2010 Achievement Report

International Project for the Development of Infrastructure
for Rationalizing Energy Use
Project on Human Resources Development
for Energy Conservation(Project for the Promotion of Energy Conservation in
Major Industries in ASEAN Countries)

Achievement Report

March 2011

The Energy Conservation Center, Japan

Preface
In recent years, the need to achieve sustainable economic development has emerged
as efforts to prevent global warming are becoming a common issue for humankind. Inorder to overcome the difficult conditions posed by the state of complete
incompatibility between these two positions, technological innovations - including
technologies that can promote efficient use of energy and prevent an expansion of theenvironmental burden of energy use and technologies for developing energy sourcesthat place no burden at all on the environment - are required.
To contribute the balanced development of economies and the environment indeveloping countries, it will be necessary to ascertain the current status of energy use
and environmental conservation measures in the countries, as well as to provide
acceptable, appropriate support to them.
Under these circumstances, we conducted energy conservation audits (Hereinafter referto as “Audit”) on a single industry in each of the ten ASEAN member countries andcarried out transfers of Audit technologies during phase 1 in the years between 2000
and 2003. During phase 2 in the years between 2004 and 2008, we endeavored to
conduct Audits and establish a foundation for the promotion of energy conservation inorder to implement and disseminate improvement measures.
The goal of phase 3 was to utilize the foundation for the promotion of energy
conservation including technologies which are transferred up to now through theself-efforts of each ASEAN member country, and then disseminate and distributewidely throughout each ASEAN member country. In accordance with this goal, we
provided support in 2010 for conducting autonomous Audits by each ASEAN member
country as we had first put forth in 2009 and promoted the implementation anddissemination of improvement measures.
In terms of specific activities, we carried out on-the-job training (OJT) for Audits at
new factories in order to ensure the regional dissemination of Audit technologies.
Furthermore, we compiled technical directory (TD) and produced an in-house database(IHD) for each industrial sector.
This year, we carried out OJT for Audits at beer factories in Cambodia and Lao PDR,
and an apparel manufacturing factory in Thailand. At the same time, we focused ourefforts on dissemination activities by holding seminars and workshops in each of thesecountries, inviting governmental and factory-related officials belonging to otherindustrial sectors from non-host countries, presenting successful case studies in energy

conservation, and promoting information sharing within the ASEAN region.
We hope that this project will contribute to energy and environmental conservation inindustrial sectors in each ASEAN country and that these countries will achievesustainable economic development in harmony with the environment. We also expectthat this project will serve as a bridge of technological exchanges and friendshipbetween Japan and the various countries in question.
March 2011
The Energy Conservation Center, Japan

Contents
Abbreviations
Overview ········································································································1
I. Purpose and background of this project····································································5
II. Cambodia (food manufacture industry) ···································································7
1. Overview of activities ····················································································7
2. OJT of Audits on Factory A··············································································7
3. Seminar and workshop ················································································· 22
III. Lao PDR (food manufacture industry) ································································· 27
1. Overview of activities ·················································································· 27
2. OJT of Audits on Factory B············································································ 27
3. OJT for simplified Audit of building (Hotel C)······················································ 36
4. Seminar and workshop ················································································· 37
IV. Thailand (textile industry) ··············································································· 41
1. Overview of activities ·················································································· 41
2. OJT of Audits on Factory D ··········································································· 41
3. Seminar and workshop ················································································· 45
V. Developing TD and IHD·················································································· 47
1. Overview of the activities ·············································································· 47
2. Developing TD system ················································································· 47
3. Developing an IHD system ············································································ 48
4. Current state of building sector IHD and revisions as implemented······························· 48

Abbreviations as used in this report are as follows:
General
AHU
AVR
BMS
CFL
COP
CSR
DCS
DB/BM
DHCR
DO
DSM
EE&C
EEI
EM H/B
EMS
ESCO
FP
FRL
GDP
GMP
GTG
HACCP
HVAC
IDF
IHD
ISO
JBIC
KPP
LED
OJT
PCB
PROMEEC
SEC
SCADA
SH
TD
TOD

Air Handling Unit
Automatic Voltage Regulator
Building Management System
Compact Fluorescent Lamp
Coefficient of Performance
Corporate Social Responsibility
Distributed Control System
Database / Benchmark
Direct Hot Charge Rolling
Dissolved Oxygen
Demand Side Management
Energy Efficiency and Conservation
Energy Efficiency Indicator
Energy Management Handbook
Energy Management System
Energy Service Company
Focal Point
Fluorescent Lamp
Gross Domestic Product
Good Manufacturing PracticeGas Turbine Generator
Hazard Analysis and Critical Control Point
Heating, Ventilation & Air Conditioning
Induced Draft Fan
In-House Database
International Organization for Standardization
Japan Bank for International Cooperation
Key Process Parameter
Light Emitting DiodeOn the job training
Printed Circuit Board
Promotion on Energy Efficiency and Conservation
Specific Energy Consumption
Supervisory Control and Data Acquisition
Sensible heatTechnical Directory
Total Oxygen Demand
i

TPM
VAP
VSD

Total Production Management
Voluntary Action Plan
Variable Speed Drive

ASEAN & UN
ACE
ASEAN Centre for Energy
ADB
Asia Development BankAPAECASEAN Plan of Action for Energy Cooperation
ASEAN
Association of South-East Asian Nations
EAS-ECTF
East Asia Summit - Energy Cooperation Task Force
SOME-METI ASEAN Senior Officials Meeting on Energy - METI
UNEP
United Nations Environmental Program
UNIDO
United Nations Industrial Development Organization
UNESCAP
United Nations Economic and Social Commission for Asia and thePacific
Japan
AOTS
ECCJ
METI

Association for Overseas Technical Scholarship
Energy Conservation Center, Japan
Ministry of Economy, Trade and Industry

CambodiaMIME
DIME

Ministry of Industry, Mines and Energy
Department of Industry, Mines and Energy

LAO PDR
MEM/DOEPDEM
EDL

Ministry of Energy and Mines/ Department of Electricity
Provincial Dept of Energy & Mines
Electricite Du Lao PDRThailand
DEDE
CPH
ESCC

Ministry of Energy / Department of Alternative Energy Development
and Efficiency
Castle Peak Holding PLC
Energy Saving Consultation Centerii

Overview
The member countries of ASEAN have been continuing rapid economic growth andthe energy consumption are expected to dramatically increase for the coming years. It
will likely become necessary to focus on efficient energy utilization and global
warming prevention. As this project enters its eleventh year, the activities ofcounterpart ACE and ASEAN member country officials are becoming even moredeveloped and established, and further awareness of energy consumption reduction in
the countries in question have become widespread reflecting the rising energy costs
along with recent increase of crude oil price and the implementation of the Kyoto
Protocol on February 16, 2005.
As the second year of Phase 3, this year has been positioned as the year in which wewill summarize the results of activities undertaken over the last ten years andconsolidate the implementation and dissemination of results achieved so far throughgreater self-efforts. That is to say, we set the target to establish a foundation to promoteenergy conservation for the purpose of implementing and disseminating the results of
Audits conducted at factories of ten industries in all ASEAN member countries overthe last ten years. Specifically, the following activities were conducted in each of three
countries: Cambodia (food products industry), Lao PDR (food products industry), andThailand (textiles industry).
Guidance for Audits
Factories which requested Audits were visited and OJT for auditors were
implemented by Japanese experts. Audit technologies shall be transferred to auditors
and its candidates in the countries that are visited. Audit results shall be reported to
the factories that are visited and used for future energy conservation activities.
Holding seminars and workshops
Factory officials, including those from other industries, and factory andgovernmental officials belonging to other ASEAN countries participated andpresented their activities and implementation of improvement measures in order todisseminate results of successful cases and know-how to ASEAN member countries.
Producing technical directory (TD)
Effective technologies in ten different industries and successful cases of suchtechnologies were introduced in ASEAN member countries, and related information
was shared. The probability that such technologies will be implemented anddisseminated has increased.
Formulating in-house database (IHD)
We will continue to engage, as last year, in implementation and dissemination
efforts among actual factories in the steel and ceramics industries. We shall develop
1new IHDs for the automotive, oil refining, and pharmaceutical industries and utilize
these IHDs on a trial basis at actual factories and investigate the effectivenessthereof.
Seminars and workshops held in each country have attracted numerous participantsfrom factories and government. These seminars and workshops have fulfilled theirsignificant roles in terms of the sharing and dissemination of information.

2

The contents of PROMEEC projects for major industries this year are as follows:
I. Activities in Cambodia: September 6 to September 14, 2010
1. OJT for Audit was carried out at a beer factory in Cambodia. The local audit teamincluded engineers from the Ministry of Industry, Mining and Energy and local
government bodies, university officials, and engineers belonging to the factory to beaudited. The leader was the engineer of the beer factory.
2. A seminar and workshop were attended by 37 persons, and a proactive exchange of
information was undertaken through the following presentations and discussions:(1) Presentations of energy conservation policies and programs by Cambodian andJapanese sides;(2) Presentations of implementation cases concerning energy conservation by officials
from other ASEAN member countries;(3) Presentation of Audit results by the local audit team;
II. Activities in Lao PDR: October 4 to October 11, 2010
1. OJT for Audit was carried out at a beer factory in Pakse, second largest city in Lao
PDR. As a new trial, OJT for simplified building audit was also carried out at thesame time. The local audit team included engineers from the Ministry of Industry
and Mines, the Electricite du Lao PDR (DMS), local governments, and the factory
to be audited. Engineers belonging to the beer factory served as leaders for OJT of
Audits conducted on the beer factory, while workers from DSM served as leaders
for OJT of simplified building audits.
2. A seminar and workshop was attended by the aforementioned engineers and 49
persons, including participants from the beer factory and elsewhere. A presentation
on best practices was given by ASEAN member country officials, and the results ofbeer factory and hotel audits were reported.
III. Activities in Thailand: November 22 to November 29, 2010
1. OJT for Audit was carried out at an apparel manufacturing factory in Bangkok. The
local audit team consisted of engineers from the Ministry of Energy, EC-relatedcompanies, and the factory to be audited.
2. A seminar and workshop were attended by 65 persons. The event was held on a
grand scale thanks to participations from the Ministry of Energy, the textiles industry,and energy technology and service companies. A presentation on best practices inthe textiles industry in Thailand was given, and the results of the audit performed ona textile factory were reported.
3

Finally, in implementing this project, we were able to obtain the full cooperation of
persons in charge from ACE, relevant organizations and companies from each country.
We hereby take this opportunity to express our sincere appreciation for their efforts.

