ECCJ / AOTS Malaysia training course

Malaysia

Energy conservation check item (factory, building)

Energy conservation measure for factories (Energy Conservation Guidebook for Factories 2003-3)
2 Check item for energy conservation measure for factories -1
3 Check item for energy conservation measure for factories -2
4 Check item for energy conservation measure for factories -3
5 Check item for energy conservation measure for factories -4
Energy conservation measure for buildings (Energy Conservation Guidebook for Buildings 2004-3)
6 Check item for energy conservation measure for buildings -1
7 Check item for energy conservation measure for buildings -2
8 Check item for energy conservation measure for buildings -3

Check item for energy conservation measure for factories -1

General administrative matter
1. Energy management system
- Organization improvement, human resource development
- Compatibility with environmental management
- Energy conservation target, investment budget
- Long- and medium-range plans
- Adoption of official preferential treatment systems
- State of implementation of energy conservation
2. State of implementation of measurement / recording; state of installation and employment of measuring instruments
- State of maintenance, inspection of measuring instruments
- State of implementation of periodic measurements and recording
3. State of facility and equipment maintenance
- Periodic inspection, routine inspection
- Repairing of leaks (water, air, steam)
- Heat insulation, insulation
- Facility and equipment cleaning (filter, strainer), etc.
4. Management of energy consumption
- State of keeping daily reports
- Daily consumption, daily load variation curves
- Monthly consumption, ratio to the consumption of the preceding year graphs
5. Energy unit consumption management for major products
- Energy unit consumption versus delivery price
- Energy unit consumption versus production amount
6. Environmental conservation related management
- State of implementation of measured for reducing CO2 emission
- State of utilizing the Law for Promoting Energy Conservation and Recycling
- State of LCA (Life Cycle Assessment)
- Waste treatment: state of promotion of waste reduction, sorting and recycling
- Wastewater treatment
7. Improvement of processes
- Improvement of processes
- Reviewal of the factory line
- Realization of continuous operation, efficiency improvement

Check item for energy conservation measure for factories -2

Air conditioning, refrigeration facility
1. Operation management - Optimization of set temperature and humidity - Reduction of outdoor air for ventilation - Start and stop control of heat generating machines - Adjustment of cooled water outlet set temperature - Scheduled operation - Prevention of outdoor air intrusion, state of ventilation - Shielding of radiation heat from high-temperature machines
2. Energy conservation measure, improvement of building insulation, shielding of solar insolation
- Utilization of outdoor air
- Recovery and utilization of waste heat, heat pump
- Rotation control (VAV, etc.) of transportation machines (pumps, fans)
- Adoption of local cleaning, local exhaust
- Stratified air conditioning, reduction of air volume to be conditioned
- Utilization of the ice thermal storage system
3. Operation management of cooling facilities, operation power of refrigerator
- Inlet and outlet pressures of the refrigerant
- Inlet and outlet temperature and pressure of water
4. Operation management of auxiliary facilities, operation power of the cooling tower
- Water quality control (electric conductivity)
- Operating power of pumps (capacity, head)
5. Cold insulation, refrigerating facility, management on entering and exiting
- Insulation management
- Efficiency improvement
Pump, fan; compressor
1. Operation management of pumps, fans
- Opening and closing of valves
- Improvement of routes (pining, ducts)
- Operation flow rate, operation pressure
- Degree of design allowance
- Rotation control, start and stop control
2. Operation management of the compressor systems
- Reviewal of the type (screw, reciprocating, blower)
-Compatibility between capacity and type
- Reduction of discharge pressure and user-end pressure
- Separation between high pressure and low pressure lines
- Ventilation facility, ambient temperature
- Reviewal of pipe size, piping route
- Installation of air receiver
- Start and stop control
- Optimum capacity control
- Leak prevention measure
- Utilization of waste heat

Check item for energy conservation measure for factories -3

Boiler, industrial furnace, steam system, heat exchanger,
waste heat, wastewater, etc.
1. Combustion management of furnace; air ratio, exhaust gas control - Burner, fuel, air supply system - Combustion control system - Regenerative combustion system - Fuel conversion
2. Furnace operation, efficiency control; load factor, state of startup and shutdown
- Start and stop control
- Thermal efficiency, heat balance, heat distribution
- Water quality control, blowing operation control
3. Furnace insulation; thermal insulation and radiation loss prevention; outer wall surface temperature, duct temperature
- Insulation, insulating material (heat storage loss)
- Sealing of openings, furnace inside pressure
4. Furnace flue gas temperature control, waste heat recovery; exhaust gas temperature
- Heat recovery (water supply, air preheating)
- Flue gas recirculation
5. Operation management of steam; dryness, carryover
- Set pressure, temperature of steam for facilities
- Steam flow rate
6. Management of steam leaks / insulation; piping system, tank, etc.
- Facility with steam load
7. Optimization of steam piping system
- Route, pipe size
- Removal of unnecessary piping
- Integration of multiple steam systems
8. Load leveling of steam system
- Installation of accumulator
- Replacement of ejectors with vacuum pumps
- Load side measure
9. Recovery and use of steam drain
- Recovery of medium / low pressure steam (back pressure turbine)
- Steam trap management
- Place of recovered drain collection, drain recovery and collection system
- Utilization of flash steam
10. Operation management of heat exchangers
- Adequacy of type
- Adequacy of use and heating medium
- State of maintenance (fouling, pressure loss)
- Temperature of heating medium, and heated material
- Temperature efficiency ratio
11. Reduction of waste heat / wastewater
- Heat recovery from hot water
- Rationalization of exhaust gas duct
- Recirculation of cooling water
- Concentration control of impurities in water

