UTILITY BUSINESS CONTINUITY FOR

SUPPORT PRODUCTION PLANNING 2024

~ X0 – X2 ~
NAT 42 IFR
2020/02/04
D2

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CONTENT

1. ORIGIN OF THE REQUEST

2. PROJECT ORGANIZATION
3. STAKES & OBJECTIVES
4. CURRENT CONDITION & COST PROPOSAL
5. PROJECT PLANS
6. RISK ANALYSIS

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1. Origin of The Request
MSA declared about production planning ramp up until 2024.
For that case, we need to do analysis about supporting element in order to achieve the target
year by year.
Utility Department is one of the many important element that realize the plan because it
provides the energy source for overall production activity (Electricity, Steam, Compressed air,
Water & Cooling Water, Nitrogen).

To Ensure the production continuity we need to calculate the utility capacity related to the
production planning 2024.
So, the results are as follows :

a. There are deficiencies in the compressed air supply energy if the production capacity is
increased.
The Purchase of 2 units of Air Compressor (1 unit at 2019 & 1 unit at 2021) with Capacity 22 m3/min
is needed.
b. There should be a back up System and modification in the Chilled Water System for Stability
& quality supply.
c. Power Factor Value Improvement for Optimizing Electrical Usage
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A. AIR COMPRESSOR UNIT FOR SUPPORT PRODUCTION PLANNING
Subject Unit 2019 2020 2021 2022 2023 2024 Maximum
Ramp Up
Production Plan (MAX) Production
PCR PCS/DAY 28.106 30.862 33.066 33.727 33.948 33.948 2019 ~ 2024

MC PCS/DAY 22.965 25.469 27.561 28.112 28.296 28.296

TBR PCS/DAY 324 540 635 713 783 783

Total Production kg /Jam 17.190 19.356 20.913 21.495 21.799 21.799

Compressed Air Capacity needed (a) 80% Utilization

m3/min 351,58 391,16 422,63 434,37 440,52 440,52
(80% Utilization)

Compressed Air Capacity Actual (b) m3/min 373,82 373,82 373,82 373,82 373,82 373,82

m3/min 22 -17 -49 -61 -67 -67

Δ (Shortage Capacity) (a-b)
Unit 0,5 -0,4 -1,1 -1,3 -1,5 -1,5

Starting from 2020 the Factory will be lack of Compressed Air Supply if the
production planning is increased

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B. CHILLED WATER BACK UP SYSTEM & MODIFICATION
At Sept. 2019 ===> Bulging at Chilled Water Storage Tank System
The Chilled Water Storage System Supply all cooling system for TCU & Production Machine

IMPACT ====> If Anything Happen to Chiller System will Interupt the Production Process
for that case we need 7 days to repairment the chiller system.
Production Lost Cost = USD 1.930.000

ACTION PLAN :
1. Additional More Steel Support to decrease the deflection ( Sept ~ Nop 2019)  DONE
2. Install Stiffener to stop the deflection (Dec 2019 ~ Jan 2020)  DONE (RESULT : OK)
3. Need some modification at the Chilled Water Storage Tank (2020)
4. Define & Execute the contigency plan to avoid the similar problem

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 C. POWER FACTOR VALUE IMPROVEMENT
SUBSTATION PARAMETER PERFORMANCE Standard Judgement
Capacitor Load 65% 65% Max. 80%
Cabin 1.1
Trafo 1
Power Factor KVAR Energy Need to0,95
be Compensated
0,95 0,95
OK
Capacitor Load 50% 50% Max. 80%
Trafo 2
Power Factor by using Capacitor
0,95 0,95 0,95
OK