4

I. Purpose and background of this project
In order to promote the dissemination of energy conservation technologies in majorindustries, this project aims to contribute to the promotion of conservation of energy
and environment in ASEAN member countries by promoting energy conservation
measures in major industries in the countries by supporting activities undertaken by
ASEAN.
This project was commenced by the ASEAN Centre for Energy (ACE) in 2000 withthe aim of reducing energy consumption in the ever-growing industrial sectors in the
ASEAN region. ASEAN refers to this project as PROMEEC (Major Industries).
PROMEEC (which stands for the Promotion of Energy Efficiency and Conservation) isa cooperative project which is carried out in collaboration with the Ministry of
Economy, Trade and Industry, and certified at a meeting of ministers in charge ofenergy from the 10 member countries of ASEAN. Through relevant activities,
cooperation in terms of technical and operational support has been extended for thepromotion of energy conservation in the industrial sectors in ASEAN member
countries.
The objectives of this project are as follows:
1. To establish closer collaborative relation between ASEAN member countries andJapan in the energy conservation sector;
2. To promote greater energy efficiency and energy conservation in major industries in
ASEAN member countries;
3. To promote technology transfer from Japan and the adoption of examples of
excellent energy conservation practices in major industries in ASEAN member
countries;
4. To raise the level of energy conservation technologies in ASEAN member countries
through Audits and related OJT;
5. To produce technical directory (TD) and database (DB) and formulate benchmarks(BM) for Audits in ASEAN member countries.
Based on the recognition that this project is, as set forth below, to be promoted in 3
phases, this year is positioned as the second year of Phase 3 activities in accordancewith discussions between ACE and ASEAN member countries.
Phase 1: Technologies and experiences on energy efficiency & conservation, EE&C
were transferred from Japan to ASEAN member countries.
Phase 2: Japan and ASEAN member countries jointly implemented improvement
measures for EE&C in each country and disseminated said measures in each5

country as well as in other countries.
Phase 3: Energy conservation is promoted through the self-help efforts of ASEAN
member countries.
In Phase 1, Audits and audit technology transfer were carried out on a single industry
in each of the ten ASEAN member countries (completed in 2003). In Phase 2,
establishment of a foundation to promote energy conservation for the purpose of
implementing and disseminating improvement measures were being conducted, alongwith Audits (completed in 2008). In Phase 3, the goal was to utilize the base for energy
conservation promotion, including technology which is transferred, through theself-help efforts of each ASEAN member country, and disseminate and distribute it
widely throughout each ASEAN member country (commenced in 2009).
In accordance with the background and aims above, autonomous Audits by each
ASEAN member country was supported, and the implementation and dissemination of
improvement measures was promoted in 2010.
Specifically, Audits to ensure the regional dissemination of Audit technologies wereconducted at new factories. In addition, we compiled technical directories (TD) andproduced an in-house database (IHD) for each industrial sector.
Audits were conducted at beer factories in Cambodia and Lao PDR and an apparel
manufacturing factory in Thailand. At the same time, we held seminars and workshops,
invited governmental and factory-related officials belonging to other industrial sectors
from non-host countries, presented successful case studies in energy conservation, andpromoted the information sharing within the ASEAN region.

6II. Cambodia (food manufacture industry)
1. Overview of activities
In order to implement the Project for the Promotion of Energy Conservation in Major
Industries in ASEAN Countries (of the International Project for the Development ofInfrastructure for Rationalizing Energy Use, a METI-outsourced project), we visited
Cambodia from September 5 to 16, and carried out an OJT of Audit at a beer factory
situated in Sihanoukville, a seminar and workshop for the purpose of exchanging
information with officials from Cambodian industry and ASEAN member countries.
23 persons, including engineers from the Ministry of Industry, Mining and Energy andconcerned local government bodies, university officials, and engineers belonging to thefactory to be audited as well as engineers from ECCJ and ACE, participated in the
OJT of Audit that was conducted on the beer factory. A seminar and workshop wereattended by a total of 37 persons, including the persons referred above and wereconcluded on a successful note.

Dispatched officials: Hiroshi Shibuya, Taichiro Kawase (Technical Cooperation
Department); Tsutomu Kawasaki (Mayekawa Mfg. Co., Ltd., dispatched instructor)
Schedule of activities:
Sept. 6 to 13: OJT of Audit (Factory A)
Sept. 14:
Seminar and workshop (in Sihanoukville)
2. OJT of Audits on Factory A(1) Participants: 23 persons
Ministry of Industry, Mines and Energy (MIME): 4 participants/ Mr. Lien Vuthy(local team leader), Mr. Khlaing Amradararith, Mr. Khlaut Ousa, Mr. Chhon
Chhim
Department of Industry, Mines and Energy (DIME): 3 participants/ Mr. Chan
Chourn, Mr. Som Savath, Mr. Koeut RA
Factory A: 3 participants/ Mr. TY Puthy, Mr. Chor Sambath, Mr. Nop Chanra
ACE: 2 participants/ Mr. Christopher Zamora, Mr. Junianto
ECCJ: 3 participants/ Hiroshi Shibuya, Taichiro Kawase, Tsutomu Kawasaki
interpreter (one person), others (seven persons)(2) Overview of factory: Factory A
The factory started its operation under the current framework in 1992, working for 18
years. The factory is currently in a state of full operation, with the capacity for beer7

production at 480 kiloliters per day. The factory has three smoke tube boilers with asteam generation capacity of 10 tons per hour and steam pressure of 7 bars. Heavy
fuel oil and diesel fuel are used for fuel and a forced-draft system based on the use of
combustion air fans is utilized. An ammonia refrigerant-based mechanicalcompression-type refrigeration system has been adopted, with compressors consistingof three reciprocal-type units and six screw-type units. Ammonia condensation isachieved with the use of five evaporative condensers while ammonia evaporation isachieved with the use of plate-type heat exchangers; glycol (PG) cooling and chilledwater production is thereby undertaken. As air compressors, three 75 kW screw
compressors are installed. Their discharge pressure is rated at 7.5 bars and their flowrate is rated at 11.6 m3/min. The installation works of ammonia compressors,
evaporative condensers, ammonia receivers, and other equipment units is presently
underway in order to improve the capacity to produce beer.
(3) Audit overview
1) Composition of audit teamThe overall audit team was divided into 2 groups: the utility audit team and the process
audit team. The utility audit team consisted of a total of 10 persons: one engineer
belonging to the factory, 4 officials from related government agencies, engineers
belonging to other factories in the vicinity, and 2 officials from ECCJ and ACE. The
factory engineer served as the team leader. The process audit team consisted of a totalof 15 persons: 2 engineers belonging to the factory, 5 officials from related government
agencies, engineers belonging to other factories in the vicinity, and 3 officials fromECCJ and ACE. A factory engineer served as the team leader.
2) Steps of the audit work
The audit was performed according to the following sequence: interview concerningenergy conservation activities at the factory; inspections of the equipments, datacollection, and analyses based on measurements using measuring instruments,
operational logs, and other sources; the formulation of energy conservation measures;and the reporting of audit results to factory officials. At each step of the audit,
explanations of the significance of the work performed was given to participants,
intermediate data analysis was conducted, and explanations and instructions were
given in regards to the data analysis process. In order to thoroughly engage in
explanations and instructions on an interactive basis, explanations were given bygathering the participants together in front of a white board, and participants
themselves measured and took records.

83) Measurements and data collection
As many participants of OJT have not experienced measurements before, guidance wasgiven in advance on the purpose of measurement work, measurement items,
measurement sites, and the measuring instruments to be used. In carrying out
measurement work, persons in charge of each measuring instrument were assigned,
and data were collected under the assumption that such work would be performed in
the presence of factory supervisors. With respect to data for which measuring
instruments could not be prepared, readings of gauges attached to equipment weretaken, and data from operational logs were gleaned.
4) Audit of utility equipments(i) State of the boiler equipment- Three boilers with a steam generation capacity of 10 tons per hour and steam pressureof 7 bars have been installed. Under normal operations, the number 2 boiler isrunning and the number 3 boiler is on standby. Where steam pressure in the factory
is insufficient, the number 3 boiler starts operation.
- For fuel, the number 2 boiler operates by a heavy fuel oil firing process and has aheavy fuel oil heater attached while the number 3 boiler operates by a diesel fuel oil
firing process and no fuel oil heater is attached. Fuel flow is read hourly with an
integrating meter and recorded in the daily log.
- Steam flow are ascertained with an integrating meter installed on each boiler’s watersupply line and recorded in the daily log every hour; blow downs are undertaken
manually on an intermittent basis. The blow down volume is not ascertained.
- Water supply to the boilers is done by degassing mixture of process-generated returncondensate and soft water processed only with brine-softening equipment.
- The ventilation system is a forced draft system by combustion air fans.
- The volume of combustion air is automatically adjusted according to mechanicallywith the fuel flow. The valve position indicator corresponding to the volume of
combustion air was set to approximately 50%. At this time, the boiler load was low
at a little over 4 tons per hour compared to the rated load of 10 tons per hour.
- No air pre-heater or economizer has been installed. No gas exhaust duct damper
could be confirmed.
(ii) Boiler audit- Exhaust gas temperatures and oxygen concentration of exhaust gas
The loss of exhaust gas represents the largest source of energy loss of boilers. In
this connection, the temperature of the exhaust gas and the oxygen concentrationof the exhaust gas were measured in order to ascertain the extent of the loss of
exhaust gas. The temperature of the exhaust gas was 170˚C by checking theexhaust gas thermometer installed onto these boilers. The oxygen concentration
ranged between 0.9 % and 1.2% based on measurements taken with an oxygen
9

analyzer. If the oxygen concentration is 1 vol. %, the air ratio will be 1.05. As thetemperature of the exhaust gas is 170˚C, the amount of exhaust gas that would be
lost is approximately 7%.
According to the energy conservation standards of the Energy Conservation Law
in Japan, the temperature of exhaust gas should be between 180 and 220˚C and theoxygen content should be between 3.5 and 5.0% in the case of small-sized boilers.
Accordingly, boiler number 2 at the factory satisfies these standards, such that it
can be said that there are no outstanding issues from the standpoint of energy
conservation. These boilers have no air pre-heaters or economizers installed. In
this fact, what accounts for these boilers’ high level of efficiency? A low-load
operation is the most important factor in this case. As indicated earlier, the boiler
load is low at a little over 4.4 tons per hour compared to the rated capacity of 10
tons per hour. Thus, there is considerable space in the heat transfer area of thesteam generating tubes, resulting in the decline of exhaust gas temperature. A low
air ratio operation is the second most important factor that can be identified in thiscase. Consequently, highly efficient operations that satisfy the standards of theEnergy Conservation Law in Japan are undertaken.
Nevertheless, where heavy fuel oil is burned and operations with an air ratio of
1.05 are undertaken, the possibility of incomplete combustion of fuel is high. In
other words, unburned fuel loss is generated. Upon visually examining the exhaustgas from the stack of the boiler, black smoke - albeit a small amount - wasobserved. However, to estimate the actual combustion efficiency, it will benecessary to measure the concentration of carbon monoxide in the exhaust gas andquantitatively study the extent of the incomplete combustion.
- Heat loss from the surface of boilers
The surface temperature of boilers was measured using both a contact-type
thermometer and a radiation thermometer. The values obtained using both
thermometers differed by no more than approximately 2˚C from one another,
thereby indicating that they were in favorable agreement. The data obtained using
the contact-type thermometer and the results of calculations of heat dissipation are
as follows:
Pont
Front burner side
Rear exhaust funnel side
Rear cylinder part

Surface temperature (˚C)
60 (avg. of 4 sites; area of 4m2)
44 (avg. of 2 sites; area of 4m2)
37 (avg. of 6 sites; area of 35m2)
Total

