Improvement :

Auto-Cleaning Condenser Chiller

[ESCO Activity FY20]

(Approval PAS)
Preparation
PR Implementation
(TDEM Discussion & Vendor Selection Genba Approval
Process & Evaluation
Commitment)
PRESENTATION CONTENT:
1. Background

2. ENERGY Reduction Activity FY20

3. ESCO Approval FY20

[TDEM-TMMIN Commitment]

4. Detail List Activity ESCO FY20

5. Flow Process Chiller System

6. Proposed : Auto Cleaning Condensor Chiller

7. Information Genba Eco-Brush [Menara Astra]

 I. BACKGROUND
A. TMMIN Milestone of CO2 Emission & Water Reduction
Steady improve daily activities & adoption of the latest
innovative low CO2 & water reduction technologies
CO2 AWARD & RECOGNITION

 AWARENESS Purchased :
100%

Face to Face
Continuos Communication
Improvement Education Green Award by Env. Award by
ASEAN Best Energy
Award in Laos 2015 KRW Regent 2016 Ministry of Env.
Participating COP 23
2016 Bonn – Germany, Nov’17
Karakuri
System
Automation


Water Spray
3 Wet CO2 Target
ENERGY Painting Rain Water
Process Recycle
EFFICIENCY Facility
Economizer &
Membrane Bio Achievement
Inverter
Reactor (MBR) FY15-current :
approx. 11%
Substitute
to Natural RO
Gas

 ENERGY
CONSERVATION Auto-pump
Purchased : 5%
Adjustment

Solar PV

Co-Generation Eco-Brush
2017 2020 2025 2050
 9 July 2020
TDEM TMMIN
B. Reduction Scenario EVP Director
7th Toyota Environmental Action Plan (CY2020 ～ 25)
TMMIN
KRW1&2 CO2 reduction scenario Mr. Surapong T. Mr. Nandi J
3．Target setting
1．Asia CO2 Emission 2． CO2 Emission （kton/year） CO2 factor: 0.7392 CO2 -ton /MWh (Indonesia)
*Target setting method: CO2 KPI Reduce from FY13 base
Nenkei
（kton） CO2 Emission （kton/year） 2013 2019
80 ‘20 ‘21 ‘22 ‘23 ‘24 ‘25
TMV（2%） BAU Countermeasures result Prospect
TAP（3%） TKAP（1%）
TMP（3%） Production Plan / Resut (k unit) 165 191 89 213 246 <- <- <-
IMC（4%）
ASSB（4%） TMT 60 PE
(A) BAU (k Ton) 58.4 48,6 25,3 58,6 67,2 <- <- <-
（28%） Technology
58.4 kton
KZ
（11%） 582 kton Annual (k Ton) - - 2,93 4,52 5,57 4,33 3,48 2,22
Counter
30 Scenario(Target) Daily
FY 2018 -measures
TKM 44,15 kton : Kaizen (B) Accumulated (k Ton) - - 2,93 7,45 13,02 17,35 20,83 23,05
（13%） 25,3 kton
STM  24％ (2013 base) Renewable
Scenario (k Ton) (A)-(B) - - 22,37 51,15 54,18 49,85 46,37 44,15
（15%） Energy (RE)
TMMIN
（18%） 2001 2013 2020 50年
Target Renewable energy ratio - - - 4% 8% 12% - -
2025
（Base year)
Energy actual / target (GJ/unit) 2.72 3.59 3.52 3.45 3.38 3.31 3.23 3.16
4．CO2 reduction items & schedule
(2018 – 2019) (2019 – 2020) (2020 – 2021) (2021 – 2022) (2022 – 2023) (2023 – 2024) (2024 – 2025) Total (‘20 - ‘25)
Target setting Activity Activity Activity Activity Activity Activity Activity
Invest.
Guideline CO2
(Mil
ROI
CO2 Invest. ROI CO2 Invest. ROI CO2 Invest. ROI CO2 Invest. ROI CO2 Invest. ROI CO2 Invest. ROI CO2 Invest. ROI (kton) (Year)
USD)
(kton) (Mil USD) (Year) (kton) (Mil USD) (Year) (kton) (Mil USD) (Year) (kton) (Mil USD) (Year) (kton) (Mil USD) (Year) (kton) (Mil USD) (Year) (kton) (Mil USD) (Year)