Trafo 1
Capacitor Load
Power Factor
40% So it can be transformed into
0,95
Active
40% Power
0,95
Max. 80%
0,95
OK
Cabin 2.1
Capacitor Load 40% 40% Max. 80%
Trafo 2 OK
Power Factor 0,95 0,95 0,95
Capacitor Load 60% 60% Max. 80%
Trafo 1 OK
Power Factor 0,95 0,95 0,95
Cabin 3.1
Capacitor Load 50% 50% Max. 80%
Trafo 2 OK
Power Factor 0,95 0,95 0,95
Capacitor Load 45% 45% Max. 80%
Cabin 5.1 Trafo 1 OK
Power Factor 0,95 0,95 0,95
Capacitor Load 50% 50% Max. 80%
Cabin 6.1 Trafo 1 OK
Power Factor 0,95 0,95 0,95
Capacitor Load 30% 30% Max. 80%
Trafo 1 OK
Power Factor 0,95 0,95 0,95
Cabin 7.1
Capacitor Load 40% 40% Max. 80%
Trafo 2 OK
Power Factor 0,95 0,9 0,95
Capacitor Load 100% 100% Max. 80%
Cabin 8.1 Trafo 1 Δ
Power Factor 0,95 0,95 0,95
Capacitor Load 20% 20% Max. 80%
Cabin 1.2 Trafo 1 OK
Power Factor 0,95 0,95 0,95
Capacitor Load 100% 100% Max. 80%
Cabin 2.2 Trafo 1 X
Power Factor 0,90 0,90 0,95
Capacitor Load 25% 25% Max. 80%
Trafo 1 OK
Power Factor 0,95 0,95 0,95
Capacitor Load 30% 30% Max. 80%
Cabin 3.2 Trafo 2 OK
Power Electricity Can’t Absrob Optimally due to the low value of Power
Power Factor 0,95 0,95 0,95
Capacitor Load 70% 70% Max. 80%
Trafo 2 OK
Factor (PF)
Power Factor 0,95 0,95 0,95
Power Substation
StandardCabin
of 2.2 & 8.1Factor
Power show the poor performance of power factor
is 0,95
It means The Electricity doesn’t absorb optimaly due to the lack of Capacitor Capacity 6
2. PROJECT ORGANIZATION
• Project Sponsor : Kuntarso
• Steering Committee
– Kevin Grant
– Michail Sutiono
– Kuntarso
– Hery Arsandy
– Donald McLanders
• Project Leader
– Witarman / Ribut
• Team Member
– Joko Utomo (Utility Maintenance)
– Eman Jaya (Utility Project)
– Winarto (Utility Operation)
– Rosdiana Fajar (Project Administrator)

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3. STAKE & OBJECTIVE
To ensure the business continuity by calculate the utility capacity & review the utility
system related to the production planning 2024 :
a. Purchase 2 units of Air Compressor (1 unit at 2019 & 1 unit at 2021).
with Capacity 22 m3/min.
b. Chilled Water Storage Tank Modification & Contigency Plan for Stability Supply of Cooling
System
c. Extend Capacitor unit at Power Substation Cabin 2.2

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4. CURRENT CONDITION & COST PROPOSAL NATURE : 42 IFR
a). Purchase 1 unit of New Air Compressor 2019 ~ 2021
Subject Unit 2019 2020 2021 2022 2023 2024 Maximum
Ramp Up
Production Plan (MAX)
Production
PCR PCS/DAY 28.106 30.862 33.066 33.727 33.948 33.948 2019 ~ 2024
MC PCS/DAY 22.965 25.469 27.561 28.112 28.296 28.296

TBR PCS/DAY 324 540 635 713 783 783

Total Production kg /Jam 17.190 19.356 20.913 21.495 21.799 21.799

Compressed Air Capacity needed (a) 80% Utilization

m3/min 351,58 391,16 422,63 434,37 440,52 440,52
(80% Utilization)

Compressed Air Capacity Actual (b) m3/min 373,82 373,82 373,82 373,82 373,82 373,82

m3/min 22 28
-17 40
-49 28
-61 22
-67 22
-67
Δ (Shortage Capacity) (a-b)
Unit 0,5 0,6
-0,4 0,9
-1,1 0,6
-1,3 0,5
-1,5 0,5
-1,5

ADDITIONAL AIR COMPRESSOR Unit 0,0

1,0 1,0
0,0 1,0
0,0 0,0 0,0 0,0

Balance Capacity Compressor Unit 1,5

0,5 -0,4
1,6 -1,1
1,9 -1,3
0,6 -1,5
0,5 -1,5
0,5

Additional 1 unit Additional 1 unit

Air Compressor at 2019 Before 2020 Ram up Air Compressor at 2021 before 2022 Ramp up

