CISM DEVICE COF & CISM (FOL & EOL)

EOL 22 39 Humidity out NG


PRODUCTION LOT 504

DATE SCALE

FEB, 2018 1 : 100 specification


DRAWING NO. SIZE

PEB-FFD-MC-1112/R1

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REDRAWING BY
A3
FARIZ YUDHO A.S
PT. EPSON BATAM
REMARK
CHECKED BY
1 Air con system and humidity improvement at Device Prod’n (CISM area)

1.2 Propose Improvement FY’ 2019


1.2.1 Separated ducting COF and (EOL/FOL) 1.2.2 Switch OFF 1 unit air con (EOL & FOL)

AC Before After Reduce


AC 1 AC 2 AC 3
20HP 3 2 1
Condition ON ON OFF

AC 6
AC 1 AC 2 AC 3
F/A AC 4 AC 5 EOL &
FOL Prod

AHU ROOM Table summary result monitoring Temp & Hum


Area Temp Humidity Judgement
COF EOL & (20 – 25.5) (40 – 60)
prod FOL Prod
FOL 22 48 OK
EOL 22 52 OK

Result : Temperature and humidity at EOL and Result : Temperature and humidity maintain
FOL area not stable (monitoring by SWA) stable condition (monitoring by SWA) in
specification and air con can switch OFF 1 unit.

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1 Air con system and humidity improvement at Device Prod’n (CISM area)

1.3 Effect electrical saving FY’ 2019


Item Before After Reduction

AC 20HP 3 2 1

Condition OFF ON OFF

kWh/month 35,850 21,997 13,853

Monthly electrical saving


KWH
40,000 35,850 Tangible benefit
30,000 1. Investment cost = 8,900 SGD
21,997
2. Monthly saving cost = 13,853 kWh x
20,000
0.201 = 2,784 SGD/Month = 33,413
10,000 SGD/year
3. Payback period = 3.1 month
- 4. CO2 reduction = 10.9 Ton Co2/month
Before After
Electrical consumption

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1 Air con system and humidity improvement at Device Prod’n (CISM area)

1.4 Monitoring stable effect FY’ 2019

Overall monthly monitoring electrical consumption of CISM air con


50,000
45,000
40,000 35,850
35,000
30,000
kWh

25,000 21,997
20,000 18,264
15,000
10,000
5,000
-
May 19 Jun-19 Jul-19 Aug-19 Sep-19 Oct-19 Nov-19 Dec-19 Jan-20 Feb-20 Mar-20 Apr-20
Benchmark
2019 2020

Monthly monitoring effect stable of electrical consumption

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2 Energy saving activity with Combine High Vacuum IK to Device

2.1 Background and Propose FY’ 2019


Background : Current condition each department have high vacuum for production
activity and from flow rate data monitoring Device production small consumption and
possible to reduction activity.
Propose : Combine high vacuum pipe IK to Device

Utilities 504 Utilities 507 Utilities 508A


1 unit Becker ON
(37 KW)

1 unit VC 400 OFF 2 unit VC ON 1 2 unit VC 500 ON 1


(9 KW) 1100 (30 KW) unit (15 KW) unit

1 unit VC OFF
Propose 500 ( 15 KW)
combine pipe

Device Production IK and molding


Prod
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2 Energy saving activity with Combine High Vacuum IK to Device

2.3 Effect electrical saving FY’ 2019


Item Qty Before After Reduction
HV VC 400 1 1 0 1
HV VC 500 3 1 1 0
HV VC 1100 2 1 1 0

HV Becker 1500 1 1 1 0

kWh/month 42,507 36,027 6,480

Proposed :
1. Connecting high vacuum IK piping to device.
2. Target stop high vacuum machine device after additional new high vacuum IK.
3. Total Saving per month SGD 1,302.48 (6,480 KWH/month).
4. Total saving from monthly maintenance cost Device vacuum machine SGD1,500 /month
5. Investment cost for piping SGD 4,000
6. ROI = 1,4 month
7. CO2 reduction = 50.1 Ton CO2/month

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2 Energy saving activity with Combine High Vacuum IK to Device

2.4 Monitoring stable effect FY’ 2019

Overall monthly monitoring electrical consumption of high vacuum


50,000
45,864
40,970
40,000
30,831
30,000
kWh

20,000

10,000

- - - - - - - - - -
May 19 Jun-19 Jul-19 Aug-19 Sep-19 Oct-19 Nov-19 Dec-19 Jan-20 Feb-20 Mar-20 Apr-20
Benchmark
2019 2020
High vaccum IK High vaccum Device Total

Conclusion : base on overall monthly monitoring electrical consumption of High vacuum


has been decrease, it’s means high vacuum device can switch OFF and sharing
consumption from IK high vacuum.