Super high trasfer efficiency Recycle ASH exterior robot Recycle ASH exterior robot
Complete Co-generator Booth control range expansion Dry Booth #1 Water borne 3wet
air-less paint & Dry booth zone #2 & VOC control oven zone #1
PE Tech.

paint/casting
low CO2 technology
17 5,72 5,7 - - - 3,51 3,3 1,57 2,58 3,62 4,55 1,34 1,75 3,75 0,49 2,70 2,60 1,43 12,1 8,12 9,35 23,47 3,58
installation by 2030

Paint shop 3 year plan

Daily Kaizen

2% / year
Energy Saving 2.73 0,18 1.35 1.68 0,19 0.6 1,01 1,88 1,50 0,79 - - 0,79 - - 0,79 - - 0,79 - - 6,90 2,06 1,64

On-site Solar Installation w/ On-site Solar Installation On-site Solar Installation <-
Self- investment : 0,22 MW 2,2 MW 2,2 MW 2,2 MW
Complete to install
RE

- - - - - - - - -
Solar on site by 2025
0,20 0,14 12 2,2 2,06 12 2,2 2,06 12 2,2 2.06 12 6,80 6,32 12

Total 18,68 5,91 6,1 2,93 0,32 1,12 4,52 5,18 1,50 5,57 5,68 6,11 4,33 3,81 7.88 3,48 4,76 7,3 2,22 12,1 8,12 23,05 31,85 5,74
C. Energy Consumption AP
TMMIN Position

MWh/Unit Energy Gentan-I FY19/20

1.6

1.4 1.34
1.22
1.2 1.15

1
0.79
0.8 0.73
0.67
0.6 0.5 0.53 0.53
0.42 0.42 0.43
0.4 0.36

0.2

0
KZ-KN
TMT-S

TMMIN-K1

TMV

TMMIN-K2

TKM-1

ASSB-BR

ASSB-SA

TKM-2
KZ-CL

TMT-G1

TMT-G2
TMT-BP

• TMMIN KRW-1 at Position No.2 & KRW-2 at Position No.4 at AP Electric Gentani FY19/20
• Need more effort to reduce energy to beat TMT-S

Refer.TDEM Data (April 2020)

2. ENERGY REDUCTION ACTIVITY FY20
Medoari Cost Energy Reduction [Activity Progress Plant #1 & Plant #2]
Plant #1
Bio/Year

0.07 Medonasi 3% Plant #2

0.32 • Energy loss

0.4 • Yokoten Essence 0.02 Medonasi 2%

Medoari 2.3
• Best model yokoten Bio (97%) 0.16 • Energy loss
0.50
42% (TDEM) BMC
2.37 0.86 0.10 • Yokoten Essence
Medoari
50% 0.15 • Best model yokoten
0.65 • ESCO 0.84 Bio
0.204 • ESCO (TDEM) BMC (98%)

0.35 • Shop M/C Efficiency up 0.23 • Shop M/C Efficiency up

Company Initial Company Initial
Target Target

• Strategy
1. Eliminate Energy Loss (Muda Energy)
2. ESCO Daily Kaizen - Improve Equipment Rank (A-B-C) Activity (Efficiency Up)
3. Renewable Energy [Solar Panel, Microhidro , etc]
4. Benchmark [Yokoten Activity]
- TDEM Best model BMC & yokoten essence for ABC & start-stop M/C
3. CO2 Reduction Target & Achievement (TMMIN-TDEM Commitment)

• Auto Cleaning Condensor Chiller (P#1)

FY19:
• Target : 1,420 Ton CO2
• Achievement : 1,680 Ton CO2

• Auto Cleaning Condensor Chiller (P#2)

FY20: 1,051 Ton CO2

 4. Detail List ESCO Activity FY20
TDEM Plan Actual data ROI 2021

Paint Reduction Budget Reduction Budget Plan Act

NO. Process Kaizen Detail PIC Complete
SxS
▲CO2 ▲Cost ▲Cost ▲CO2 ▲Cost ▲Cost
(US$) (IDR) (US$) (IDR) Year Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
（ton） (US$) (IDR) （ton） (US$) (IDR)
P/O
Optimize Condensor Approch by Complete
1
Chiller
Factory
• Auto Cleaning
Automatic Cleaning Condensor 236 26,353 Condensor Chiller : 3-unit
372,729,798 32,110 454,162,235 0 0 1.2 Bayu H.P Nov/19 Proposal, Specification
Construction

