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METI / ECCJ / ACE Training Program MTPEC03 (2006.01)

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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