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3 Energy saving activity water chiller pump molding
3.1 Background FY’ 2019
Chiller Main Pressure Supply Requirement Gap Judgement Temperature
room (bar) molding line Molding (℃)
Chiller 3,5 bar Line A, B, C 2.5 – 3 bar 0.5 bar Need improvement
room 1

22℃

Chiller 3.6 bar Line D & E 2.5 – 3 bar 0.6 bar Need improvement
room 2

22℃

Conclusion : Base on table analysis pressure chiller machine room 2 is high (3,6 bar) , so production
requirement machine just (2.5 – 3 bar). To achieve the water supply kept on low temperature and
efficient to production. So, opportunity for reduce the pressure is high, and can take more energy saving
by reduce pump rotation.
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3 Energy saving activity water chiller pump molding
3.2 Challenge target saving in 20% FY’ 2019
Power
Reduce Capacity (KW) Reduce Capacity (kWh)
Setting % power consumption

(Hz) absorb Pump 1 Pump 2 Pump 3 Pump 4 Pump 1 Pump 2 Pump 3 Pump 4 kW/d

40 80% 4.92 4.92 4.92 4.92 118 118 118 118 473

30 60% 3.69 3.69 3.69 3.69 89 89 89 89 354

20 40% 2.46 2.46 2.46 2.46 59 59 59 59 236

10 20% 1.23 1.23 1.23 1.23 30 30 30 30 118

0 0% 0.00 0.00 0.00 0.00 - - - - -

Elect. Usage Percentage Electrical saving chiller pump with inverter control
Setting Saving total
after use VFD Total 20,000 100% 120%
100%
80%

kWh/m
(Hz) 15,000 60%
kW/month kW/month saving 80%
10,000 60%
40 14,178.3 3,544.59 20% 40%
40%
5,000 20%
30 10,633.8 7,089.17 40% 20%
- 0%
20 7,089.2 10,633.76 60% Hz 40 30 20 10 0

Full load 50Hz Elect. Usage after use VFD


10 3,544.6 14,178.35 80%

0 - 17,722.93 100%

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3 Energy saving activity water chiller pump molding
3.3 Use inverter for all water pump chiller molding 2 FY’ 2019
Proposed implementation and evaluation energy saving activity at chiller room 2
Table evaluation using inverter control at chiller pump
No Description Condition Freq Current Power Pressure Temp Judgement
(Hz) (A) (kW) (bar) (℃)
1 Pump full running Before 50 10.8 6.77 3.6 22 OK

2 Pump control After 43 8.8 5.09 3 22 OK


running
MCCB Inverter
Saving 7 2 1.68 0.6 0

Monthly result saving electrical


6,000
4,874
5,000
4,000
3,665
kWh

Pump 3,000
Before (3.6 bar) After (3 bar)
2,000
Inverter control 1,000
- Electrical saving= 1,210 kWh/month
Before After
Ton CO2 = 0.9 Ton CO2
kWh/month

Conclusion : Based on implementation and monitoring at 1 unit motor pump chiller 2 with inverter setting
43 Hz pressure proper production requirement (pressure and temp). The electrical consumption reduce
automatically. Next implementation for 3 units (33 KW) chiller pump at Chiller Room 1.
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3 Energy saving activity water chiller pump molding
3.4 Energy saving result if implementation 4 unit chiller pump FY’ 2019
INVERTER CONTROL MOTOR PUMP

Monthly electrical consumption chiller pump


are 4 unit
24,000
21,000 19,498
18,000
14,659
15,000

kWh
12,000
9,000
6,000
3,000
-
PUMP PUMP PUMP PUMP Before After
11KW 11KW 11KW 11KW kWh/month

Electrical saving effect :


1. Control chiller pump are 4 unit using inverter 5. Ton CO2 = 3.7 Ton CO2
2. Before = 19,498 kWh/month 6. Total Saving per month SGD 962/month
3. After = 14,698 kWh/month 7. Investment cost for inverter SGD 9,000
4. Electrical saving = 4,719 kWh/month 8. ROI = 7 month

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4 Control Hi Bay lamp operation at Annex building lot 509 and 510

4.1 Background FY’ 2019

Current electrical consumption of hi bay lighting 509 & 510

1 kWh = SGD 0.201


Voltage = 220 V (1 Phase)
Capacity = 150 watt
Running time = 24 hour
Qty Lamp = 76

1 unit (kWh) = (Capacity * time saving * Month) / 1000


= (150 Watt * 24 hours * 30 days) / 1000
= 108 kWh/month

Electrical cost for 76 unit


8,208 kWh/month
1,649 SGD/month
Manual control switch

Background : Previously control hi bay lamp manual operation and no operation control
ON and OFF, so the lighting always ON condition every day.