Check item for energy conservation measure for factories -4

Substation facility, motor, lighting equipment,
electrical heating facility
1. Substation facility management; demand, load factor, power factor control
- Consumption control
- Tariff control (contract power)
- Utilization of nighttime power
2. Transformer facility management; transformer capacity, voltage
- Demand factor / load adjustment
- Shutting off of unnecessary loads
3. Motor capacity / operation management; facility capacity, voltage, number
- Rotation control
- Termination of idle operation
4. Operation management of lighting equipment; adoption of high-efficiency lamps and equipment
- Adoption of automatic switches, zone controlled lighting
- Location of lighting equipment installation, circuit partitioning
- Proper illuminance control
- Turning off of lights during idle hours, sunlight utilization
- Cleaning of lighting equipment, replacement of lighting equipment
5.Operation management of electrical heating facility
- Improvement of supply voltage, power factor
- Control of material feeding and product withdrawal, material preheating
- Temperature control, heating control
- Insulation control
- Improvement of load factor
- Continuous operation
- Reuse of exhaust heat
6.Load leveling measure
- Reviewal of operation pattern (operation hour, operation rate, load factor, etc.)
- Measures for facilities (heat storage facility, absorption-type water heater / cooler, etc.)
7.Co-generation introduction, etc. introduction plan
- Type of facility, capacity, fuel
- Seasonal load fluctuation
- Operation rate, heat electricity ratio
- Inspection, standby electric power supply, pollution prevention measure
8.New energy, etc.
- Fuel cell
- Photovoltaic power generation
- Solar heat

Check item for energy conservation measure for buildings -1

General administrative matter
1. Energy management system
- Organization improvement, human resource development
- Energy conservation target, investment budget
- Setting of management standards
- State of implementation of energy conservation
2. State of implementation of measurement / recording
- State of installation and operation of measuring instruments
- State of maintenance, inspection of measuring instruments
- State of implementation of periodic measurements and recording
- State of introduction of measurement and control systems
3. Management of energy consumption
- State of keeping daily reports
- Daily consumption, daily load variation curves
- Monthly consumption
- Graph for the ratio to the consumption of the receding year
4. State of facility and equipment maintenance
- Periodic inspection, routine inspection
- Management of facility performance , coefficient of performance (COP)
- Management of system performance (COP)
- Facility and equipment cleaning (filter, strainer)
5. Energy unit consumption management
- Heating value unit consumption (MJ/m2 year)
- Energy cost unit consumption (1,000 yen/m2 year)
- Unit consumption by use of building
- Unit consumption by consuming end
6. Plan-do-check-action (PDCA) management circle
- State of implementation of PDCA management
- State of implementation of continual improvement
Heat source, heat transfer facility
1. Management of combustion facility performance
- Air ratio, exhaust gas management
- Burner, fuel, air supply system
- Combustion control system
- Fuel conversion (boiler, generator, etc.)
2. Management of refrigerator performance
- Coefficient of performance (COP)
- Setting of cooled water outlet temperature
- Setting of cooling water temperature
- Removal of scale from heat exchangers
- Temperature efficiency ratio of heat exchangers
3. Operation management, efficiency management
- Load factor, state of startup and shutdown
- Start and stop control
- Thermal efficiency, heat balance, heat distribution
- Steam pressure
- Water quality control, blowing operation control
4. Operation management of auxiliary facilities
- Operation control of cooling towers
- Water quality control (electrical conductivity)
- Operation control of pumps (capacity, head)
- Improvement of routes
5. Operation management of heat carrier facilities
- Start and stop control of pumps, fans
- Rotation control of pumps, fans
- Improvement of routes (open, closed)
- Flow rate, pressure
- State of opening and closing of valves (automatic valve, header bypass valve, etc.)
6. Exhaust gas temperature, recovery of waste heat
- Exhaust gas temperature control
- Heat recovery (HP, CGS, etc.)
7. Management of steam leaks / insulation
- Piping system
- Facility with steam load
8. Management of heat storage; heat storage efficiency
- Heat storage, heat liberation time
- Improvement of heat carry routes

