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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
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)
DATE SCALE
PEB-FFD-MC-1112/R1
Confidential
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)
AC 6
AC 1 AC 2 AC 3
F/A AC 4 AC 5 EOL &
FOL Prod
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.
AC 20HP 3 2 1
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
1 unit VC OFF
Propose 500 ( 15 KW)
combine pipe
HV Becker 1500 1 1 1 0
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
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
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.
Confidential PT. EPSON BATAM
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
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
0 - 17,722.93 100%
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.
Confidential PT. EPSON BATAM
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
kWh
12,000
9,000
6,000
3,000
-
PUMP PUMP PUMP PUMP Before After
11KW 11KW 11KW 11KW kWh/month
Background : Previously control hi bay lamp manual operation and no operation control
ON and OFF, so the lighting always ON condition every day.
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.
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
Confidential PT. EPSON BATAM
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 :
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
Confidential PT. EPSON BATAM
5 Energy saving activity air con system at COB production
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.
Confidential PT. EPSON BATAM
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
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