10

Heat loss (kcal/h)
1,297
531
2,116
3,944

Total heat loss was equivalent to approximately 0.5% of the heat generated by the
combustion of the fuel. Heat loss for regular boilers range between 1 and 2%,
which is a relatively low level. This is because the average surface temperature forthese boilers at 40˚C is low compared to normal boilers, whose average surface
temperature is 60˚C. At the same time, these boilers satisfy the standards of theEnergy Conservation Law in Japan with respect to surface temperature, which thesurface temperature should be no higher than between 70 and 80˚C. Based on theabove data, it can be determined that there is no need to augment the existing
thermal insulation with new thermal insulation.
- Measuring the condensate recovery rate
A quantitative estimate was made to which extent clean condensate is returned tothe boiler house. By the heat balance of the water that enters and leaves the boiler
feed tank, the condensate recovery rate was estimated to be 16%. The recovery
rate at Japanese beer factories is approximately 60%, which suggests that there issignificant room for improvement. For the time being, we recommend to startfrom focusing on recovering condensate in steam traps and steam heaters.
- Boiler efficiency
According to the estimation of boiler efficiency by indirect method, the calculation
result of 91.9%. Such a high level of efficiency is unrealistic, and it is highly
possible that the unburned fuel loss has attributed to incomplete combustion or
blow down loss has actually been underestimated.
- Evaporation ratio
Based on data obtained from the number 2 boiler’s cumulative flow meter, theevaporation ratio was estimated 14.6. Compared to the evaporation ratio at
Japanese factories which is between 14 and 15, this boiler can be described quite
highly efficient.
- Guidance of combustion control
Combustion control should be undertaken by measuring the temperature of
exhaust gas or the concentration of oxygen or by otherwise using measuring
instruments. However, many small to medium-sized enterprise do not possess suchmeasuring instruments. In this connection, we inspected the number 2 boiler as
example with participants, the color and form of the burner flame, the smoke inthe exhaust gas from stack, and let them understand that combustion control canbe undertaken without the use of measuring instruments. As it happened that blacksmoke was seen in the exhaust gas from stack, we provided instructions throughthe use of a white board on such matters with respect to the cause of this blacksmoke as the state of the mixture of heavy oil and air in the burner, the meaning of
the diameter of atomized heavy oil droplets, and the relationship between the11viscosity of heavy oil and the diameter of oil droplets. In addition, a visualinspection of the flame revealed that the flame was a dark-red color on this day.
We explained that, with proper combustion, the flame should be a red-orange color
and that a dark-red flame is an indication of insufficient air.
(iii) Reinforcing thermal insulation of the steam piping system
Lack and damage of thermal insulation could be seen at various points of the steam
piping system. Prompt repairs are required. In addition, valves, flanges, and manyother piping attachments lack thermal insulation.
(iv) Audit of the refrigeration system
In order to ferment raw material and store products at low temperatures at a beer
factory, significant amounts of law temperature energy from refrigeration are
required. Much of this energy is supplied as electrical energy used to powerammonia compressors. Energy conservation measures for a refrigeration system canbe generally divided into refrigeration supply-side measures, refrigeration
demand-side measures, and common measures. For this audit, we investigatedmatters concerning the lowering of the ammonia condensation temperature and thelowering of the refrigeration load.
- State of refrigeration equipment
At this factory, an ammonia refrigerant-based mechanical compression-typerefrigeration system has been adopted, with compressors consisting of threereciprocal-type units and six screw-type units. Ammonia condensation is composedwith the five evaporative condensers while ammonia evaporation is consisting of theplate-type heat exchangers. Glycol (PG) cooling and chilled water production are
thereby undertaken.
- Energy conservation effects by lowering the ammonia condensation temperature
In general, the efficiency of a refrigeration system is evaluated by coefficient of
performance (COP). COP is defined, in simple terms, as an indicator of the numberof kilowatts of refrigeration that can be obtained by consuming one kilowatt ofelectrical power. With a chiller which is designed at condensation temperature of
38˚C and evaporation temperature of -9˚C, the COP will improve by 2.2% if thecondensation temperature is lowered by 1˚C. In the case of a chiller with 132 kW ofshaft power, 132 x 0.022 = 2.9 kW of energy can be conserved. This formula is also
valid for any rise in the evaporation temperature. If too much cooling was takenplace on the process side, approximately 2.2% of power consumption savings could
be expected by raising the cooling temperature by 1˚C.
- Lowering the refrigeration load
While measurements were taken of the surface temperature of low-temperature pipes
and the heat inflow and power-saving effects were calculated, it was determined that12

the amount of electrical power saved was low and that the recovery of theconstruction costs with thermal insulation would be difficult.
(v) Audit of compressed air system- State of the operations of air compressors
Three 75 kW screw compressors have been installed. Their discharge pressure is
rated at 7.5 bars and their flow rate is rated at 11.6 m3/min. For the control ofpressure, set values have been determined for the on-loading pressure and theunloading pressure for each compressor. When the compressor reaches on-loadingpressure it starts compression, and goes into an unloading state when it reaches
unloading pressure. The actual discharge pressure averages approximately 7 bars.
While we skipped measurements of the time of unload status due to time constraints,
there was no unload state period, judging from the sounds of compressors. It could
be assumed that these compressors are operating at full capacity all the time.
- Investigation of the compressed air consumption process
The number of employees who are aware of the purpose of using compressed air andthe required pressure level is unexpectedly low. For example, compressed air is often
used for the purpose of water drainage. Up to 1 bar of pressure is normally sufficient
to drain water, and an air compressor can be converted into an air blower. In thisconnection, we conducted interviews concerning the purpose of using compressed
air and the required pressure levels, and obtained the following investigation results:
Purpose of using compressed air
Required pressure/ bar
Remote-controlled valve drive
4(Fermentation tank sequence, CIP sequence)
Remote opening/closing of grain screw conveyer
6
Lifting drive of packaging machinery (barrels)
5
Lifting drive of packaging machinery (bottles and cans)3
Supplying instrument air to pneumatic control valves
6
At this factory, we ascertained that compressed air is used for mechanical drivers andcontrol valves, and their maximum required pressures are 6 bars. Generally speaking,a reduction of discharge pressure from 7 bars to 6 bars will result in a 7 to 8 %decrease in power consumption. Accordingly, we advised the factory to inquire withdriver machine manufacturers and control valve manufacturers to determine whether
required pressure levels can be reduced and to investigate machinery that can be run
at lower levels of pressure.
- With respect to the energy conservation effects of lowering the temperature of intake
air, the temperature of compressed intake air at this factory was 31.7˚C. The
13

temperature of outdoor air in the shade at this time was 30˚C. Given such a
difference in temperatures, the power saving rate will only be approximately 0.5%
and the recovery of duct construction costs to intake the outside air will be difficult.
- Location of the air compressor room
The air compressors room at this factory is located near the center of a rectangularfactory building. It is estimated that the piping that extends from the air compressors
room to the terminal process is no more than 200 meters in length. At this distance,
the pressure drop from the air compressors to the terminal process should be under
0.5 bars. However, there is an actual drop in pressure of at least 1 bar. It is highly
possible that the diameter of the compressed air pipes is too small.
5) Process audit(i) Main energy consumption area as at beer factory
The beer production process is approximately the same at any factories such that the
major energy consumption areas are as indicated in the following diagram. Steam istypically consumed in the wort brewing process to boil up raw materials and in the
packaging process to wash containers and sterilize products. Electrical power istypically consumed in the fermentation process for cooling.

30% ~40% of Energy
is consumed during
wort boiling

MT

MK

Silo Raw material
Treatment
30%~50% ofElectricity isconsumed forrefrigeration
load.

WK

WP

WC

ST

High BOD
effluent isdrained from
Brewhouse.

BC
BBT

BC BF
Filtration

Fermentation/
Maturation Tank

30%~50% of coolingload is consumed for
production of coolingwater.
20% to 30%
Energy isconsumed at
Packagingarea.

Brewhouse

CO2
FT

MF

POWER ・・・・・
STEAM・・・・・・
WARM Water・・・
COOLING.・・・・

FL

WH
WA／PAST

Packaging & Warehouse(ii) Locations where energy consumption improvement is possible at beer factories- Wort pan and wort cooler (recovering exhaust steam at boiling process andrecovering waste heat from heated wort);- Beer cooler (beer temperature control);14

- Total hot water management for the factory (recovering waste heat from hot waterand reducing volume of hot water used);- Total steam condensata management (improving the drain recovery rate);- Management of bottle-washing machines (reducing the volume of steam used);- Pasteurizers (reducing the volume of steam and the service water used).
Total hotwater
management

Pasteurizer
at package
Sec.

Bottle cleaner at
Package Sec.

Total steam
drain recovery

C
C
V

B
B
T

Wort cooler
at Brewing Sec.

Beer cooler
at Filtration Sec.

(iii) Ascertaining the state of energy use in main process equipments and improvement
points- Wort cooler: There are two types of wort coolers at A Factory, two-step cooler andone-step cooler. The temperatures profile is as follows. One-step cooler is more
efficient for cooling than two-step cooler.
2 step cooling

1 step cooling
Hot wort

Cold wort

Brewing W

Ice Water

Hot wort

Cold wort

Brewing W

Brine

Ice waterBrine

2 step cooling
Wort temp

In
94

In (out)
17.4

Ice water tem

4.0

74.4
-0.6

PG tempout

13 (12)
14.3

There are 2 Wort cooler in A Factory
1 step cooling & 2 step cooling like figures.
2 step cooling Wort cooler had better to change to 1 step cooling.
After that, Refrigerant energy can be saved.

15

<Improvement points>
Replacing the two-step cooler to one-step cooler will be more efficient for cooling.
And it is possible to increase cooling capacity by increasing the number of plates in aplate-type heat exchanger.
- Beer coolers
The bellow figure is a flowchart of the processes of wort and beer at Factory A.
Further recovery of waste heat extracted from wort will be possible. In addition,
while it was determined that centrifuges were in constant use, it will be possible toreduce the operation time of centrifuges, which consume a large amount of electrical
power, by implementing a more precise regimen of yeast management. Furthermore,while the filtration room is managed under low-temperature conditions, its doors
were open and frost was formed on coolers. Air conditioning needs to be attentively
managed.
Mash Kettle
Mash Tun

Mash
FilterWhirlpool
Tank

Wort Kettle

Pre-run Tank

M

Wort
Pre Heater

Wort
Pre Cooler
Deareated Water
Equipment

Fermentation
Tank

Maltose &Hot water

Bright Beer
Tank
350HL x 6
600HL x 8

Storage Tank

to Package
Wort
CoolerBeer
Cooler

Separator

Beer
CoolerBeer
Filter- Bottle-washing machine
The actual temperatures of each tank in the bottle-washing machine differedsignificantly from their target values. While this could be attributed to some factor orother, appropriate temperature levels should be sought. In addition, while hightemperature rinse water of 46˚C was being discharged as wastewater, it should bepossible to recover and reuse, such as by supplying the water to a pre-wash tank.
- Bottle/can pasteurizers (sterilizers)
The bottle pasteurizers are appropriately subject to temperature management.
16However, as for the can pasteurizer, the circulating hot water temperatures of theheating tank and the hold tank were reversed, and a change to settings is necessary
from the standpoint of energy conservation.
(iii) Improvement points of thermal insulation- Feed cooker: The upper part of the feed cooker is not insulated. By applying thermal
insulation, heat loss can be reduced.
- Thermal insulation of beer pipes from the BBT (bright beer tank) to fillers: Dew
formation is occurring on the outer surface of the thermal insulation. Since theinsulation performance is poor, an upgrading of the thermal insulation to an
appropriate grade will be necessary.
- High-temperature parts of the bottle-washing machine and the pasteurizers: By
applying the same thermal insulation to these high-temperature parts as used for the
hot-water tank, heat loss can be reduced.
(iv) Ascertaining of hot water usage and investigating improvement points
The present state of hot water usage in the factory was exceedingly simple comparedto other beer factories. But the amount of hot water used at each site has not been
confirmed. Hot water is produced from recovery of waste heat at many sites
throughout Japanese beer factories. Accordingly, it is difficult to ascertain the total
amounts of hot water produced and used. Hot water management at beer factories
tends to become more important when more energy conservation measures are
implemented.
Flowchart of current processes for hot water and wort17

Waste heat recovery sites
Process
Feed
Same as above
Same as above
Cooling system
Air-compression
systemCarbon dioxide
purification system
Packaging system
Boiler system

Equipment/syste
m nameWort kettle
Wort pre-cooler
Wort cooler
Chillercompressor
Air compressor

Recovery of exhaust steam from boiling
Recovery of waste heat from pre-whirlpool tank wort
Recovery of waste heat from post-whirlpool tank wort
Recovery of waste heat from chiller refrigerant
compressor
Recovery of waste heat from compressed air