(Chiller P#1) - No.1 /Quatation/Approval

P#1 : 2-Unit
Optimize Condensor Approch by P/O
Construction Complete
Chiller
2 Automatic Cleaning Condensor 256 28,886 408,569,202 41,040 580,467,708 0 0 1.4 Ivan K Nov/19
(Chiller P#2) - No.1 P#2 : 1-Unit
Factory Proposal, Specification
/Quatation/ Approval
P/O Complete
Chiller Reduce Flowrate CDP ChillerP#1 Nov/ Proposal, Specification Construction
3 46 5,888 83,283,948 6,000 84,863,700 0 0 1.0 Nov/19
Factory No.4 Gunawan /Quatation / Approvall

P/O Complete
LED Lighting Replacement at Assy Proposal, Specification Construction
4 Assy Shop 113 14,453 204,417,339 28,966 409,686,828 0 0 2.0 Haris Z Nov/19
Shop (175 Unit) /Quatation / Approvall

P/O
Complete
Reduce Flowrate Pompa Degrease Bayu H.P Proposal, Specification Construction
5 ED Frame 19 2,398 33,916,591 2,000 28,287,900 0 0 0.8 Nov/19
(P20) 11 KW Yudha /Quatation / Approvall

P/O Complete
Reduce Flowrate Pompa Phospate Bayu H.P Proposal, Specification Construction
6 ED Frame 26 3,270 46,249,897 3,000 42,431,850 0 0 0.9 Nov/19
(P20) 15 KW Yudha /Quatation / Approvall

P/O Complete
Bayu H.P Proposal, Specification Construction
7 ED Frame Reduce Flowrate Pompa UF1 7.5 KW 13 1,635 23,124,949 2,000 28,287,900 0 0 1.2 Nov/19
Yudha /Quatation / Approvall

P/O Complete
Bayu H.P Proposal, Specification Construction
8 ED Frame Reduce Flowrate Pompa UF2 7.5 KW 13 1,635 23,124,949 2,000 28,287,900 0 0 1.2 Nov/19
Yudha /Quatation / Approvall

P/O Complete
Reduce Flowrate Pompa DI Spray Bayu H.P Proposal, Specification Construction
9 ED Frame 6 799 11,305,530 2,000 28,287,900 0 0 2.5 Nov/19
7.5 KW Yudha /Quatation / Approvall

P/O Complete
Reduce Flowrate Pompa ED No.2 15 Bayu H.P Proposal, Specification Construction
10 ED Frame 26 3,270 46,249,897 3,000 42,431,850 0 0 0.9 Aug/19
KW Yudha /Quatation / Approvall

P/O Complete
Reduce Flowrate Pompa ED No.5 15 Bayu H.P Proposal, Specification Construction
11 ED Frame 26 3,270 46,249,897 3,000 42,431,850 0 0 0.9 Sept/19
KW Yudha /Quatation / Approvall
P/O Complete
Optimize Condensor Approch by Construction
Chiller
12 Automatic Cleaning Condensor 159 20,328 287,511,661 26,244 371,190,288 0 0 1.3 Bayu H.P Feb/20 Proposal, Specification
Factory
(Chiller P#1) - No.2 /Quatation/ Approval
P/O
Toso Booth Booth Temperature Range Agung W Proposal, Specification Construction
Complete
13 100 12,754 180,390,482 10,000 141,439,500 0 0 0.8 Sept/19
P#1 Expansion (Daihatsu) Bayu HP /Quatation / Approvall

CO2 : ↙ 1,051 Ton R.O.I : 1,25 Year

CR : IDR 1,767,124,140

Invest : IDR 2,282,257,408

5.1 Flow Process Chiller System

COOLING TOWER

PUMP

Condensor

TOSO

CHILLER

STORAGE TANK
CAP : 3400 M3

PUMP
5.2 Chiller Cleaning System (Current Condition)
Losses
Item System Period Activity Cleaning Remark
Estimation

Condensor Manual 1X/3- • Man Hour Cost (4X/Y)

Cleaning Cleaning Month - 3 MP x 4x/Y x 8 Hour x 141,781
(Heavy = IDR 13,610,976
Handling- If 1X/Month Cleaning (to level
Safety up EFF) :
Issue) = IDR 13,610,976 x 3
= IDR 40,832,928