By Adding 2 units of Air Compressor (1 unit at 2019 & 1 unit at 2021),

Compressed Air Supply can be able to Support Ramp Up Production until 2024 (21,79 Ton Tyre / Hour) 9
 4. CURRENT CONDITION & COST PROPOSAL NATURE : 42 IFR
a). Purchase New Air Compressor 2019 ~ 2020
TRANSFORMATOR 2000 kVA PANEL LOW VOLTAGE 400 V
PANEL SWITCHGEAR 20 kV
20 kV to 400 V + CAPACITOR BANK No DESCRIPTION STATUS

1 TRANSFORMATOR Existing
NEED TO
2 2 1 3 2 NORMALIZATION
2 MV PANEL NEW (Buy)
LV PANEL
3 CABLE NEW (Buy)
NEW AIR COMPRESSOR 300 kW
4 AIR COMPRESSOR NEW (Buy)
3 UNIT

TO PLANT
4
PRODUCTION Air Compressor Unit Already
Purchased at 2019
ETA : Mid Februari 2020

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 4. CURRENT CONDITION & COST PROPOSAL NATURE : 42 IFR
a). Purchase New Air Compressor 2019 ~ 2020 (Budget & Realization Detail)
No Item Spec Qty PR NUMBER Budget Realization
Transformator (Service) 2000 Kva (Normalisation Unit) 1 unit 0001/PR/01/20/A3043 USD 3.820 -
SUPPORT INSTALLATION TRAFO

Civil Building for New TRAFO Civil Building +Ventilating System 1 Lot 0009/PR/08/19/A3043 USD 9.710 -

Panel switchgear 20 kV SM6 DM1A Schneider 1 unit

Busduct 400 V sekunder trafo BUS Duct 4000 A 1 Lot 0002/PR/01/20/A3043 USD 185.000 -

0003/PR/01/20/A3043 USD 10.200

Panel Switchboard LV 400 V + Capacitor 4000 A 1 set
Bank

Kabel to Panel Air Compressor 1 x 185 mm Cu (8x Pulling Cable) 800 meter 0025/PR/09/19/A3043 USD 14.474 USD 14.474

Kabel 24 kV Primer Trafo Single core N2SXY 95 mm Cu 70 meter NONE - -

AIR COMPRESSOR NEW 300KW Flowrate : 2.860 m3/h (8 barg) 1 UNIT 0004/PR/08/19/A3043 USD 241.279 USD 48.276
AIR COMPRSSOR

DISMANTLING COMPRESSOR ATLAS COPCO Dismantling Unit existing (Scrap) 1 Lot 0015/PR/01/20/A3043 USD 38.50 -

Air Compressor & Pipeline installation Mech & Elect Installation 1 Lot 0014/PR/01/20/A3043 USD 13.000 -

TOTAL USD 481.434 USD 62.750

Need to prepare : USD 418.684

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 4. CURRENT CONDITION & COST PROPOSAL
b). BACK GROUND - CHILLED WATER ISSUE/PROBLEM
Issue : Impact :
Temperature Chilled water leaving from Chiller between 27 to 30⁰ C, 1. May caused breakdown on the production equipment
while requirement is 18 ⁰C for extruder and 23 ⁰C for other 2. Giving impact to the product quality of Extruding System
equipment  NEED TO RE~DESIGN THE INSTALLATION OF COOLING
SYSTEM
 MODIFIED WATER STORAGE TANK
ANALYSIS  MODIFIED PIPING INSTALLATION
 AIR COOLED CHILLER system capacity not enough (CHILLER RUNNING  ADDIITONAL COOLING TOWER FOR CONDENSOR
ONLY 34% FROM FULL CAPACITY) NEW CHILLER
 CAUSE : LOW PERFORMANCE /EFFICIENCY & HIGH BREAKDOWN COST
NEW CHILLER
 SPECIFICATION OF AIR COOLED CHILLER ACCEPT Temperature NEW CHILLER
Water
(Entering / Leaving : 12º / 7º C)
 OPERATIONAL TEMPERATURE FOR CHILLED WATER SYSTEM IS
NOT MATCH WITH SPECIFICATION OF AIR COOLED CHILLER
(Entering / Leaving : 28º / 23º C)

