Energy Management Standard Registered Investigation Body Authorized by the Ministry of Economy, Trade and Industry (METI) ECO-CHECK NETWORK JAPAN

Table of Contents 1 1. What is energy management standard? ・・・ 2 2. Energy management standard for combustion equipment ・・・ 3 3. Energy management standard for heating, cooling, and heat-transfer equipment ・・・ 8 4. Energy management standard for air conditioning equipment ・・・ Energy management standard for waste heat and waste heat recovery equipment ・・・ Energy management standard for electrical power equipment ・・・ Energy management standard for cogeneration equipment ・・・ Energy management standard for prevention of heat loss by eradiation and heat conduction ・・・ Energy management standard for prevention of electrical loss by electric resistance ・・・ Energy management standard for electric motors, electrical heating equipment, etc. ・・・ Energy management standard for lighting equipment, etc. ・・・ Samples of energy management standard ・・・ 27

1. What is energy management standard? 2 1.Energy management standard is to establish manuals initiatively before executing operation, measurement, recording, maintenance and inspection for more effective energy use by factories and offices. 2.Those manuals must contain achievable management criteria, provided that the criteria levels must be as high as possible. 3.The management criteria must be reviewed at regular intervals and targeted for further higher levels. To execute the above and continue promoting energy savings is the purpose of energy management standard.

2. Energy management standard for combustion equipment 2.1 Operation management (1)Management of combustion air ratio While keeping a good combustion, the equipment must be managed in as low air ratios as possible. Example 1: Air ratio and fuel increment in heavy oil combustion furnace 3 Air ratio Fuel increment rate % 200  C exhaust gas 300  C exhaust gas

Example 2Management criteria of air ratio in boiler combustion under the Energy Saving Act in Japan 4

Example 3Management criteria of air ratio in industrial furnace combustion under the Energy Saving Act in Japan 5

(2)Management of load allocation in multiple equipment For example, when two or more boilers are installed in the factory, the most efficient load allocation must be established and managed in all boilers. Example 1 : Load allocation of boilers (3)Management of temperature, pressure, fuel condition, etc. for keeping a good combustion Example-1 Heavy oil combustion: Pressure, temperature, spray steam pressure, etc. at burner inlet Gas combustion: Gas pressure, etc. at burner inlet Pulverized coal combustion: Particle diameter of fuel carbon, coal moisture, pressure at burner inlet, etc. 6

2.2Management of measurement and recording Measurement items and frequency on fuel quantity, combustion efficiency, and air ratio must be established. Example 1: Major measurement items ・ Fuel feed quantity ・ Exhaust gas temperature ・ Oxygen concentration in exhaust gas ・ Pressure and temperature at burner inlet ・ Fuel condition, etc. 2.3Management of maintenance and inspection Maintenance and inspection items and frequency of combustion equipment must be established. Example 1: Major maintenance and inspection items ・ Fuel feed system ・ Burner body ・ Fuel control system, etc. 7

3. Energy management standard for heating, cooling, and heat-transfer equipment 3.1Operation management (1)Management of heat medium for heating or cooling by heat medium The purpose of this management is to prevent overheating or overcooling and excessive use of heat medium. Example 1: Heating water or oil by steam with heat exchangers Management items: Pressure, flow rate, etc. of steam (2)Management of heat pattern in industrial furnace For industrial furnaces, heat patterns must be established to improve the heat efficiency. Also after establishing, they must be reviewed for maximum improvement. Example 1: Improvement of heat pattern 8

(3)Rational layout in heating or cooling rooms In heating furnaces or cooling rooms for heating or cooling materials, products, etc., management standard of rational layouts in furnaces and rooms must be established Example-1 (4)Load allocation for multiple heating equipment or cooling equipment For factories where multiple heating equipment or cooling equipment is installed, load allocation must be established for higher heat efficiency in all multiple equipment. … This corresponds to the thought in load allocation of boilers. (5)Shortening waiting time in repeated heating process For process where heating is repeated, management standard of process must be established to make waiting time as short as possible. 9

(6)Integration of intermittent operations For the equipment where heating or cooling is operated intermittently, management standard must be established to integrate operations as much as possible. Example-1: Integration of operations (7)Water quality management for feed water to boilers For quality of feed water to boilers, management standard must be established to prevent scale buildup and sludge adherence on heat-transfer tubes. (8)Management of temperature, pressure, and flow rate of heating/cooling medium and heated/cooled fluids Management standard of temperature, pressure, flow rate, etc. is desired to perform required heating/cooling by minimum heat energy. 10

3.2Management of measurement and recording Measurement and recording items and frequency must be established for temperature, pressure, flow rate, etc. in heating/cooling medium and heated/cooled fluids. 3.3Management of maintenance and inspection Maintenance and inspection items and frequency must be established for portions (heat-transfer pipes) related to heat-transfer performance 11