Temperature Max 3.5°C Average Temperature - Chiller P#1

Condensor 2.0-3.4°C Condensor (2-Unit) :
Approach Approach IDR 434 Mio / Y
- Chiller P#2
Chiller Menara
(1-Unit) :
Asta 0.4°C IDR 277 Mio/Y

• Heat Transfer Index (Condensor Approach)

3.5°C

2.8

2.0
(After 1-Month 1-Month 3-Month
Cleaning)
Manual Cleaning Tube Condensor Chiller Time
6. Proposed : Auto Cleaning Condensor Chiller System
A. Principles of Operation
• The automatic valve reverses the water flow in the H/E every few hours for 30 sec.
• Nylon brushes (housed in baskets connected to the tube ends) are then propelled
through the pipes, cleaning any scaling or fouling
• After the reversion the brushes position
in their baskets, no pressure loss

• Comparing EQOBRUSH with Ball Based systems [TMT]

(ECO-BRUSH)
• Higher investment, Lower Maintenance
• All pipes get brushed on each cycle  all
pipes remain clean
• Invest + Maint 5Y = IDR 336 Mio (500TR)
Ball Systems
• Lower Investment, High Maintenance
• Strainer to catch balls needs
replacement, balls get lost and need
replacement
• Invest + Main 5 Y = IDR 332 Mio (470TR)

Condensor Tube Brush Cleaning Condensor Tube Ball Cleaning

B.1. Benefit: Energy saving
Fouling Factor Table. Fouling Scale thickness in Power increase
Factor (FF) mm required

0.000 0.000 0.00%

0.0001 0.03 1.10%
0.0005 0.15 5.50%
0.0010 0.30 11.0%
0.0020 0.61 22.0%
0.0030 0.91 33.0%
0.0040 1.22 44.0%

The Graph illustrates potential savings

USD 49,000 800 TR

USD 41,000 700 TR
USD 28,000
B.1.2 TMMIN CHILLER ENERGY CONSUMPTION FY19 Data
Chiller Energy Consumption P#1
450,000 418,255 421,211
397,699 399,403 391,132
400,000 379,046 368,819
338,981 350,702 348,851 337,960
350,000 2-SHIFT
300,000
241,022
250,000
Energy Consumption : 4,393,000 KWH/Year
200,000
(IDR 5,930,658,000)  2-Shift Operation
150,000
Potential Energy Saving: 652,372,380 (11%)  2-Unit
100,000
If 1X/Month Cleaning : 2/3 (652,372,380)
50,000
: IDR 434,914,920/Year
-
A-19 M-19 J-19 J-19 A-19 S-19 O-19 N-19 D-19 J-20 F-20 M-20

Chiller Energy Consumption P#2

600,000

509,690
500,000 462,358 467,148 457,764
420,238 2-SHIFT
400,000
325,741
297,635 296,163
282,905
300,000 271,424 1-SHIFT
236,302
190,454
200,000
Energy Consumption : 5,604,000 KWH/Year
100,000
(IDR 7,565,400,000)  2-Shift Operation
Potential Energy Saving: 416,097,000 (5.5%)  1-Unit
0 If 1X/Month Cleaning : 2/3 (416,097,000)
Apr-19 May-19 Jun-19 Jul-19 Aug-19 Sep-19 Oct-19 Nov-19 : IDR 277,398,000
Dec-19 Jan-20 Feb-20 Mar-20
B.2 Price Comparison with TMT (Eco-Brush & Ball Cleaning)
Chiller Capacity TMMIN TMT Remark

Capacity 500 TR 470 TR Operation Ball cleaning

(Eco-brush) (Ball Cleaning) at TMT not effective
because ball circulation
300TR get loss and need
(Eco-Brush) frequently replacement.

Ball Cleaning Quotation for Ball

Quotation Cleaning & Eco-brush
557,000 BATH (470TR)
(IDR 262,904,000) from TDEM.
Based on quotation and
Eco-Brush (500 TR) Eco-Brush compare with capacity.
USD 21,750 691,154 BATH (300TR) TMMIN more cheaper
(IDR 315,375,000) IDR 326,225,000 than TMT.