Cooling Line Extruder

TCU All Machine

(Mixing, Calender, Extruder, Cushion etc.)
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b.1) Chilled Water System Milestone
Bulging at the North &
Start Install No Complete due Completed Piping & South Side of Storage Tank
Chilled Water Install Stiffener at Storage
to Cash Flow to Chiller Installation Tank Repair At
Storage Tank Cover Piping Maintenance Day Dec 2019
Installation

On Progress
Install New
Reinforcement
Januari 2019 Additional Support Stiffener Failed
Start Piping & to Stop the Bulging
Chiller Installation / Deformation

SOUTH NORTH The Tank shell on south and north side was
bulging Due to the lack of Vertical external
support UNP 150x75.

This Support is the main frame to

strengthen the shell from hydrostatic and
dynamic pressure from inlet/outlet nozzle

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b.2) Modification & Repairment Process
1st Step Repairment Process for Storage Tank
SOUTH NORTH SOUTH NORTH

BEFORE AFTER
September 2019 : December 2019 At Maintenance Day :
Bulging at the north & south side of Storage Tank Install Stiffener Structure to Stop the deformation
RESULT ===> FAILED (STILL BULGING / DEFORMED)
DUE TO POOR OF WELDING SPOTS

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b.2) Modification & Repairment Process
2nd Step Repairment Process for Storage Tank
SOUTH NORTH SOUTH NORTH
H-Beam
200x200

WF
150x75

Beam Reinforcement
at south & north side
BEFORE AFTER

Install Stiffener Structure to Stop the deformation Replacement of Stiffener Structure using Beam
RESULT ===> FAILED (STILL BULGING / DEFORMED) Reinforcement at South & North Side
RESULT = GOOD
For Step 2 Need Additional
CAPEX Budget : USD 102.000
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b.2) Modification & Repairment Process
3rd Step Repairment Process for Storage Tank

SOUTH NORTH SOUTH NORTH

H-Beam
200x200

WF
150x75

Beam Reinforcement
at south & north side Beam Reinforcement
BEFORE AFTER at East & West side

Install Beam Reinforcement at East & West Side to Avoid another bulging / deflection

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b.2) Modification & Repairment Process
4th Step Repairment Process for Storage Tank
SOUTH NORTH

Budget For Step 2 = USD 102.000

Step 3 = USD 25.000
Step 4 = USD 35.000
TOTAL = USD 162.000 17
b.3) Contigency Plan NEW CHILLER

NEW CHILLER

NEW PIPING
INSTALATION

Cooling Line Extruder

TCU All Machine

(Mixing, Calender, Extruder,
Cushion etc.) NEW PIPING &
PUMP INSTALATION
NEW PIPING & PUMP
INSTALATION

ESTIMATE BUDGET
===> USD 47.000
1. Install New Pump for Circulating Chiller
2. The maximum Chilled Water temperature
that can be produced is 26ºC
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4. CURRENT CONDITION & COST PROPOSAL NATURE : 42 IFR
C). CAPACITIVE LOAD REVIEW to IMPROVE POWER FACTOR AT POWER SUBSTATION 2.2
Cabin 2.2 Trafo 1 At the Maximum Load
Kapasitas Trafo 3208 A (Trafo Capacity = 3.208 A)
Load Trafo 2900 A ===> 1.900 kW
Cos phi Actual 0,9
By Using Multiplier Factor (0,69)
PF = 0,95 Running Step Capacitor 12 to reach power factor until 0,95
PF = 0,68 (AFTER) Total Step Capacitor 12
(Before) Exisiting Capacitor Unit that Capacitive Load that need to
already Install = 1.200 kVar Compensated :
= (1.900 kW x 0,75)/0,8
Lack of Capacitor Capacity = 1.781 kVar
= 1.781 – 1.200 kVar
Estimate Budget
= 581 kVar
= USD 70.000