Carbon dioxide
compressor
Barrel-fillingmachineBoilerRecovery of waste heat from compressed carbon
dioxideRecovery of waste heat from high-temperature waste
water generated by the barrel interior washing process
Recovery of waste heat from exhaust gas

Comment

If Factory A pursues the production of hot water recovery from waste heat, it isbelieved that it will become more important to ascertain the volume of hot waterproduced and used, as like Japanese beer factories. A flowchart outlining current
processes at Factory A and a table of sites at which waste heat is typically recovered
are presented above:(v) Energy consumption analysis for the factory by energy intensity
At beer factories as well as other factories that use large amounts of energy in Japan,
focus is placed on energy management in the context of factory operations. However,
it is a fact that priority is typically directed at increasing production volumes atoverseas beer factories - in particular, at beer factories in countries in which
production volumes have been increasing dramatically in recent years - and thatinterest in factory productivity and energy conservation is significantly low on thepart of factory managers to factory workers working on the frontlines of the
production.
In commencing this section, we started the lecture by first confirming its importance.
We then collected data corresponding to the last three years, produced a table, andcreated graphs. We also lectured that significant amount of information can beacquired from graphs by referring to other cases. Trends of performance data of
Factory A differed considerably from typical patterns. While the causes of thesedifferences were not ascertained, it was clear that many points should be improved.
We explained that useful information for improving the efficiency of energy usage
can be derived from the following: the bellow graph of the relationship between
annual production volume and specific steam consumption in Factory A indicatesthat the linear lines for three recent years - 2007, 2008, and 2009 - are drawn as if
they can be reconciled into a single line; a highly precise figure for the expected18

volume of energy use can also be obtained when estimating expected energy use by
the factory by using this graph; and one can assume, where these lines deviate fromlines of other years, that there have been 4M (men, machines, materials, andmethods) changes in factory equipment or production processes.
Graph - 1: Intensity of water and electricity consumption
Specific Water Consumption

Spesific Electrical Power Consumption
2007
250.0

S p e c ific E le ctr ica l P o w e r
C o n su m p tio n ( kW h /k L )S p e c ific W a te r
C o n s u m p tio n ( m 3 /k L )12.00010.000

2008

200.0

8.000

2007

6.000

2008

4.000

2009

150.0

2009

100.0

2.000

50.0

0.000

0.0
Jan Feb Mar

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Apr

May JunJul

Aug Sep

Oct

Nov Dec

month

month

Graph - 2: Relationship between annual production volume and intensity of steam
consumption
07 08 09 SSC/PrVlm
07SSC/PrVlm

1000.008SSC/PrVlm

S p e c ific S te a m C o n s u m p tio n (t/k L )900.0

y = -0.0259x + 903.19

800.0

09SSC/PrVlm

700.0line 07SSC/PrVlm

600.0line 08SSC/PrVlm

y = -0.0439x + 867.9

500.0

y = -0.0508x + 980.94

400.0

line 09SSC/PrVlm

300.0
200.0
100.0
0.0

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

Production Volume(kL)Specific consumption for this factory is trending upwards on a year-on-year basis.
This suggests that efficiency of production is declining due to some factor, alongwith increase of production volume. We reiterated that efforts to improve energy
efficiency can be made by re-checking 4M changes in factory equipment or

19

production processes as implemented over the course of the last three years as statedabove.
7) Introducing advanced equipment and systems(i) Mechanical Vapor re-compression system (VRC)
In this system, exhaust steam discharged from a wort kettle is recovered by ascrubber, and then compressed by a compressor and ejector, and re-used as heatedsteam. The amount of steam required for boiling can be reduced to less than half ofthe existing system.
* This system was developed for energy saving with the aid fromJapanese Government
Saving steam byreusing thedischarged steam
Existing system

New VRC system
Energy Storage Tank Vapor scrubber

Discharged steam
has great energy!

85oC

80~85oC

99oC

Exhaust steam

Exhaust
steam
80oC
99oC
Wort
KettleWolt fromMash filter

80oC

Wort Pre-heater

WK

Mechanical
Vapor
Recompressor

100oC
Wort
Kettle

Motor

WK

96oC

Electricity

78 C
o

78oC

Live steam

Wolt from
Lauter Tun

ThermoLive steam
Compressor
Boiler Room(ii) System for reducing carbon dioxide with a nitrogen generator
By introducing a nitrogen generator and replacing carbon dioxide with generated
nitrogen at sites where carbon dioxide is used, the consumption of energy used for
purifying carbon dioxide is reduced.
Sites at which carbon dioxide can be replaced by nitrogen gas
Tank
Pressure/ MPa
Gas Flow m3/h
Storage tank
0.50
500
Forafnaharaf tank
0.15
200
Bright beer tank
0.15
300
Gas-water tank
0.05a
300
Filtration cushion tank
0.15200(iii) Co-generation system that uses biogas generated by the anaerobic treatment of20

waste water:<Procedure>- Selection of high-concentration waste water discharged from the feeding process
and introduction them into anaerobic treatment equipment;- Anaerobic treatment of high-concentration waste water;- Desulfurization of generated biogas;- Use of biogas as boiler fuel;<In an area where natural gas can be supplied>
A gas mixture of natural gas and biogas can be used as fuel to operate a
co-generation system.
Desulphurization system
Bio Gas1000mmAq
H2S density:
10 ppmH2S density:
150 ppmto Boiler

H2S density:
1500 ppm
CH4 Emission
rate:
6000 Nm3／day

Nutrient

Air
Bio Gasfrom Reactor

Microbial type
Desulphurizationequipment

Dry type
Desulphurization
facility(4) Comments
While the trainees pursued their tasks with enthusiasm, there were few questions
about critical points. Although a beer factory was chosen as an OJT site, most of theparticipants were unfamiliar with the sort of sequential processes such as production
and shipping of beer. For this reason, the audit activities were apparently not easy tocomprehend. Cambodian industry primarily consists of such examples of lightmanufacturing as apparel and shoe manufacturing, such that even the employees ofFactory A possessed a poor grasp of the basic knowledge required for energy
management. Accordingly, our experts endeavored to provide guidance by revisiting
the basics such as energy management and energy conservation measures. After thecompletion of training, many of the trainees indicated that they obtained useful21

information and knowledge pertaining to energy conservation that they wished to put
into practice in their own factories. While there may be doubts, we hope that energy
conservation would be disseminated at more factories in the future.
3. Seminar and workshop(1) Time and place
September 14, 2010 (08:30 to 17:00)
Ballroom, Sokha Beach Hotel(2) Participants: 37 persons
Seminar participants consisted of 37 persons, including members of ECCJ and ACE
and officials belonging to MIME and other Cambodian government bodies. In addition
to the participants of the OJT program held over the preceding week, more than 10
persons from the local province of Sihanouk were in attendance. Speakers were also
invited from Malaysia and Indonesia. All sorts of programs were organized for thisevent (the theme of global environmental protection awareness was included from thisyear), which continued enthusiastically until around 17:30. The outline of the seminaris described below.
To launch the seminar, opening addresses were given by vice-director Mr. Vuthy, Mr.
Shibuya, and Mr. Zamora on behalf of the Cambodian government, ECCJ and ACE.
Outlines of presentations given by each seminar presenter are as stated below.
(3) Presentation outlines
SESSION I: Policies, Programs, and Initiatives on EE&C
(i) Outline and Achievements of PROMEEC Project:
Mr. Zamora of ACE introduced the following as elements of the PROMEEC Project:- The overall outline of the ASEAN Plan of Action for Energy Cooperation / APAEC
2010-2015;- Energy Efficiency and Conservation, positioned as number 4 program: The goal isto achieve an 8% reduction in energy intensity by 2015, with 2005 as the baseyear; etc.;- Past record of PROMEEC activities: Compilation of achievements of activities
from the first year, 2000 to the latest year.
(ii) Realized Activities/Outstanding Improvements through PROMEEC Project
Mr. Vuthy, Cambodia FP, presented the following as the results of the PROMEEC
Project in Cambodia and other matters:22

- Outline of electrical power in Cambodia: Power generation capacity of EDC/
Electricity of Cambodia in 2008 was 210 MW; estimated to reach 3,045 MW in
2024. EDC electricity charges range from 9 to 25 US cents (between 40 and 80
US cents in the provinces);- Demand for electrical power in Cambodia: if electrical power demand is forecasted
highly, demand in 2024 would be six times as great as in 2010;- Outline of Cambodia’s energy policies;- Support for energy conservation initiatives by countries and institutions;- Past record of PROMEEC activities in Cambodia(iii) Japan’s EC Policy and Measures and EE&C Experiences in Industries
ECCJ’s Mr. Shibuya presented Japanese energy conservation policies, measures andexperiences in industry as follows:- Energy use performance trends in Japan and comparisons with other countries by
each sector;- Background of energy conservation policies of Japan;- Approach and case studies of Japanese companies regarding energy conservation;- Introduction of JASE-World, etc.;
SESSION II: EE&C Best Practices in Industries(iv) EE&C of unequal Compressors in DX - Active Heat-pipe and Intertwined Coil in
Air Conditioning Unit
Mr. John Budi H. Listijono from Indonesia presented the following as part of a 2007
ASEAN Energy Award for “Energy conservation achieved by way of the installationof large and small compressors for heat pipe-using air-conditioning units”:- System using heat pipes designed for DX (an abbreviation for “direct expansion”)
air-conditioning units;- Adjustments carried out using two large and small air compressors.
(v) EE&C of Chiller Energy Management System
Malaysia’s Mr. Thirumalaichelvam Subramaniam presented the following as part ofa 2009 ASEAN Energy Award for “Energy conservation achieved by energy
management for chillers”:- A centrally regulated air-conditioning system consisting of various types of sensors,data collection at 10-second intervals, software for control, and more;- Savings achieved through the introduction of this system.
(vi) EE&C Best Practices in Japanese Brewery
Dispatched instructor Mr. Kawasaki introduced energy conservation case studies ofJapanese beer industry as follows:23

- Business environment of the beer sector;- Changes in specific consumption at Japanese beer factories;- Energy conservation and utility consumption ratios at beer factories;- Application of VRC and other new technologies to beer factories.
(vii) Audit Results and Recommendations
Local team leader Mr. TY Puthy of Factory A presented a report on the results of the
Audits performed on utility and process equipments.
SESSION III: The Way Forward(viii) EE&C Measures for Industries
Dispatched instructor Mr. Kawasaki briefed energy conservation measures on thefood products industry in general:- Specifically, heat recovery from dry exhaust gas at milk factories, heat recovery
from tunnel-drying exhaust gas at candy- manufacturing factories, adjusting room
temperature at meat factories, and more.
(ix) Development of Technical Directory, In-house Database and Online Energy
Information System: ACE’s Mr. Junianto introduced matters relating to ASEAN’s
technical directories (TD), in-house databases (IHD), and online energy information
system.
SESSION IV: Environmental Awareness and Financing(x) Situation of Environmental Awareness in Cambodia
Mr. Vuthy briefed the following terms of environmental awareness in Cambodia:- While it is possible to generate 10,000MW electricity by hydraulic power asrecyclable energy, no more than 20MW of electricity is currently generated;- Education and training for environmental issues and increase in awareness ofgeneral public are necessary;- Environmental issues in Cambodia are affected by impediments for awareness,finance and systems.
(xi) Situation of Environmental Awareness and Financial Support System in Japan
ECCJ’s Mr. Shibuya presented about environmental awareness and financial support
systems in Japan.
(xii) Financing Opportunities and Schemes in the ASEAN region
ACE’s Mr. Junianto introduced financial support systems in the ASEAN region24(4) Comments
With a large number of presentations given and not enough time to properly explain
their contents, some participants were likely not able to adequately comprehend thesepresentations. For this reason perhaps, there were no questions about energy
conservation during the Q&A session; a professor from BB University asked twoenvironment-related questions: (i) regarding the ozone hole and the ban on the use ofrefrigerants (such as R-22) and (ii) regarding the global warming issue. It seems
necessary to decrease the number of presentations or lessen the contents ofpresentations.