4. Energy management standard for air conditioning equipment 4.1Operation management (1)Management of air conditioning conditions and air conditioning load Air-conditioning load must be as low as possible to reduce energy for air conditioning equipment. For this reason, it is necessary to always lighten air conditioning conditions. Accordingly, management standard for the following items are desired for establishment. 12

Example-1: Management items of air conditioning conditions ① Air conditioned compartments, houses, rooms, etc. ② Management of window shades ③ Operating time and period of air conditioning equipment ④ Room temperature ⑤ Air conditioning frequency (CO2 concentration in room) ⑥ Moisture (if required) (2)Management for improving overall energy efficiency of air conditioning equipment 13 In order to increase overall efficiency of air conditioning equipment, temperatures of cooling water and cold water, flow rate, etc. must be properly established and managed according to seasonal fluctuations of air conditioning load. Example-1:Improvement in overall efficiency of air conditioning equipment

14 (3)Management of load allocation in multiple heat source equipment (refrigerator, boiler, etc.) For example, when two or more refrigerators are installed in the factory or building, the most efficient load allocation must be established and managed in all refrigerators. … This is the same concept as that in load allocation of boilers. (4)Management of load allocation in multiple air conditioning equipment Similar management to heat source equipment is required. 4.2Management of measurement and recording (1) Measurement and recording items and frequency must be established for reducing air conditioning load. Example: Room temperature, CO2 concentration in room, operating time, moisture (if required), etc. (2)Measurement and recording items and frequency must be established for improving individual and whole efficiencies of heat source equipment, heat transfer equipment, and air conditioning equipment. Example: Temperature and flow rate of cold water and cooling water, air flow rate, electric current and voltage, etc. 4.3Management of maintenance and inspection Maintenance and inspection items and frequency must be established for filters, thermal insulating material, automatic control devices, etc.

5. Energy management standard for waste heat and waste heat recovery equipment 5.1Criteria for utilizing waste heat (1)Criteria of waste gas temperature or waste gas heat recovery rate The higher waste gas temperature is, the larger waste heat loss becomes. Therefore, temperature management or waste gas heat recovery is required. Example-1: Management criteria of boiler waste gas under Energy Saving Act in Japan 15

Example-2: Criteria of waste gas heat recovery rate in industrial furnace under the Energy Saving Act in Japan (2)Other criteria for utilizing waste heat Steam drain and heated solid or fluid posse sensible heat and latent heat. Therefore, sensible heat, latent heat, pressure, combustible components, etc. must be recovered as much as possible by establishing recovered temperature, quantity, properties, etc. as management standard. 16

17 Example-1: Recovery criteria of steam drain Steam drain conforming to the following conditions is entirely recovered. ① 80°C or above in temperature ② Within 50m from boiler feed water tank ③ 1.0 m 3 /day or above in flow rate of drain ④ Recyclable properties as boiler feed water Even for other conditions except the above, steam drain of three years or less in investment recovery is deemed to be recoverable. 5.2Management of measurement and recording Management standard must be established on periodical measurement and recording of items required to promote utilization of waste heat temperature, flow rate, properties of waste solid and fluid, etc. 5.3Management of maintenance and inspection Management standard must be established on maintenance and inspection items and frequency. This standard must cover periodical removal of contamination on heating surface, inspection of medium piping for waste heat recovery, etc.

6. Energy management standard for electrical power equipment Operation management (1)Management for keeping high efficiency Management items and criteria required for keeping high efficiency of electrical power equipment must be established. Example 1: Management items of steam turbine generator ・ Temperature and pressure of main steam ・ Temperature and pressure of reheated steam ・ Vacuum degree of condenser ・ Generating efficiency, etc. Example 2: Management items of diesel engine generators ・ Fuel consumption rate (ℓ － fuel/kWh) ・ Pressure inside cylinder ・ Supercharger pressure, etc. (2)Management of load allocation for multiple generators For factories where two or more generators installed, starting and stopping condition and load allocation of individual generators must be established as management standard to improve the whole generating efficiency according to power demand. (3)Management of reduced-pressure operation under partial load of steam turbine When reduced-pressure operation of boiler is practicable, management standard on reduced-pressure operation of boiler must be established in conformity to partial load of steam turbine.

19 6.2Management of measurement and recording Management standard must be established on measurement items required for generating efficiency and its improvement and frequency. 6.3Management of maintenance and inspection For maintenance and inspection items and execution, frequency must be established as management standard to keep high efficiency.