Cabin 2.2 Trafo 1

Kapasitas Trafo 3208 A
Load Trafo 2746 A
The Exisiting Current Cos phi Actual 0,95
Load Will improve after
we Extend The Running Step Capacitor 15
Capacitor Bank
Total Step Capacitor 18
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 4. COST PROPOSAL SUMMARY
Budget Budget
NATURE PRIORITY DESCRIPTION GOAL REMARKS
Approved Needed

To Fullfill Compressed Air Demand to support

production planning until 2021
1 AIR COMPRESSOR INSTALLATION 450.000 481.434
The Air Compressor already purchased on 2019 Minus Budget will
PROPOSED to reclass
42 IFR
SUSTAINABILITY
1 2 CHILLER TANK MODIFICATION To Avoid Long Breakdown - 162.000 from CAPEX
UPGRADE MIXER #1
Baseline : Stop 7 days
(USD 200.000)
3 CONTIGENCY PLAN CHILLER (Lost Cost = USD 1.930.000) - 47.000

Power Electricity can absorb optimaly by Extend

4 CAPACITOR UNIT CABIN 2.2 60.000 60.000
the Capacitor unit
TOTAL 510.000 750.434

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 5. PROJECT PLANS

Budget PROJECT PLAN & BUDGET NEEDED

No. Action UoM
(USD) Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Plan X0 X0 X1 X2
1 AIR COMPRESSOR INSTALLATION 481.434
USD 48.143 288.860 144.430

Plan X0 X1 X2
2 CHILLER TANK MODIFICATION 162.000
USD 102.000 6.000 54.000

CONTIGENCY PLAN CHILLER Plan X0 X1 X2

3 47.000
SYSTEM USD 9.400 32.900 4.700

Plan X0 X0 X1 X2
4 CAPACITOR UNIT CABIN 2.2 60.000
USD 6.000 48.000 6.000

Total Budget 750.434 USD - 150.143 310.260 - 86.900 149.130 48.000 6.000 - - - -

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 6. RISK ANALYSIS
CAPEX Potential risk
Can’t Support Production
Planning until 2021
Inventory of Spare parts will
AIR COMPRESSOR PROJECT increase
There will be any addiitonal
annual operational and
maintenance costs
Cause
Lack of Compressed Air Capacity to fullfill Lost the opportunity to achieve the
the demand
Air Compressor that have been
purchased are not used (Pending for
Installation)
Air Compressor that have been installed
need to maintain at good condition
Effect Proposed Action(s)
Reduce production planning in accordance to
production planning the Compressed Air Supply Capability
Increased Maintenance Cost for Air
Compressor Inventory
Air compressor unit must be properly stored
and covered in the box
Increased Operational & Maintenance
Costs for Air Compressor Operation

1. Chilled Water Tank Modification

Interrupt the production
process
CHILLER SYSTEM
MODIFICATION
Interrupt the maintenance
activity at Chiller System
Can’t Support Production
CAPACITIVE LOAD REVIEW Planning until 2021
to IMPROVE POWER FACTOR
AT SUBSTATION 2.2
Room temperature at
Substation 2.2 will increase
Production Stop due to repairment
Chilled Water Storage Tank Leakage 2. Make the contigency plan just in case if the
process that needs 2 weeks minimum
same problem is occur.
Need to Dismantling the unused Chiller
Chiller Maintenance Area become limited Unsafe Condition for optimum
Equipment around Main Chiller System
due to Reinforcement Construction Maintenance Activity
OPEX 2020 : USD 29.656
Power Electricity for substation 2.2 can't
Reduce production planning in accordance to
support when the production planning at Lost the opportunity to achieve the
the Power Electricity Supply Capability at
maximum load (Especially for Extruding & production planning
Substation 2.2
Cutting)
Capacitor Installation will generate more Overheat at others Electrical When Install the Capacitor unit must be add
heat Equipment at Substation 2.2 exhaust fan or Air Conditioning unit

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THANK YOU

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