Photo of completion of OJT for Audits

Measurements of temperature of
low-temperature pipes

Seminar and workshop stage

Seminar and workshop venue

Attachments (not attached)
I: Audit- 1: Audit groupings- 2: Audit Results for Utility Units in Cambrew- 3: Audit Report on Process Units in Cambrew
II: Seminar and workshop-1: Outline and Achievements of PROMEEC Project25

- 2: Realized Activities/Outstanding Improvements through PROMEEC Project- 3 : Japan’s EC Policy and Measures and EE&C Experiences in Industries- 4: Using unequal Compressors in DX - Active heat-pipe system and Intertwined coilcan maintain the comfort condition during full load and partial load and save up
to 40% of operation cost
- 5: Chiller Energy Management System- 6: Best Practices at Japanese Breweries- 7: Audit Results and Recommendations- 8: Overview of Energy Saving Technologies in Food Industry (General)- 9: Technical Directory for Major Industries and Buildings PROMEEC 2010-2011- 10: In-house Database for Building and Industry PROMEEC 2010-2011- 11: Online Energy Information System PROMEEC 2010-2011- 12: Situation of Environmental Awareness in Cambodia- 13: Environmental Awareness and Financial Support System in Japan- 14: Financing Support System in ASEAN
III: Materials of lecture- 1: Energy Conservation Technologies in Utility Factories- 2: Energy Conservation in Industrial Refrigeration

26

III. Lao PDR (food manufacture industry)
1. Overview of activities
In order to implement promotion of energy conservation in major industries of the
PROMEEC Project, we visited Pakse, Lao PDR from October 2 to 13, and carried out
OJT for Audits at a beer factory in the food manufacture industry and OJT for simplified
building audits, and held a seminar and workshop to exchange information with
officials from Laotian industry and ASEAN member countries. A total of 24 persons officials from the central government, 10 officials with regional governments, 5
industry officials, 4 experts from ECCJ, and 2 engineers from ACE - participated in
OJT for audits. The seminar and workshop was attended by a total of 43 persons,
including officials from ACE and ECCJ; these participants consisted of the persons
referred above and 19 additional persons representing local industries and otherinterests.
Dispatched experts:
Tsutomu Okamoto (Technical Cooperation Department); Taichiro Kawase,
Yukimitsu Sano (technical experts); Tsutomu Kawasaki (Mayekawa Mfg. Co.,
Ltd., dispatched instructor)
Schedule of activities:
Oct. 4 to 8: OJT – OJT of Audit and audit results report
Oct. 11: Seminar and workshop
At starting local activities, we paid a courtesy call on Mr. Bounthong Dyvixay, Ph.D.,
head of the Energy and Mine Department of Champasack Province (PDEM). The
purpose of this visit was stated by ECCJ’s Mr. Okamoto and a request was made forcooperation for PROMEEC industrial activities. The department head indicated thatelectrical transmission losses of 10% are sustained in Lao PDR and that he is awarethat energy conservation is important given the increasing demand for electrical powerin his country. In addition, ECCJ advised him to approach the Japanese embassy if the
support of Japan is required. We exchanged opinions, and suggested him to visit Japanand observe energy conservation activities and the highly efficient state of the country
on a firsthand basis.
2. OJT of Audits on Factory B(1) Participants: 24 persons (8 persons transferred to OJT for building-focused Audits
from the third day)27

Ministry of Energy and Mines / Department of Electricity (MEM/DOE): Threeparticipants (Mr. Bouathep Malaykham (local team leader), Mr.
Thammanonne Nakhavit, Mr. Viengsay Chantha)
Provincial Dept of Energy & Mines (PDEM): 4 participants (Mr. Khampasong
Keobandid, Mr. Paseuth keokhounmeung, Mr. Thouy Phetsavanh, Mr. Amkha
Sakhamdi)
Electricite Du Lao PDR (EDL): 6 participants (Mr. Khoonakhone Khinphoonsinh,
Mr. Khampasong Lattanaphone, Mr. Khamphanh Sosengdala, Mr. Sayanh
Bouphavanh, Mr. Phayvanh Manivong, Mr. Bounchiang Keovilayvanh)
Factory B: 4 participants (Mr. Kikeo Somesaway, Mr. Somphone Phonthachack,
Mr. Vongsavanh Syammala, Mr. Nivanxay Khosana)
Hotel C: One participant (Mr. Thouy Phetsavanh)
ACE: 2 participants (Mr. Junianto, Ms. Cindy Rianti)
ECCJ: 4 participants (Tsutomu Okamoto, Taichiro Kawase, Tsutomu Kawasaki,
Yukimitsu Sano)(2) Overview of the Factory B
Factory B possesses two boilers with a steam generation capacity of 8 tons per hourand steam pressure rated at 8 bars. Heavy Fuel oil is used for fuel and the ventilation
system is a forced draft system using combustion air fans. A mechanical compressortype cooling system uses ammonia as its coolant and four 116.4 kW reciprocal-type
compressors have been installed. Ammonia condensation is achieved with two
evaporative condensers while ammonia evaporation is fully achieved with the use ofplate-type heat exchangers. Glycol (PG) cooling and chilled water production are
thereby undertaken.
(3) Audit overview
1) Composition of audit team
The Audit and OJT were conducted by splitting participants into a utility group and aprocess group. A leader and a note-taker were appointed by each group. A leader ofthe utility group was selected from participants while a staff at Factory B was
appointed as the leader of the process group. Although it is best to select every leader
from participants, we understand the difficulty for participants to comprehend theprocesses and accepted the selection.
2) Audit process
The audit was performed according to the following process: interview concerningenergy conservation activities at the factory in question; an inspection of factoryequipment, data collection, and analyses of measurements using measuring
28

instruments, operational logs, and other sources; formulation of energy conservation
measures; and reporting of audit results to factory officials. At each stage of the audit,
explanations of the significance of the work were given to participants, intermediate
data analysis was conducted, and explanations and instructions were given in regards
to the data analysis process. In order to thoroughly engage in explanations andinstructions on an interactive basis, explanations were given by gathering theparticipants together in front of a white board and participants themselves were madeto carry out and record measurements.
3) Measuring instruments
Measuring instruments as outlined in the following five points were brought in fromJapan and the usage and measurement methods of them were explained. For actual
measurements, our experts first showed how measurements were to be taken before
letting participants themselves take measurements and record the results thereof.
- Radiation thermometer (temperature measuring instrument) HiTESTER 3443
(manufactured by HIOKI E.E. CORPORATION)- Thermohygrometer HNCHNR (manufactured by Chino Corporation)- Digital oximetry for combustion management XP-3180-E (manufactured by New
Cosmos Electric Co., Ltd.)- Clamp tester (ammeter) 2343 04 (manufactured by Home-Yokogawa Meters &Instruments Corporation)- Contact-type thermometer (owned by expert Mr. Kawase)
4) Audit of utility facilities
The boiler house, cooling system and compressed air system constitute the mostimportant utility systems to be found in a beer factory were identified as targets of
OJT on EC Audit.
(i) Boiler- State of the boiler
Two boilers with a steam generation capacity of 8 tons per hour and steam pressure
rated at 8 bars have been installed. Under normal operations, the number 2 boiler isrunning and the number 1 boiler is on standby. In addition, these boilers are run withsteam pressure lowered to 6.5 bars for energy conservation. Heavy fuel oil firing
process is introduced for fuel and a heavy fuel oil heater is attached. The fuel oil
temperature in the burner is controlled at 80˚C. Fuel flow is controlled by acomputer on a cumulative basis each minute using an integrating meter. Feed water
into these boilers consists of mixture of advanced treated water (RO water) producedwith the use of a reverse osmosis membrane and degassed water obtained bydeaerating process-generated return condensate with a deaerator. The volume of
combustion air is automatically adjusted according to mechanical links with the fuel29

flow. The valve position indicator corresponding to the volume of combustion air
was set to approximately 40%. At this time, the boiler load was low at a little lessthan 3 tons per hour compared to the rated load of 8 tons per hour. The ventilation
system is a forced draft system by combustion air fans. An exhaust funnel extends
for 25 meters from the exhaust side of the boiler and is at slightly positive pressure at
the boiler outlet. No air pre-heater or economizer has been installed. No gas exhaust
duct damper could be checked.
- Reducing heat loss from exhaust gas
The temperature of the exhaust gas and the concentration of oxygen in the exhaustgas were measured in order to ascertain the extent of the loss of exhaust gas. The
temperature of the exhaust gas was between 180˚C to 220˚C according to theexhaust gas thermometer installed onto these boilers. The concentration of oxygen
was between 6.1% and 7.9% in line with the temperature of the exhaust gas based on
measurements taken with an oxygen concentration analyzer. This fluctuation
indicates that these boilers function in a manner that reflects changes in the volumeof steam consumption of processes caused by replacing the feed batch. If the average
concentration of oxygen is 7%, the air ratio will be 1.5. As the average temperatureof the exhaust gas is 200˚C, the amount of exhaust gas loss is approximately 9%.
The temperature of exhaust gas should be between 180˚C and 220˚C and theconcentration of oxygen should be between 3.5% and 5.0% for small-sized boilers.
Accordingly, boiler number 2 at Factory B satisfies Japanese standards for thetemperature of exhaust gas but does not satisfy said standards for the concentrationof oxygen. Thus, there is room, from the standpoint of energy conservation, forlowering the concentration of oxygen (or the air ratio). If we suppose theconcentration of oxygen could be reduced by 5%, the amount of heat loss fromexhaust gas would be reduced by approximately 7%. In other words, boiler
efficiency would be ameliorated by 9–7 =2%. Upon visually examining the smoke
being emitted from the exhaust gas stacks of these boilers, no black smoke wasobserved at all. The flame was also a whitish-orange color; no dark-red color
indicating incomplete combustion was observed.
- Measuring heat loss from the surface of boilers
The surface temperature of boilers was measured and the volume of heat loss wasestimated according to a formula for calculating heat dissipation. The surface
temperature was measured using both a contact-type thermometer and a radiation
thermometer. The values obtained using both thermometers differed by no more thanapproximately 2˚C from one another, thereby indicating that they were in favorable
agreement. The data obtained using the contact-type thermometer are as follows:30

Measuring Point
Front burner side
Rear exhaust funnel side
Rear cylinder part
Total

Boiler surface temperature (˚C)
68 (avg. of 3 sites; area of 4.2m2)
52 (avg. of 3 sites; area of 4.2m2)
36 (avg. of 6 sites; area of 39.7m2)

