SPA SMART PNEUMATIC ADVISOR PT SEJAHTERA BERSAMA BUANA

SPA SMART PNEUMATIC ADVISOR PT. SEJAHTERA BERSAMA BUANA One Stop Solution for Energy Saving and Factory Efficiency

Basic Pneumatic Cost Maintenance Cost Investment Cost 8% Compressed air production 80% 12% 8% 80% Compressed air production is 80% of total cost in pneumatic system. Investment cost is just 12% of total cost. Maintenance cost is just 8% of total value If we want to reduce the total cost we have to highlight on the compressed air production cost. Lack of attention on this section costs unnecessary spending in total production, 90% industry ignore this issue. One Stop Solution for Energy Saving and Factory. COMPUTER Efficiency REPAIR & SUPPORT

Electric Consumption COMPRESSOR DATA Std Price kw π Volt cos Rp/kwh KWh Rp COST 80% LBP WBP Load/unload COST/MONTH TOTAL 80% 110 1. 73 380 0. 8 1, 036 113, 935. 80 91, 148. 64 1, 822, 972. 80 510, 432. 38 2, 333, 405. 18 1, 866, 724. 15 56, 001, 724. 42 90 1. 73 380 0. 8 1, 036 93, 220. 20 74, 576. 16 1, 491, 523. 20 417, 626. 50 1, 909, 149. 70 1, 527, 319. 76 45, 819, 592. 70 75 1. 73 380 0. 8 1, 036 77, 683. 50 62, 146. 80 1, 242, 936. 00 348, 022. 08 1, 590, 958. 08 1, 272, 766. 46 38, 182, 993. 92 45 1. 73 380 0. 8 1, 036 46, 610. 10 37, 288. 08 745, 761. 60 208, 813. 25 954, 574. 85 763, 659. 88 22, 909, 796. 35 One Stop Solution for Energy Saving and Factory. COMPUTER Efficiency REPAIR & SUPPORT

How SPA give quickly add value for my company? What is SPA? One Stop Solution for Energy Saving and Factory. COMPUTER Efficiency REPAIR & SUPPORT

Terminology ENERGY Energy efficiency air compressed. AIR QUALITY Avoidance machine failure and increase service lifetime pneumatic component. AIR CONSUMPTION Know consumption compressed air per machine and leakage. LEAKAGE Location, tagging and documentation. MACHINE EFFICIENCY Strategic design of air compressed system for efficiency. REPORTING Result of measurement , analysis. One Stop Solution for Energy Saving and Factory Efficiency

SPA, What’s to do? 01 SURVEY 02 03 MEASUREMENT DATA 04 05 ANALYSIS SOLUTION 04 REPORTING One Stop Solution for Energy Saving and Factory. COMPUTER Efficiency REPAIR & SUPPORT

One Stop Solution for Energy Saving and Factory Efficiency

MEASUREMENT Measure at downstream and upstream pipe line, acquired data : FLOW PRESSURE SPEED STROKE TIME LEAKAGE One Stop Solution for Energy Saving and Factory Efficiency CYLINDER USAGE

00 00 12. 08. . 1 1. 08 . 1 0. 08 00. 0 0 . 0 9 08 00 00 . 0 8. 08 . 0 7. 08 00 . 0 6. 08 . 0 5. 08 . 0 4. 08 . 0 0. 08 . 0 2. 08 . 0 1. 08 . 0 0. 08 Measurement Flow 6 5 4 3 STATIS IDEAL PROCEES LOSS 2 1 0 One Stop Solution for Energy Saving and Factory Efficiency

Ideal Air Consumption • Why? • Ideal air consumption often become a mystery for most of the people • this subject is very complicated for Utility engineer and production officer • How? • We have tools to determines the ideal requirements of an ideal air consumption for every machine and cylinder One Stop Solution for Energy Saving and Factory. COMPUTER Efficiency REPAIR & SUPPORT

Energy SURVEY MEASUREMENT ANALYSIS REPORT Power Consumption Power Requirement Compressor Air Output Energy Cost Pressure Level Air Demand Flow Consumption Fluctuation Load/Unload Cycles per Hour Pressure & Air Flow Consumption Power Consumption Savings Total Leaks Before Productive Time One Stop Solution for Energy Saving and Factory. COMPUTER Efficiency REPAIR & SUPPORT

SURVEY MEASUREMENT Visual inspection of the air treatment plant Residual Oil Content Compressed Air Quality Air Temperature ANALYSIS REPORT Analysis of the result Recommended to improvement Documentation Improve air quality One Stop Solution for Energy Saving and Factory. COMPUTER Efficiency REPAIR & SUPPORT