1 USD = 14,500 IDR 1 BATH = 472 IDR

B.3. Total Reduction Cost

1. Man-Hour Cleaning : IDR 40,832,928 /Unit
2. Energy Reduction: (If 1x/Monthly Cleaning)
- Chiller P#1 (500TR & 700TR) : IDR 434 Mio / Year
- Chiller P#2 (800TR) : IDR 277 Mio/Year
B.4 Project Calculation

No Capacity Invest Saving ROI

EQB KV200-ST – PN 10
1 MATERIAL Q235 – USD 21,750 PLANT#1
SPECIAL DESIGN (500TR)
1.42 Year
IDR 514
EQB KV250-ST – PN 10
2 USD 28,750 Mio/Year
MATERIAL Q235 (700 TR)

PLANT#2

EQB KV300-ST – PN 10 IDR 317

3 1.64 Year
MATERIAL Q235 (800 TR) USD 35,750 Mio/Year
 B.5 Vendor Comparison
AUTO CLEANING CONDENSOR CHILLER COMPARISON
Vendor Candidate : 1. PT WATCO Group PTE LTD (SINGAPORE)
2. INTEGRATED Quality Service Co (THAILAND)

Chiller 500TR Chiller 700TR Chiller 800TR

Integrated Quality Service
WATCO Group PTE LTD Integrated Quality Service CO. WATCO Group PTE LTD Integrated Quality Service CO. WATCO Group PTE LTD
No Item CO.
(SINGAPORE) (THAILAND) (SINGAPORE) (THAILAND) (SINGAPORE)
(THAILAND)
INDONESIA INDONESIA INDONESIA INDONESIA
Original Original INDONESIA Original Original INDONESIA
Conversion Original Quotation Conversion Conversion Original Quotation Conversion
Quotation Quotation Conversion Quotation Quotation Conversion
(1 USD = 14,500 (BATH) (1 BATH = 470 (1 USD = 14,500 (BATH) (1 USD = 14,500
(USD) (USD) (1 BATH = 470 IDR) (USD) (BATH) (1 BATH = 470 IDR)
IDR) IDR) IDR) IDR)

1 Type of Auto Cleaning System ECO-BRUSH System ECO-BRUSH System ECO-BRUSH System ECO-BRUSH System ECO-BRUSH System ECO-BRUSH System

ECO-BRUSH
2 13,300 192,850,000 899,500 422,765,000 17,850 258,825,000 901,500 423,705,000 23,100 334,950,000 1,155,400 543,038,000
System

3 QUOTATION Shipping Cost 600 8,700,000 8,700,000 600 8,700,000 8,700,000 600 8,700,000 178,700 8,700,000

4 Installation 7,850 113,825,000 518,900 243,883,000 10,300 149,350,000 518,900 243,883,000 12,050 174,725,000 602,300 283,081,000

TOTAL COST 315,375,000 675,348,000 416,875,000 676,288,000 518,375,000 834,819,000

Remark : We proposed PT WATCO Group PTE LTD (As a representative in Indonesia)

7. Genba Check Auto Cleaning Condensor [Menara Astra]
A. Activity Date : August 12, 2020

B. Participant : - TMMIN : Enjang R, Bayu H.P

- Facility Menara Astra : Prastyo
- Watcho : Ilhamsyah

C. Purposed : Benchmark Auto-cleaning Condensor Chiller at Menara Astra Facility

D. Principle of Operation Auto Cleaning Condesor Chiller Chiller

- The automatic valve reverses the water flow in the Heat System
Exchanger every few hours for 30 sec.
- Nylon brush cleaning scaling or fouling at condenser Chiller
Condens
Nylon
Reverse Valve or
Brush
A. Chiller Condition at Menara Astra Facility Process
1. Total Chiller at Menara Astra : 5 Unit
- 3-Unit Centrifugal Chiller Water Cooled [1000 TR];
2-Unit Chiller SMARDT Magnetic Bearing [500 TR]
2. Condensor Approach Chiller at Menara Astra is very good
Centrifugal Chiller : 0.4 °C, Smardt Magnetic Bearing : 1.5 °C
3. Eco-brush at Menara Astra already install starting Chiller Installation [2015]
4. Replacement eco-brush at Menara Astra every 4-years

Automatic Valve at Condensor System Parameter @Chiller Scada Monitoring

• Condensor
Approach :
- Certrifugal Chiller
1000 TR : 0.4 °C
THANK YOU