Heat loss (kcal/h)
1,931
938
2,249
5,118

Total heat loss equals approximately 0.7% of the heat generated by the combustionof the fuel. For regular boilers it is normally between 1 and 2%, so heat loss of theseboilers can be described relatively low. This is because the average surface
temperature for these boilers, at 40˚C, is low compared to regular boilers, whose
average surface temperature is 60˚C. At the same time, these boilers satisfy theenergy conservation standards of the Energy Conservation Law in Japan, which sets
the surface temperature at no higher than between 70 and 80˚C. Based on the above
data, it can be determined that there is no need for additional thermal insulation.
- Measuring the condensate recovery rate
A quantitative estimate was made of the extent of clean condensate returning to theboiler house. An estimate can be made by confirming the thermal balance of thewater that enters and leaves the boiler feed tank; the condensate recovery rate wasestimated to be 61%. The recovery rate at Japanese beer factories is between
approximately 50 and 70 %; this factory was within this range.
- Evaluating the thermal performance of boilers
We estimated boiler efficiency by indirect method to equal 90.1%. However, whilethese two-year-old boilers are late-model units, this high level of efficiency is
unrealistic considering the fact that no economizer or air pre-heater has been
installed. While the calorific value of heavy fuel oil was assumed 10,000kcal/kg, theactual calorific value is possibly a little less. It will be necessary to recalculate boiler
efficiency using the correct value.
- Insulation inspection for the steam piping system
We inspected the thermal insulation of the steam piping system. The thermal
insulation was favorable in the boiler room, feed room and packaging room. Valves,
flanges and headers were insulated. No leaks were observed from the steam traps.
This fact could be expected as these boilers started operation only two years ago.
(ii) Refrigeration system- State of the refrigeration system
At this factory, an ammonia refrigerant-based mechanical compression-type31

refrigeration system has been installed, with compressors consisting of four 116.4
kW reciprocal-type units. Ammonia condensation is achieved with the use of two
evaporative condensers while ammonia evaporation is achieved with the use ofplate-type heat exchangers. Glycol (PG) cooling and chilled water production are
thereby undertaken.
- Evaluating the performance of evaporative condensers
The performance of evaporative condensers is evaluated to which extent thecondensation temperature of ammonia approaches the wet-bulb temperature of theambient air. The difference between the condensation temperature of ammonia andthe wet-bulb temperature is referred to as the temperature approach. While thedesigned value of the temperature approach varies slightly depending on the
manufacturer, it is approximately equal to 8˚C. Where a shell-and-tube condenser isused, the temperature approach is approximately equal to 13˚C. The temperatureapproach for this factory was equal to 28.9 – 24.8 = 4.1˚C. Accordingly, we canconclude that the evaporative condensers in use here are performing at a satisfactory
level.
- We observed non-insulated low-temperature pipe sections made from stainless steel
for which insulation needs to be enforced.
(iii) Compressed air system- State of the operations of air compressors
Three 55 kW screw compressors, oil-free two-stage screw type for the production offoodstuff, have been adopted. Their discharge pressure is rated at 8.0 bars and theirflow rate is rated at 7.2 m3/min.. In line with the current state of low operations, one
air compressor is being utilized, one air compressor is on standby, and one aircompressor is maintained as backup.
- Energy conservation by reducing the discharge pressure
The pressure drop from the compressor room to the terminal process is typicallydesigned to be no more than 0.5 bars. In the case of this factory, it is estimated that
there are 200 meters of piping extending from the compressor room to the terminal
process. At this distance, it is presumed that the pressure drop will not exceed 0.5
bars. The current discharge pressure is average 7.0 bars; if this were to be reduced to
5.0 bars, it is estimated that a 17% energy conservation effect would be achieved.
- Evaluating the performance of a cooling tower to cool compressed air
These air compressors utilize chilled water to cool their piston cylinders. A forced
draft tower is employed for this cooling tower. The performance of this cooling
tower is evaluated by how much the temperature of the chilled water approaches the
wet-bulb temperature of the ambient air. The difference between the temperature ofchilled water and the wet-bulb temperature is referred to as the temperature approach.
32

While the designed value of the temperature approach varies slightly by
manufacturer, it is approximately between 5 and 5.5˚C. The temperature approachfor this factory was determined to equal 29.5 – 25.8 = 3.7˚C. Accordingly, we canconclude that the cooling tower in use here is performing at a satisfactory level.
5) Audit of process facilities- We decided to ascertain the energy usage by key process equipment and investigate
relevant improvement points, introduce advanced technologies of Japan, ascertain
the use of hot water as an important utility in beer factories and investigate relevant
improvement points, and provide guidance on methods of energy evaluation for thefactory as a whole by specific consumption.
- Wort cooler: While the wort cooler consists of a plate-type heat exchanger, it ispossible to raise the temperature of the raw materials and hot water on the outlet side
by either upgrading or increasing the number of plates in use.
- Beer cooler: Triple valves are installed on the P.G. side (coolant side) of the beercooler. Even though the P.G. temperature of the chiller outlet is -4˚C, the temperature
at the beer cooler inlet is -0.1˚C, such that beer cannot be adequately chilled. The
control method or equipments must be improved.
- Improvement points for thermal insulation
The room temperature in the areas around the bottle-washing machines andpasteurizer was relatively high compared with Japanese brewery factory. The central
area where the steam heater is installed was especially hot. Temperature
measurements revealed that the bottle-washing machines were 75˚C on their surfaces
and the pasteurizer was 65˚C on its surface. We advised that the thermal insulation
above section is effective both for improvement of work environment and energy
conservation. And we advised that heat dissipation could be reduced by cold
insulation on the low-temperature valves.
- Ascertaining the state of hot water usage and investigating improvement points
The state of hot water usage was exceedingly simple compared to other beer
factories. In addition, the volume of hot water used at each usage site had not been
ascertained. At Japanese beer factories, hot water is produced using waste heat at
many sites, such that it is difficult to ascertain the volume of hot water produced andused on an overall basis. There is a tendency for hot-water management at beer
factories to become more important as more energy conservation measures are
implemented. As hot-water production based on the use of waste heat at Factory B is
pursued, it is believed that the ascertainment of the volume of hot water produced
and used will become increasingly important as is the case at Japanese beer factories.

33

- Approach of energy analysis for the entire factory in terms of specific consumption
At Japanese beer factories as well as other factories that consume significant amountof energy, focus is placed on energy management for factory operations as well as
legal necessity. However, it is a fact that priority is typically directed at increasing
production volumes at overseas beer factories—in particular, at beer factories incountries in which production volumes have been increasing dramatically in recent
years—and that interest in factory productivity and energy conservation issignificantly low throughout factory managers to factory workers working on thefrontlines of the production process. In commencing this unit, we gave a lecture by
first recognizing its importance. We then collected data corresponding to the last
three years, produced a table, and created graphs.
Graph – 1: specific water consumption and specific electrical power consumption
Spesific Electrical Power Consumption

Specific Water Consumptio n
1.400
1.200
1.000
0.800
0.600

2008
2009
2010
2011
2012

0.400
0.200
0.000
Jan Feb Mar Apr May Jun

S p e c ific E le c tr ic a l P o w e r
C o n s u m p t io n ( k W h / k L )S p e c ific W a te r
C o n s u m p tio n ( m 3 /h l)

2008

35.0
30.0
25.0
20.0
15.0
10.0
5.0
0.0

2009
2010
2011
2012

Jan

Jul Aug Sep Oct Nov Dec

Feb

Mar

Apr

May

Jun

month

Jul

Aug

Sep

Oct

Nov

month

Graph – 2: annual production volume – relation of specific consumption as
referred to above
08SSC/PrVlm

07 08 09 10 11 SSC/PrVlm

09SSC/PrVlm

Specific Steam Consumption(t/kL)

120.0

10SSC/PrVlm
11SSC/PrVlm

100.0

12SSC/PrVlm

y = -0.0012x + 94.399
80.0

line 07SSC/PrVlm

y = -9E-05x + 50.158

line 08SSC/PrVlm

60.0line 09SSC/PrVlm

40.0line 10SSC/PrVlm

y = -0.0002x + 57.689

20.0

line 11SEC/PrVlm

0.0

0

10000

20000

30000

40000

50000

60000

Production Volume(hl)We also issued guidance on the significant amount of information that can beobtained from graphs while referring to other cases. Trends that differedconsiderably from typical patterns were identified by performance data
corresponding to Factory B.
34

Dec

While the causes of these differences were not ascertained, it was clear that there aremany points that should be improved.
We explained that useful information for improving the efficiency of energy usage
can be derived from the following: the above graph of the relationship between
yearly production volume and specific steam consumption in Factory B indicatesthat the linear lines for three recent years—2008, 2009, and 2010—are almost drawn
as if they can be reconciled into a single line; operation of this factory started in
2008, and this graph suggests that equipment and systems were not at a complete
level and operators were unfamiliar with operations in the first year; a highly precise
figure for the expected volume of energy use can also be obtained for expectedenergy use by the factory by using this graph; when a line differs from lines drawn
for other years, there might have been 4M (men, machines, materials, and methods)
changes in factory equipment or production processes.
The linear approximations for 2009 and 2010 for this factory are virtually
overlapping, indicating that the factory has stabilized. From the standpoint of energy
conservation, however, the fact that various improvements have not yet been
implemented is also indicated at the same time.
- Introducing advanced equipment and systems
We introduced three systems: a mechanical vapor re-compression system (VRC), a
system to reduce carbon dioxide by using nitrogen-generating equipment; and aco-generation system that uses biogas generated by the anaerobic treatment ofwastewater. See the contents of introduction prepared for audit of Factory A for more
information.
(4) Comments
While a beer factory was selected as a site for OJT of Audit, most participants, as likethe foregoing PROMEEC industrial OJT held in Cambodia, appeared to find it difficult
to understand the audit activities, as they were unfamiliar with such sequential
processes as those involved in producing and shipping beer. The employees of Factory
B also possessed a poor grasp of the basic knowledge required for energy management.
Accordingly, our experts endeavored to provide guidance by revisiting the basics ofenergy management and energy conservation measures. We emphasized that thisactivity is OJT for Audit, and had participants take measurements, collect and analyze
data, and prepare the Audit report by themselves as much as possible and instructed
them to submit the report to the factory and make relevant presentations at our seminar.
For the purpose of developing human resources, we utilized materials appropriately
prepared in accordance with audit contents, delivered lectures on audit technologies,
and introduced five types of measuring instruments and provided instructions on their35

practical application. While these technical lectures and measurement practice are newexperiences and difficult to grasp the content for a majority of the participants, there is
no doubt that the first step towards the development of human resources for thepromotion of energy conservation was taken.

3. OJT for simplified Audit of building (Hotel C)
Experts for building Audit arrived at this location on October 6 and were expected tostart OJT activities for Audits of buildings, but the audit site had not yet been
determined as of 9:30 the previous morning. However, the consent was subsequently
obtained from the chief manager of Hotel C, at which they were staying, to have thehotel itself undergo OJT for Audits. Thus, it was determined at the last minute that OJT
activities for Audits on buildings could be conducted. From 14:00 on October 5,
director-general Mr. Bouathep and ECCJ’s Mr. Okamoto went to the hotel and spokewith Mr. Thouy Phetsavanh, the chief manager of the hotel. They outlined the OJT
activities for Audits on buildings to be carried out from the afternoon of the following
day (October 6), requested his cooperation, and extended an invitation to participate ina seminar.
(1) Participants: 8 persons
MEM/DOE (1 person), PDEM (1 person), EDL (2 persons), Hotel C (1 person),ACE (1 person), ECCJ (2 persons)(2) Building overview: Hotel C- History of the Hotel: Construction on this building commenced in the central part of
the Pakse District to serve as the palace of Jao Ma Ha Chee Vit, who was king at thetime. The structure was completed in 1969 and enabled to accommodate by 1975.
However, due to changes in political circumstances, the king fled to France and thebuilding was left used for a long period, not used as a palace. While this building
subsequently operated as a hotel for a decade beginning in 1994 thanks to Thai
capital, the business was abandoned due to a failure to maintain profitability. The
building was renovated to be used as a hotel, using Laotian capital, for two years
from 2003. Between 2005 and 2008, the hotel operated partially while renovation
work continued. This work was completed in 2008, and the hotel started operations.
- Scale: 15,514 m2 total floor area; 115 guest rooms; 5,251 m2 air-conditioned area;
first through fifth floors used as guest rooms; fourth floor used as special room; sixth
floor used as circular conference room; annex house 40 rooms, 2-storied.
- Key facilities:
Overview of air-conditioning system / air-conditioners for guest rooms: 18 kBTU x
36

48 units; 12 kBTU x 95 units (package-type air-conditioners); conference room
(sixth floor): 100,000 BTU x 2 units; first-floor multipurpose room: 50,000 BTU x 2units.
Overview of electrical system / 220 V incoming power; 50 Hz; no transformer.
Feed water and drainage system / lift pump: 4.5 kW x 1 unit.
Overview of elevators: elevator: 10 kW x 1 unit; 7 kW x 1 unit.
- Overview of energy consumption: annual electrical power consumption (2009)
398,640 kWh- Unit cost of electricity: 835 kip/kWh (0.1 USD/kWh, @ 1 USD = 8,080 Kip)
(3) Overview of simplified audit
This hotel differs significantly from modern hotels in use of natural ventilation, theinstallation of localized air conditioners and the use of electrical heaters for supplying
hot water to each room and block. A natural energy supply is used for the boilers
through the burning of firewood, which limits the items of Audit. In this context,
investigative matters were summarized into twelve items as based on daytime andnighttime surveys; discussions were carried out with participants with respect toadditional surveys and measures. Five improvement points were identified as follows:
1) reducing nighttime lighting in the garden, on walls, along the parapet, and along
passageways; 2) reducing night-time lighting at the reception desk; 3) having thefirst-floor washroom lights turn on and off through the use of sensors; 4) using LED
lighting; 5) shutting down one of the two elevators after 22:00 every night.

