METI / ECCJ / ACE Training Program MTPEC06 (2007.01)

[II] Factory Energy Audit for Energy Conservation

Contents:

Objectives of Factory Energy Audit
ECCJ Activities on Energy Audit
The Results of ECCJ Energy Audit
Check Items for Energy Conservation
Measures in Factories

1. Objectives of Factory Energy Audit

< Energy audit is one of very effective tools for energy onservation activity in a factory. >

Objectives: Fact-finding (Energy loss, Management state), study of causes & measures and advice for improvement

< Auditing items >

Management (organization, target, standard, operation- manual, maintenance, measurement, record, etc.)
Energy loss (heat, steam, electricity, compressed air, etc., idling time, shut-down time, etc.)
Energy efficiency (energy unit consumption, 1- loss/input, etc.)
--- by equipment, line, factory

< How to audit >

Document review, walk-through check, on-site inspection with measuring devices

< Advice/Recommendation of counter measures,
Estimation of E-C effects (potential/cost savings) >

Type of audit:

<Utility audit> Common energy / Utilities:
Usually audited by In-house auditors (Energy managers/ Energy engineers) or out sourcing audit
(* Out sourcing audit: a part of ESCO, Audit consultant, ECCJ service, etc. -- Specialists)

As for utility energy, it should be considered as an common issue for the whole factory, thus the results of the utility audit (Furnaces, boilers, steam systems, compressors, pumps, etc.) at Line A can easily be transferred for Line B and other lines.

<Process audit>
Energy consumed in process: Usually audited by In-house auditors (Process engineers and Energy engineers / Energy managers).

It is difficult to audit without special knowledge and experiences about the manufacturing process/line (technology, facilities, systems).
Process audit (energy) is usually implemented as a comprehensive audit (productivity, quality, cost, maintenance, etc.). It can obtain bigger results.

2. ECCJ Activities on Energy Audit

(1) Main Activities of ECCJ

for Industrial Sector	① Energy conservation audit services for factories ② Education & training on energy conservation ③ State examination for energy managers (assigned by the Gov.) ④ Dissemination (conference for successful cases of EC activities, excellent energy conserving equipment, etc.) ⑤ Technological development and spillover
for Residential, Commercial & Transportation Sectors	① Energy conservation audit services for buildings ② Ranking catalogue for energy efficient appliances 　　 (dissemination of Top Runner Program ) ③ Promotion of Energy labeling system ④ Energy efficiency products retailer assessment system ⑤ International energy star program implementation ⑥ Dissemination of Energy conservation indicator “E-Co Navigator” ⑦ Energy education at elementary and middle schools ⑧ ESCO research and development
for Dissemination etc. (cross sector)	① Energy conservation campaign & exhibition (ENEX) ② Commendation (Grand energy conservation prize) ③ Information & data base, Publicity and publishing ④ Survey and monitoring ⑤ International cooperation & Communications

(2) Audit Service System Flow

(Free-of-Charge Audit by ECCJ)

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