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4 Control Hi Bay lamp operation at Annex building lot 509 and 510

4.2 Schematic diagram propose FY’ 2019

Ethernet Cable from


Office to Panel

1. Lighting Control, 2. Programmable


Monitoring and Configuration Logic Controller
from Office Lot 509 - 510 (PLC)

Auto control panel

Schedule time program


3. Contactor 4. Lighting switch 5. High bay
(Optional for lamp 150W
manual Control)
Proposed : For reduce electrical consumption at Hi bay lamp at 509 & 510, we propose install auto
control switch, the system will be working automatically base on schedule time setting.
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4 Control Hi Bay lamp operation at Annex building lot 509 and 510

4.3 Energy saving result FY’ 2019


SCADA monitoring lighting by PC Schedule setting of lamp
Qty Lot Shift Time setting Remark
lamp
39 509 Day shift 12:00 – 12:45 Break time
Night shift 00:00 – 00:45 Breaktime
2 shift 90 minutes Life time saving
37 510 Day shift 12:00 – 12:45 Break time
Night shift 00:00 – 00:45 Breaktime
2 shift 90 minutes Life time saving

Conclusion : Reduction electrical consumption of hi bay lamp base on break time night shift, day shift and also
others setting time we got saving as below.

Monthly electrical consumption Electrical and cost saving


10,000 Investment cost and electrical cost = 4,872 SGD
8,000 Time schedule saving = 3 hours/day
8,208 Lifetime lamp saving = 180 minutes
kWh

6,000 7,016
Before = 8,208 kWh /month
4,000 After = 7,016 kWh/month
2,000 Electrical and lifetime saving = 1,192 kWh/month
- Cost saving = 239 SGD/month
Before After CO2 reduction = 0.9 Ton CO2
Payback period 1.6 year
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5 Energy saving activity air con system at COB production

5.1 Improvement : switch off 1 unit air con at COB production FY’ 2019
PERIODE : July 2019
SHIFT :

No Machine Name Model No. Machine No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

1 AIR CONDITIONER RP-20AL4 AIR COOLED M/C no.8 (COB) 1 1 1 1 1 0 0 1 1 1 1 1 0 0 1 1 1 1 1 1 0 1 1 1 1 1 0 0 1 1 1


2 AIR CONDITIONER RP-20AL4 AIR COOLED M/C no.9 (COB) 1 0 0 0 0 0 0 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
3 AIR CONDITIONER RP-20AL4 AIR COOLED M/C no.10(COB) 1 1 1 1 1 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 1 1 1
4 AIR CONDITIONER RP-20AL4 AIR COOLED M/C no.11 (COB) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5 AIR CONDITIONER RP-20AL4 AIR COOLED M/C no.12 (COB) 1 1 1 1 1 1 0 1 1 1 1 1 0 0 1 1 1 1 1 1 0 1 1 1 1 1 1 1 1 1 1
6 AIR CONDITIONER RP-20AL4 AIR COOLED M/C no.13 (COB) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
7 AIR CONDITIONER RP-20AL4 AIR COOLED M/C no.14 (COB) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
TOTAL AIR CONDITIONER 6 5 5 5 5 3 3 6 6 6 6 6 3 3 5 5 5 5 5 5 3 5 5 5 5 5 3 3 5 5 5

Running qty air con COB on daily


7
6
6
5
5

Qty
3

0
Before (June) After (July)

Base on data July 2019 air con trial switch OFF 1 unit then for temperature and humidity still
maintain in specification, it’s mean 1 unit air con can switch OFF
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5 Energy saving activity air con system at COB production

5.2 Electrical consumption effect FY’ 2019


Electrical saving plan :
1. Switch OFF 1 unit air con COF 4. Ton CO2 = 7.7 Ton CO2
2. Before = 6 unit 5. Saving electrical 1 unit = 9,869 kWh/month)
3. After = 5 unit 6. Saving cost per month = 1,983 SGD/month

Overall monthly monitoring stable effect electrical consumption COF air con
80,000 Effective running on 8
67,849 63,741 July 2019
70,000
60,178
kWh

60,000
50,000
40,000
30,000
20,000
10,000
- - - - - - - - - - - - -
May 2019 Jun-19 Jul-19 Aug-19 Sep-19 Oct-19 Nov-19 Dec-19 Jan-20 Feb-20 Mar-20 Apr-20 May-20 Jun-20 Jul-20
(Benchmark)
2019 2020
AC 13,14 (15,16) COF AC 15,16 (13,14) COF AC 17 (4) COF AC 18 (9) COF AC 4 (22) COF Total

Conclusion : base on overall monthly monitoring electrical consumption of COF air con,
electrical consumption has been decrease’ it’s means effect switch OFF 1 unit air con.
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Reduce temperature room 2nd floor molding storage with adjust thermostat air
7 con system
7.1 Background and improvement FY’ 2019

Previously molding storage 2nd floor supplied 2 unit air con 20HP. Base on temperature monitoring the temperature
out specification than temperature requirement. (lower temperature)
The propose is setting thermostat at Molding air con

AC Molding Before (thermostat After (thermostat Electrical saving plan :


storage setting) setting)
1. Thermostat adjustment of Molding AC
AC 57 3 2
2. Electrical saving = ???
AC 61 7 2 3. Ton CO2 = ??
4. Saving cost = ???
Temp 25 – 27 ℃
requirement

Temperature 22 ℃ 25.6 ℃

Judgement NG OK

Conclusion : base on reduce setting thermostat of air con, temperature at molding storage 2nd floor
still stable, it’s mean air reduce on air con

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Thank You

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