4. Seminar and workshop(1) Time and place
October 11, 2010 (09:00 to 17:00)
1F Hall of the Champasak Palace Hotel(2) Participants: 49 persons(3) Presentation outlines
On behalf of the Laotian government, Mr. Bounsoy Chit PSAONG, Deputy Director
Cabinet of Champasak Province, delivered the opening address.
SESSION I: Policies, Programs and Initiatives on EE&C
(i) Outline and Achievements of PROMEEC Project: PROMEEC Project was
introduced (Ms. Cindy, ACE)(ii) Realized Activities/Outstanding Improvements through PROMEEC Projects:
37

PROMEEC Project results attained in Lao PDR (director-general Mr. Bouathep,FP)(iii) Japan’s Energy Conservation Policy and Measures and EE&C Experiences inIndustries (Mr. Okamoto)
SESSION II: EE&C Best Practices in Buildings and Industries(iv) 2010 ASEAN Energy Award for “tropical zone buildings division: ANA
MANDARA Villa: Dalat Resorts and Spa” (Ms. Nougat, Vietnam)(v) Presentation of a 2009 ASEAN Energy Award for “Thai Cold Rolled Steel Sheet
Public Co., Ltd. as a case study of improvement” (Mr. Manop, Thailand)(vi) Demand management in Lao PDR (Mr. Khoonakhone, EDL)(vii) Case studies of energy conservation in the Japanese beer industry (Mr.
Kawasaki)(viii) Audit results (a: process / Mr. Somphone; b: service equipment / Mr. Nivanxay,
Beerlao; 3. Mr. Sayanh of EDL/DSM)SESSION III: The Way Forward(ix) Energy conservation measures for service equipment (Mr. Kawase)(x) Energy management of buildings (Mr. Sano)(xi) Introduction of ASEAN’s technical directories, databases, and online energy
information system (ACE’s Mr. Junianto)(xii) Environmental awareness and financial support system in Japan (Mr. Okamoto)(xiii) Financial support system in the ASEAN region (ACE’s Mr. Junianto)(4) Comments
As like the seminar and workshop of Cambodia, participants were likely not able tocomprehend adequately the contents of presentations due to the presentations andshortage of time. Since the Q&A session was omitted on account of a lack of time as
explained by the moderator, these presentations were concluded on a non-interactive
basis. It seems necessary to decrease the number of presentations or lessen the contents
of presentations.
Given the large number of programs and the fact that there was interpretation
between Laotian and English throughout the program, the time for each presentation
was insufficient. For this reason, no question time could be scheduled for each session;
instead, we set a Q&A session after the conclusion of all presentations. However, there
was no time left to accept any questions at all. We feel that the Secretariat will need toreconsider the number of presentations and time schedule for presentations inorganizing such events in the future.

38

Participants in the OJT Audits forfactories

Hotel for building audit and venue forseminar session

Opening address at Seminar andworkshop

Photo of seminar andworkshop

Attachments (not attached)
I Audit-related materials- 1: Energy Conservation Technologies in Utility Factories- 2: EXCEL Sheet for Engineering Calculations- 3: Energy Conservation in Industrial Refrigeration- 4: Audit Data Sheets for Utility Factories- 5: Audit Results for LBC Champasak Factory (Utility)- 6: Best Practice in Japanese Brewery- 7: Audit Result for Process Units at Lao Brewery in Champasack Province- 8: Process Measure Item
- 9: Existing Hot water & Wort flow st Brewing for Lao brewery in Pakse- 10: Existing & New Beer flow in Lao Brewery at Pakse- 11: Energy Data Table & Graph.
II Seminar-related materials- 1: Outline and Achievements of PROMEEC Project- 2: Realized Activities/Outstanding Improvements through PROMEEC Projects
39- 3: Japan’s Energy Conservation Policy and Measures and EE&C Experiences inIndustries- 4: Ana Mandara Villas Dalat of Vietnam- 5: Thai Cold Rolled Steel Sheet Public Co., Ltd.
- 6: Demand Side Management- 7: EE&C Best Practices in Japan- 8: Audit Results and Recommendations（a/ Process, b/ Utility, c/ Building）- 9: Energy Conservation Technologies in Utility Factories- 10: Energy Management for Building- 11: In-house Database for Building and Industry PROMEEC 2010–2011- 12: Technical Directories for Major Industries and Buildings PROMEEC 2010–2011- 13: Online Energy Information System PROMEEC 2010–2011- 14: Environmental Awareness and Financial Support System in Japan- 15: Available Financing Windows in ASEAN

40

IV. Thailand (textile industry)
1. Overview of activities
In order to implement the Project for the Promotion of Energy Conservation in Major
Industries as the third PROMEEC project this year, we visited Bangkok, Thailand from
November 21 to 30, and carried out OJT for Audits at a textile factory and held aseminar and workshop to exchange information with officials from Thai industry and
ASEAN member countries. A total of 19 persons - 7 officials from the central
government, 2 officials from institutions related with energy conservation, 5 officials
from the textile factory in question, 3 experts from ECCJ, and 2 engineers from ACE participated in OJT for audits. A seminar and workshop was attended by a total of 65
persons, including officials from ACE and ECCJ; these participants consisted of thepersons referred above and 46 additional persons, including governmental officials andlocal industry representatives.
Dispatched officials: Tsutomu Okamoto (Technical Cooperation Department);
Akira Nakatsu, Kokichi Takeda (technical experts)
Schedule of activities:
Nov. 22 to 26: OJT for audits and audit results reportNov. 29: Seminar and workshop
2. OJT of Audits on Factory D(1) Participants: 19 persons
Ministry of Energy / Department of Alternative Energy Development and Efficiency(DEDE): 7 participants (Mr. Sarat Prakobchat, Mr. Sayam Machima, Mr.
Pramote Pintong, Mr. Piriya Klaikaew, Mr. Sittipol Kwangnok, Mr. Pitcha
Suthigul, Mr. Peanut Prajakwong)
Energy Saving Consultation Center (ESCC): 1 participant (Mr. Nopporn
Watanachai)
Factory D: 5 participants (Mr. Pisit Meesa-Ard, Mr. Pirat Joypan, Mr. Thanasate
Thanaraweewan, Mr. Yongyut Suriyapananon, Mr. Somchai Onprew)
Measuretronics Ltd.: 1 participant (Mr. Jedsada Kulvisarut)
ACE: 2 participants (Mr. Junianto M, Mr. Chanatip Suksai)
ECCJ: 3 participants (Tsutomu Okamoto, Akira Nakatsu, Kokichi Takeda)(2) Overview of the factory
Factory D, a textiles factory of Company E was established in 1976, located in the41suburb of Bangkok, produces textile for export primarily to Western countries, andannual sales is 30 million USD. With 2,200 employees, it possesses fabric cutting
machines and various types of sewing machines and irons as well as service
equipment consisting of 1 ton/hr small boilers, air conditioners, and air compressors.
Electricity (2.5 MWh/yr) and LPG (100 tons/yr) are consumed as energy sources.
The unit cost of electricity equals 3.93 B/kWh/h = 11.8 yen/kWh (@ 3 yen/B) while
the unit cost of LPG equals 17.9 B/kg-LPG =53.7yen/kg-LPG (@3yen/B). Energy
costs represent 1.2 %t of sales.
(3) OJT of Audits for Factory D
1) Equipment and systems of audit and audit groupings
While there were few types of equipment in use as noted above, the equipment andsystems of audit were divided into three groups; the trainees were likewise divided
into three groups and the tasks of leaders and each member were determined.
Group 1: cooling towers and air-conditioning system
Group 2: compressors and lighting
Group 3: boilers, steam pipe system, and more
2) Overall energy management at the factory- The adoption of efficient, energy-conserving equipment is somewhat lacking.
- No thermal insulation has been applied to valves or flanges; thermal insulation has
not been thoroughly applied.
- Maintenance and daily management of equipment is somewhat lacking.
- Drawings, specifications, and materials are insufficiently developed.
- Data colleting, record keeping, analyses, and more are also somewhat lacking.
- Energy consumption as a percentage of total sales is low (approximately 1% level),such that no concerns could be perceived.
3) Audit of equipment(i) Cooling towers: Since the cooling fans and circulation pumps were both rotating on
a constant basis, we introduced a rotation control system. Since the perforated plates
and netting used for gas rectification and straining purposes were detached from all
cooling towers (4 in total), water droplets were found to be drifting. We
recommended to locate perforated plates and netting properly.
(ii) Air conditioning of all rooms (totaling 30 in number) in which cutting, sewing, andironing are undertaken: As there were some uninsulated steam pipes in the room, wesuggested that thermal insulation be applied immediately. Since the temperature is
set to 24±1˚C, some places in the rooms were too cold; for this reason, we advised toraise the temperature by 1˚C. We additionally recommended insulating the steam
pipes used for ironing in order to lower the heat dissipation. Since the heat42

