METI / ECCJ / ACE Training Program MTPEC01 (2005.07)

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

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