7. Energy management standard for cogeneration equipment Operation management (1)Management for utilizing heat and electricity sufficiently and keeping high efficiency In operation management of cogeneration equipment, load allocation must be defined to utilize generated heat and electricity sufficiently and management standard must be established to enhance the total efficiency (2)Management of load allocation for cogeneration equipment Management standard of load allocation must be established to enhance the total efficiency in consideration of characteristic features of individual equipment. (3)Management of pressure in bleeder turbines and back pressure turbines When using steam from bleeder turbines and back pressure turbines, allowable minimum pressures must be established as management standard. Subsequent management of measurement and recording and management of maintenance and inspection are omitted.

8. Energy management standard for prevention of heat loss by eradiation and heat conduction 8.1 Criteria on heat insulation (1) Standard of hot and cold insulating According to temperatures inside pipes and operating times, thickness and standard construction are specified in JIS for each category of hot and cold insulation material. (2)Management of temperatures on outer wall surfaces of industrial furnaces Management standard under the Energy Saving Act in Japan is as follows. 21

9. Energy management standard for prevention of electrical loss by electric resistance 9.1 Operation management (1) Management of operating number of transformers and load allocation 22 When two or more transformers are installed, management standard of operating number and load allocation must be established to improve the whole transformer efficiency in consideration of efficiency characteristic in transformers. (2)Management standard on rationalization of transformer layout, voltage, and wiring size Distribution loss is proportional to the square of wiring distance and electric current. Therefore, management standard on transformer layout, voltage, and wiring size must be established to reduce distribution loss.

23 (3)Management of power factor in receiving transformer In order to reduce power loss (or to heighten active power ratio) in electrical substation equipment and distribution line, power factor must be improved. Power factor of 95% or above is criteria under the Energy Saving Act in Japan (4)Management of phase advancing condensers When “phase advancing condensers” are installed to improve power factor, management standard on starting and stopping of phase advancing condensers must be established according to starting and stopping load such as off-loading under low loading. (5)Management of unbalance in voltage When connecting single phase load to three-phase power supply, management standard must be established to prevent unbalance in voltage. Generally, unbalance in voltage must fall within 3%. (6)Management of leveling for electricity usage For stabilization of electric power supply and demand, electric power users must make every effort to level electricity usage. To achieve leveling, management standard on maximum electricity usage must be established. Installation of demand controllers must be investigated. (7)Management of electric voltage, current, power factor, etc. in electrical equipment Management standard on electric voltage, current, power factor, etc. must be established for electrical equipment as requited.

10. Energy management standard for electric motors, electrical heating equipment, etc. 10.1Operation management (1)Management on idle running prevention of electric motors Management standard on stopping when not required must be established to prevent power loss by idle running of electric motors. However, since starting frequency of large electric motors is limited, stopping criteria must be established within the allowable range. (2)Management of number of running machines in multiple fluid machines When two or more fluid machines (pumps, fans, compressors, etc.) are in parallel operation, management standard on load allocation and number of running machines must be established to improve the whole efficiency. 24

25 (3)Management for reducing load in electrical fluid machines As to electric pumps, fans, compressors, etc., required flow rate and pressure must be reviewed and management standard must be established to make electric motor load as low as possible. For this purpose, pump impeller cutting, changing to inverter, changing size of pipes and ducts, etc. must be studied. Example-1 ・ Pump discharge pressure: 0.15 ～ 0.18 MPa in management criteria value ・ Compressor discharge pressure: 0.6 ～ 0.65 MPa in management criteria value ・ Blower suction pressure: － 100 ～－ 150 mmH 2 O in management criteria value (4)Management for energy efficiency of electrical heating equipment As to electrical heating equipment such as induction furnaces, arc furnaces, and resistance furnaces, management standard must be established on loading methods of heated material, loss prevention in rest time for intermittent operation, insulation management, and disposal management. (5)Management for energy efficiency of electrolytic equipment To improve energy efficiency of electrolytic equipment, management standard must be established on distance between electrodes, electrolysis solution density, contact resistance of electric conductor, etc.

11. Energy management standard for lighting equipment, etc Operation management (1) Illumination intensity management After defining management standard on illuminance of lighting equipment, management standard of operating lighting equipment that can be dimmed by modulating must be established to eliminate excessive lighting. Example-1:JIS illumination criteria 30 ～ 75 lx:Indoor emergency stairs 75 ～ 150 lx:Warehouse, break room, and locker room 100 ～ 200 lx:Stairs, hallway, and restroom 150 ～ 300 lx:Book room, machine room, electric room, and elevator 200 ～ 500 lx:Assembly room, reception room, dining hall, and cooking room 300 ～ 750 lx:Office room, meeting room, control room, computer room, and consultation room 750 ～ 1500 lx:Office room (for detailed work), design room, and drafting room (2)Lights-off management Management standard must be established to carry out thorough lights-out and to eliminate unnecessary lighting. If possible, use of motion sensor lighting, etc. is recommended.

12. Samples of energy management standard 12.1Management standard of boilers 27

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12.2Management standard of air conditioning equipment 29

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Thank you for your kind attention. 32