dissipation from lights also results in room temperature rise, we suggested that theselights be replaced by high-efficiency type.
(iii) Air-compressors:- This factory possesses two air compressors, one of which is constantly in operation.
The number 1 unit normally operates, while the number 2 unit only operates on
extended shifts or holidays, such that its running time is short. Accordingly, only the
number 1 unit was selected for audit. The control system used with this unit is theloading/unloading control system. The configured load/unload pressure levels are
0.6[Mpa] and 0.75[MPa], respectively, and are controlled by discharge pressure.
Manufactured in 2007, the number 1 unit is new but does not utilize an inverter.
- Measuring the unloading rate for the number 1 unit
For time-series data measurements, highly valid and essential power monitors wereused. However, as there was little time for data analysis, we obtained an unloading
rate by using data for only one hour extracted from the total measurement data.
Consequently, the unloading rate was found to equal approximately 23%, whichindicates that significant unloading losses are generated. Furthermore, compressors
operate by repeatedly loading and unloading on a frequent basis (approximately 15
times an hour), which suggests that the capacity of air compressors exceeds thevolume of consumed air.
- Reducing unloading loss by reducing the capacity of the number 1 unit
As air consumption is unknown, we estimate that it equals 6.93 [m3/min.] based on
measurement data; this value equals approximately 84% (6.93/8.21) of the rated flow.
Accordingly, we estimated the energy conservation effects of replacing the 55 kW
unit with a 45 kW unit, which fulfills the standard specifications of air compressors.
As a result, we determined that a reduction of 17,490[kWh/y], or 11%, is possible.
- Reducing unloading loss by introducing an inverter
The average load is currently 42.4 kW; the corresponding amount of electrical power
consumed by inverters is estimated approximately 54% (rated 100%). The energy
conservation effect in this case is 58,080 [kWh/y], or 36%.
- Decreasing the discharge pressure (by 0.075 MPa) by introducing an inverter
By introducing an inverter and setting the discharge pressure to 0.6 [MPa], it ispossible to reduce the pressure to below the current average pressure of 0.675 [MPa]when loading. The energy conservation effect in this case is 9,095 [kWh/y], or 6.5%.
- Decreasing the discharge pressure (by 0.0375 MPa) by installing more receiver tanks
The precondition is changing the current unloading pressure setting from 0.75 [MPa]to 0.675 [MPa] to diminish the pressure fluctuation by half. If we assume that thecurrent loading and unloading times were to be maintained despite diminishing thepressure fluctuation, the receiver tank would need to be enlarged by 3m3. The energy
43conservation effect in this case would be 4,477 [kWh/y], or 3.2%.
- Reducing air leaks (by 10%)
We measured the rate of air leaks during the lunch break when the system is atstand-by mode, and surveyed air leaking sites at each location with an air leakchecker (UL-102R as made by CTRL Systems). Pressure was measured by referringto the pressure gauge on the receiver tank and time was taken by using a stop watch.
This process revealed that the rate of air leaks was approximately 21% and that there
were many sites where air is leaking.
- Suspending the use of ventilation fan by installing exhaust duct on air compressor
The exhaust air from air compressors is currently discharged indoor. By discharging
this exhaust air outdoor by the installation of an exhaust air duct, it will be possible
to stop the use of ventilation fan indoor. The energy conservation effect in this casewould equal 9,570 [kWh/y].
(iv) Lightings: We measured illumination of the model room (Room 14, Building B)
and proposed energy conservation effects of 5,940 [kWh/y] by turning off lighting in
unnecessary locations (40 lights) and 9,794[kWh/y] by switching to high-efficiency
lamps (changing to inverter-attached Hf-type fluorescent lighting). These measures
will reduce the air-conditioning load in all rooms and help contribute to energy
conservation.
(v) Boilers: We proposed to adjust a target of 5% for concentration of oxygen in fluegas from the boiler, which is currently 11%. This propose will be estimated 88,490
Bath/y. There are some inadequate thermal insulation parts in the main stem pipe
from the boiler. There are also some locations where there is no insulation covering
flanges, valves, and other components. Energy conservation effects by fixing up
thermal insulation can be expected to equal 11,500 kg-LPG/yr, 205,850 Bath/y.
(4) Comments
The OJT for Audits was targeted at participants from the central government and
ESCC. Training was undertaken with an emphasis on OJT and trainees were instructedto prepare and submit a report to the factory as well as to prepare and present
presentation materials for the seminar. There was not enough time to ascertain the stateof factory equipment and energy use, investigate items of energy conservation, andprovide guidance on the contents thereof. It must be said that, from the standpoint of
ECCJ’s dispatched experts, the Audit results of the factory that provided locations for
OJT was insufficient. Nevertheless, the factory executives accepted these audit results
positively. We believe that these project activities were undertaken due to thesignificant leadership of the FP.

44

3. Seminar and workshop(1) Time and place
November 29, 2010 (9:00 to 13:00)
Ming Mueang Meeting Room, second floor of the Twin Tower Hotel(2) Participants: 65 persons(3) Presentation outlines
On behalf of the Thai government, Mr. Thammayot Srichuai, deputy director of DEDE,
delivered the opening address. As this seminar was being held shortly after the
PROMEEC Building Seminar which was held at the beginning of November in justsame place of Bangkok, no mention was made of the PROMEEC Project, energy
conservation measures in Japan, or other such topics. And then the seminar wrapped
up in the morning.
(i) Energy conservation in the Japanese textile industry (expert Mr. Nakatsu)- History of the textile industry and the developments in chemical textiles;- Statistical materials of Japanese textile industry;- Case studies of energy conservation in the chemical fiber industry.
(ii) Case studies of energy conservation in Thai textile industry (excellent cases) (Ms.
Sukanya Pipattraisorn, Alpha Processing Co., Ltd.) (materials presented in Thai)(iii) Energy conservation in the Thai textiles industry (Mr. Montri Vitayasak, Thailand
Textile Institute) (materials presented in Thai)(iv) Findings on Audit from PROMEEC Activities (Mr. Sarat, DEDE)- Explanation of PROMEEC and overview of activities;- Audit activities and audit results
This is a summarization of the Audit results which was prepared and presented by
the FP. While the FP initially requested the ECCJ experts to make these presentations,after discussions, it was decided the trainees deliver these presentations as
announced at the start of OJT activities. Consequently, the FP was able to prepare
and present presentation materials effectively and these presentations wereconcluded successfully.

45

Daily Meeting

Photo of the last day of OJT for Audits

Attachments
1: Guideline on Audit in Electrical Equipments
2: Castlepeak Holding PCL. (PPT material of company profile)
3: Preliminary Information of Audited Factory for PROMEEC Program
4: Overall Findings on PROMEEC INDUSTRY Activity
5: Group 1 presentation materials (two Excel sheets)
6: Audit Result of energy-saving in Apparel Factory (Electric Facilities)
7: Group 2 presentation materials (Word file: five pages)
8: Group 3 presentation materials (Word file: one page)
9: Measures - Savings
10: AGENDA / INTENSIVE SEMINAR on “Experience Sharing on Energy
Conservation in Textiles industry”
11: Japan Experience on Energy Conservation in Textiles industry
12: Thailand Experience on Energy Conservation in Textiles industry (Alpha
Processing Co., Ltd. / Winner from Thailand Energy Award)
13: Thailand Experience on Energy Conservation in Textiles industry (Thailand
Textile Institute)
14: Preliminary Findings On PROMEEC Industry Activity

46

V. Developing TD and IHD
1. Overview of the activities
As a part of this year’s PROMEEC Project activity, we visited Jakarta, Indonesia,
where the office of ACE is located, to ascertain the current state of systemdevelopment and outstanding issues of the development of TD and IHD for industries
and buildings and consult with ACE officials and formulate policies about future
development work.
2. Developing TD system(1) Basic policy of TD
TD system is not aimed at developing technical databases but is rather a system tocompile and use technical items obtained through PROMEEC activities as adirectory.
(2) Original data
Case examples selected from ASEAN Energy Awards consisting of (i) Energy
Efficient Buildings and (ii) Energy Management/Best Practices for Buildings &Industries came to the basic data used for TD.
(3) System to be used
The system will link TD to the web site of the Award and applicable materials aregot by opening the awards website linked to TD. For more detailed information, theuser can contact the business offices or companies which presented the ASEAN
energy awards or obtain technical information with a different search engine. This
point will be subject to further study. We will also investigate the possibility ofenabling users to directly access to the page of ASEAN energy awards from TD(ACE will be in charge).
(4) Items to be included in TD
Items that should be included in a TD shall be selected from materials on the
ASEAN Energy Awards by an ECCJ expert and notified to ACE for registration.
Specifically, an ECCJ expert shall mark and scan items to be included in a TD on ahard copy of materials on the ASEAN Energy Awards before sending this hard copy
to ACE, whereupon ACE shall register the marked items to a TD. ASEAN EnergyAwards in the past and from the following year shall be covered.
(5) TD categories(i) Category 1; Buildings: hospitals, etc.
; industry: cement, etc.
(ii) Category 2 and beyond: categories by technology (for this purpose, the ECCJ
will provide advice after compiling the data)47

(6) Work of ACE (person in charge: Mr. Junianto)(i) Explanatory materials of TD revisions as mentioned above shall be prepared, abriefing shall be delivered at PS WS in February, and the consent of PROMEEC
members shall be obtained. Revision work shall thereafter begin.
(ii) TD System bulletins will be disseminated at each WS.
(iii) The materials size shall be appropriate so as to facilitate linking and accessing.
(iv) Access point aggregation for each TD and IHDB shall be possible (the frequencyof access to TD or IHD shall be ascertained as a benchmark for usage).
3. Developing an IHD system(1) Basic policy of IHD
The top purpose of IHD is to use it as an EM tool at business entities that are subjectof Audit. Data is received during company visit for Audit and entered into an IHD toconsolidate the data. Specific measures for this purpose are outlined below:(2) Activities at Audit (participants from ACE are in charge)(i) On the first day of an audit, a briefing on the purpose of IHD (“to be supplied andused as an EM tool after data is entered”), the forms, case examples, etc. shall begiven by PowerPoint presentation in order to get cooperation.
(ii) From the second day of an Audit, data shall be received or obtained in advance tobe entered into an IHD.
(iii) At a meeting at which Audit results are reported to the Audit client, an ACE
official shall provide a report on the results entered into an IHD by ACE(including energy consumption trends, changes in specific consumption, and, if
possible, comparisons with other business entities in the same industry). A
completed file shall be offered to the audited business entity.
(iv) Where necessary, with the approval of the audited business entity, ACE official
shall report the outlining (iii) above at an Incentive Seminar.
(3) Ongoing data collection (carried out by ACE official)
Data on previously audited business entities and business entities audited this year
shall be collected and compiled by ACE.
4. Current state of building sector IHD and revisions as implemented(1) Current state
While checking buildings-related data such as (i) data retained by ACE/ECCJ, (ii)the count of IHD that were previously presented by ACE on a trial usage basis, and(iii) the count of IHD verified this time, some progress of data entry was confirmed,
though items have not yet been uploaded to databases.

48

(2) File revisions
To produce a master file, we focused on a Cambodian hotel at which we conducted
OJT for audits in 2009, entered data, and engaged in necessary form revisions.
Since there were no entry items relating to specific energy consumption, (i) the
specific energy consumption per total floor area (excluding outdoor parking areas)and (ii) the specific energy consumption per air-conditioning area were added. As
there are no ACE standards in particular, specific energy consumption items
corresponding to ACE standards have not yet been produced. Also, graphicaldisplays differed between the 2003 version and 2007 version of Excel; revisions
were made by unifying all graphs to the 2007 version of software.
5. Current state of industry sector IHD and implemented revisions(1) Current state
While three types of master files consisting of the Cement Energy Management
Questionnaire, the Food Energy Management Questionnaire, and the Textile Energy
Management Questionnaire have been uploaded, they are not being used.
We checked (i) data retained by ACE/ECCJ, (ii) the count of IHD that have beenpreviously presented by ACE on a trial usage basis, and (iii) the count of IHD
verified this time regarding industry-related data. In regards to industry, only threecases consisting of food & textiles in 2007 and textiles in 2008 have been enteredinto ACE’s computers; the volume of data entered thus far is low and the support of
the ECCJ is required. In addition, items have not yet been uploaded to databases.
(2) File revisions
Since IHD sheets for industry differ according to every industrial sector, we entereddata partially prepared by ACE officials on the Vietnamese textile industry as audited
in 2007 and produced a master file for the textiles industry.
Since the preparation of a master file for each industry is required for every
industrial sector, ECCJ experts will need to take time to provide support.

49

The permission of the International Cooperation
Department of the International Cooperation Divisionof the Energy Conservation Center, Japan must be
obtained in advance when publicly disclosing thecontents of this report.
Tel.:+81-3-5543-3018
Fax:+81-3-5543-3022