Compressed Air Consumption Determination of compressed air loss due to leaks, know the compressed air consumption upstream and downstream. MEASUREMENT § Compressed air consumption per machine at standstill an in operation ANALYSIS § Average air consumption § Average air pressure RECOMMENDATION § Improvement One Stop Solution for Energy Saving and Factory Efficiency

Leakage Detection And Elimination Location, documentation, tagging and remedying leaks. LEAKAGE DETECTION Calculate the difference between Upstream and downstream flow Locate and diagnose early trouble ANALYSIS LEAKAGE ELIMINATION Tagging the troubled parts Locate Required maintenance measures Repair List of required spare part Replace Locate leaks with highsensitivity ultrasonic detector One Stop Solution for Energy Saving and Factory. COMPUTER Efficiency REPAIR & SUPPORT

Machine Analysis For Energy Efficiency Objective : Strategic design of the compressed air system to optimize energy consumption, stabilize processes and reduce costs. MEASUREMENT ANALYSIS Flow Inefficient compressed air uses Pressure Consumption at standstill (leakage quantity) RECOMENDATION Energy saving potential Estimate possible measures : costs, annual savings, anticipated payback period Improvement opportunities Detailed documentation INPUT/CONVERSION By request Intallation and comissioning of the developed solution Consumption during operation (consumption per cycle) Leak detection with ultrasonic sensor (no documentation in the Energy Saving Assesment Portal) One Stop Solution for Energy Saving and Factory. COMPUTER Efficiency REPAIR & SUPPORT

ANALYZING 01 Acquired data analysis 02 Leakage, Air consumption, Pressure Drop, Stroke time 03 Root problem analysis 04 Action recommendation 05 PREVENTIVE Maintenance 06 PREDICTIVE – Reduce the downtime – increase productivity One Stop Solution for Energy Saving and Factory Efficiency

Lifetime Measurement Evaluation of cycle of the cylinder and valve to enable preventive maintenance PN : Cyl 082298409 Loc : Ex 0423 Date : PN : 082888293 Loc : St 0423 Date : PN : 0828763469 Loc : Ct 0423 Date : Cylinder usage 7% - 350 Km of 5000 Km Cylinder usage 67% - 3, 350 Km of 5000 Km Cylinder usage 91% - 4, 550 Km of 5000 Km Operating hours left 32, 140 Operating days left 1, 339 Operating hours left 17, 607 Operating days left 733 Operating hours left 3, 110 Operating days left 129 Stroke time : 95 ms ADV : 50 ms RET : 45 ms Stroke time : 43 ms ADV : 20 ms RET : 23 ms Stroke time : 135 ms ADV : 40 ms RET : 95 ms One Stop Solution for Energy Saving and Factory Efficiency

Corrective Maintenance • Reactional response • Unplanned action • Emergency shutdown - Downtime • Spoiled - More unnecessary leakage • Parts inventory efficiency • Unwanted purchase One Stop Solution for Energy Saving and Factory Efficiency

Preventive / Predictive Maintenance • Predictive maintenance is another level of maintenance method • Time effective problem solving • World Class Maintenance Justification • if we able to predict the lifetime of the parts, we can prepare the anticipation of the failure • Imagine if you able to predict of human life One Stop Solution for Energy Saving and Factory Efficiency

SOLUTION & EXECUTION 01 Tagging 02 Replacement parts supply 03 Correction / repair 04 Contract Maintenance 05 COST REDUCTION - MINIMAL One Stop Solution for Energy Saving and Factory Efficiency

REPORTING 1. DATA RECORD 24/7 2. WIRELESS MODULE FOR REMOTE AREA 3. TCP/IP REALTIME MONITORING 4. MEANINGFUL DATA ACQUISITION 5. SCADA READY SOFTWARE 6. PERSONALIZED DASHBOARD One Stop Solution for Energy Saving and Factory Efficiency

COST SOLUTION BASIC PRODUCTION COST ELECTRIC / FUEL CONSUMPTION LEAKAGE VS DOWNTIME MAINTENANCE OR REPLACEMENT VALVE, CYLINDER, FITTING, TUBE, PIPE, ETC. ENERGY SAVING LESS LEAKAGE REDUCE PRODUCTION COST LESS DOWNTIME, INCREASE PRODUCTIVITY REAL COUNT One Stop Solution for Energy Saving and Factory Efficiency