Check item for energy conservation measure for buildings -2

Air conditioning, ventilation facility
1. Operation management of air conditioners
- Optimization of set temperature and humidity
- Appropriateness of humidification zones, and types
- Appropriateness of reheating
- Unevenness of humidity distribution
- Warming up operation
- Outdoor air intake control
- Reviewal of operation time
- Suspension of air conditioning to unused rooms
- Shutting off of outdoor air intrusion
- Control of indoor environment (CO2 , etc.)
2. Management of air conditioning efficiency
- Zone controlled air conditioning
- Utilization of outdoor air (cooling with outside air)
- Setting of dew point control
- Prevention of mixing loss
- Night purge
- Water spraying of roof, outdoor units of air conditioners
- Accuracy of automatic control
3. Introduction of energy conservation equipment
- Heat carrier speed control (VAV,VWV)
- Outdoor air intake control system (control on CO2 concentration)
- Cooling with outside air (outside air enthalpy control)
- Installation of total heat exchanger
- Zone controlled cooling, zone controlled ventilation
- Roof greening, etc.
4. Management of ventilation facilities
- Optimization of number of ventilation times
- Reviewal of operation time
- Operation temperature control (electric room, machine room, CVCF room)
- Suspension of ventilation to unused rooms
- Zone controlled ventilation
- Parking space ventilation control (control on CO2 concentration)
- Ventilator speed control (VAV,VWV)
Facilities for hot water supply, water supply and drainage, refrigeration,
cold storage, cooking
1. Management of hot water supply facility
- Hot water supply temperature
- Hot water supply efficiency improvement (removal of scales)
- Operation in winder only
- Operation schedule control for holidays and nighttime
- Waste heat utilization (CGS, steam drain)
- Solar heat utilization
2. Management of water supply and drainage facilities
- Utilization of reclaimed water (rain water, well water, etc.)
- Water saving measure (water saving packing, automatic washing machine,
sound effect equipment, water saving shower)
- Water supply flow rate, pressure
- Utilization of effluent water
3. Management of refrigeration, cold storage, cooking facilities
- Insulation control
- Opening and closing control of doors
- Control of showcases
- Efficiency improvement
- Insulation and defrosting control
- Management of cooking facilities (cooker, dish dryer, washing machine, etc.)

Check item for energy conservation measure for buildings -3

Substation facility, lighting equipment, electric equipment
1. Substation facility management
- Voltage control
- Power factor control
- Transformer capacity
- Demand factor / load adjustment
- Shutting off of unnecessary transformer
- Optimization of demand
- Electric power consumption control
- Utilization of nighttime electric power
- Power factor improvement control
- Demand control
- Transformer loss
- Start and stop control of transformers
2. Operation management of lighting equipment
- Proper illuminance control
- Turning off of lights during idle hours (sunlight utilization)
- Cleaning of lighting equipment, replacement of lighting equipment
- Location of lighting equipment, circuit partitioning
- Light dimming and extinguishing by automatic lighting control
- Zone controlled lighting
- Adoption of energy saving bulbs
- Improvement of coefficient of utilization (reflectivity)
- Outdoor lighting control
- Turning off at night of luminaires for emergency exist sign
- Adoption of high efficiency lamps
- Adoption of high efficiency equipment
- Adoption of inverter ballasts
- Task ambient system
- Switching control
- Daylight lighting system
3. Management of OA equipment
- Reduction of stand-by electric power
- Turning off the main switches during idle hours
- Adoption of energy-saving models
4. Management of automatic vending machines
- Adoption of energy-saving models
- Service hour control
Elevator, building
1. Operation management of elevators
- Start and stop control of elevators
- Time zone operation schedule control
- Reduction of mechanical power loss in the power transmission system
- Reduction of floors for the elevators to stop
- Adoption of inverter control
2. Operation management of escalators
- Time zone operation schedule control
- Application of occupancy sensor to the operation
3. Energy conservation of buildings
- Thermal insulating performance of structures
- Heat insulation and airtightness of windows
- Shutting off of outdoor air intrusion (air lock entry space, revolving door, etc.)
- Shielding of solar insolation of windows (curtain, light control film)
- Shielding of solar insolation of roofs (heat reflecting paint)
- Air flow window
- Roof greening
- Green office building plan
Leveling of load
1. Load leveling measure
- Reviewal of operation pattern (operation hour, operation rate, occupancy rate, load factor, etc.)
- Measures for facilities (ice thermal storage system, absorption type water heater / cooler, etc.)
2. Co-generation
- Operation management (power generation efficiency, utilization rate of waste heat, overall efficiency, etc.)
- Type of facility, capacity, fuel
- Seasonal load fluctuation
- Operation rate, heat electricity ratio
3. New energy
- Fuel cell
- Photovoltaic power generation
- Solar heat
- Wind power generation

5/6
Next