Promotion of Energy Conservation Activities
in Factories (Electricity)

Kokichi TAKEDA
Energy Conservation Center, Japan
In Thailand
Nov., 17, 2006
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1. Promotion ofEnergy Conservation Activity
2. Viewpoint of Power-saving
3．Methods of power-savingof major electric facilities
4. Power-saving Examplesof existing facilities in Japan
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1. Promotion of Energy Conservation Activity
1.1 Significance ofEnergy Conservation

Energy Conservation Activity
has contributed to Cost Down of each factory
moreover, Improvement of Cost and “SEC”(“SEC” is Specific Energy Consumption and defined asenergy conservation divided by production)＆Energy Conservation Activity
has contributed to Reduction of the global warming
・Estimation in oil：0.252 [kL／MWh]・Estimation in CO2：0.555 [t-CO2／MWh]
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1.2 Control of Energy Conservation① Establish organization control

・Management has to keep consciousnessof employees.
・All staffs have to be involved in the project.
Establishment of Criteria :Energy management, operation, inspection,
maintenance, and budget② Set the goal

③ Grasp the circumstances

Preparation of reference data and document
Setup of measuring and recording devices④ Perform⑤ Make an improvement plan

⑦ Assess the results

Implementation ofenergy conservation by
1. Small group activity
2. day-to-day business of staff
3. General development⑥ Implement revised plans

Repeat PDCA cycle of energy management
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1.3 3 steps for Promotion of Energy Conservation
1st step: Reinforce energy management and increase efficiency ofoperations
・ To avoid wastefulness
・ To optimize use of existing equipment
・ To avoid unscheduled stop of operations
2nd step: Modify and/or add equipment
・ Modification and/or addition of equipment ( It will be ineffective
if main facilities are renewed or replaced)・ Introduction of energy-saving devices
3rd step: Introduce new processes and high efficiency equipment
・ It is necessary to develop and introduce new processes.

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1.4 Work Flow of Energy Conservation Activity in Factory＜Incentive of activities bymanagement in the factory＞
・To set a goal
・To select objectives
・To set a deadline＜Establish an organizational system foractivities＞
・ To organize a team for activities･ To organize a team for measurement

・To make budget for energy conservation
measures, modification of equipment
・To estimate effects on energy
conservation measures･To transfer ideas to other equipment

ECCJ＜1st STEP： Prepare for activities＞
・To collect related information
・To make action plan for the activities
・To analyze existing processes
・To analyze energy consumption＜2nd STEP： Extract and winnow ideas
for energy conservation＞
・To collect energy conservation ideas by
1. check list
2. brainstorming
3. recruiting
・To winnow energy conservation ideas＜3rd STEP： Select measuresfor energy conservation ＞
・ To assess energy conservation measures(effect on energy conservation andinvestment)
・ To select plans for energy conservation
61.5 Energy Audit
To fill out questionnaire about situations of energy
conservation in a factory
BriefAudit

Hearing from staffs in a factory
Inspection of a factory
・Identification of basic problems in a factory･Proposal for overcoming (probability, latency and directions)

Detailed
Audit

Cooperation with specialists in energy conservation
Investigation in detail: understanding of present situation,
making guideline, and assessment of results･ Identification of quantitative issues on energy usage･ Proposal of definite guidelines (effect of investmentfor equipment and control)

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1. Promotion ofEnergy Conservation Activity
2. Viewpoint of Power-saving
3．Methods of power-savingof major electric facilities
4. Power-saving Examples
of existing facilities in Japan
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2. Viewpoint of Power-saving

Power Consumption

Power Consumption

2.1 Breakdown of Energy Consumption by its UsageECCJWorking hour

Working hour

AAB

BCCC

D89ABCD101112 13Hour1415161718

Variable part
A: to be proportional to productionB: to keep product plants
Fixed part
C: to start up or shut down lines
D: to keep utility plants
9Constant

NowP.CPower consumption☆ 3 Viewpoints of Energy Conservation Activity

ABC
D

Variable part
①Production-up
SEC-down
Fixed partC

Production Increase
Saving energy
E. S②Slim eachconsumption
V.PA
P.CA
P.C

B

D

Production③Transfer fixed
into variable part

B→AC→A
D→AA

F.P

V. P

BC
D

F. P
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Production

Production

2.2 Viewpoint of Energy Conservation Activity① Is a machine paused during a resting period in intermittent operation?
･ To pause a coupling of product lines･ To make an automatic ON or OFF② Is a capacity of equipment too large against requirement?
･ To introduce an inverter for pressure regulation in place of valve and damper･ To scale down a capacity③ Is a fluctuation of workloads properly regulated?
･ Automatic control of workloads･ Variable flow control④ Are inspection and maintenance definitely carried out?
･ Guideline on leakage prevention of air and water･ Prevention of pressure loss with cleaning filters etc･ Inspection with regular dismantlement of devices

Awareness in operators and maintenance staff on energy conservation
is of primary importance.
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2.3 Point of Selection of equipment forEnergy Conservation① Equipment (electric motor, transformer, cable）is subject to be audited
only when they are established or renewed.
It is difficult to renew electric motor, transformer, and cables except for lighting
facility for energy conservation, because these equipment contribute too little
to operating efficiency and are too expensive to increase efficiency.

② Main target is motor-powered equipment for energy conservation.
Energy conservation may be expected by avoiding wastefulness andimproving efficiency of motor-powered equipment (pump, fan, blower, aircompressor, chiller,etc) because these equipment represent a large
portion of energy consumption.

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☆ Example of energy flow and electric power consumption
Electric power receiving/distributing equipment(transformers, cables, etc.)< 95-97% >Contents inside parentheses〈 〉areexamples of efficiency (depending upon
facilities)
Contents inside parentheses( ) are examples of electric
power that can be used at theend of each equipment unit
when it has received the powerof 100 at the power receiving
Substitute
point.
transformer

Pumps,
Valves,Electricfans,Excessive supply
dampers,motors,etc.
(flowrate, pressure)etc.
inverters,
Piping,<60-85%>etc.
ducts, etc.
(Depending upon
<Depending
the way to use)
(Dependingupon
upon variable< 70-95% >
size, length,
opening:
20-100%> shape, leaks, etc)
(66-82)(7-70)
Load(95-97)(Decreasing further
Electric
due to piping(If excessivePumpmotor(39-70) pressure loss or
supply occurs, itothers)
decreases further)

Load
InverterElectric
motor

Pump
NozzlePowerreceiving
point (100)

Load
Power
receivingtransformer

Substitutetransformer

Electricmotor

Fan
NozzleNozzleSubstitutetransformer

Electricmotor

Compressor

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1. Promotion ofEnergy Conservation Activity
2. Viewpoint of Power-saving
3．Methods of power-savingof major electric facilities
4. Power-saving Examples
of existing facilities in Japan
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3．Methods of power-saving of major electric facilities
3.1 Pumps, Fans, and Blowers
Viewpoint of power-saving

Examples regarding methods of power-savinga) Reduction of flow rateAnti-leak measure of air and water, prevention of excessive use,etcb) Reduction of pressure

Reduction of operating pressure, Reduction of pressure loss
( filter, etc)c) Reduction ofexcessive specification(reduction to reasonable level)

・To replace to small capacity or machine of less pressure loss
・To change impeller, to cut down impeller diameter,
and to decrease stages of rotor impeller
・To change a rotating speed (pole change or pulley, inverter)d) Addition ofvariable flow control
and multi-unit control

・ Addition of multi-unit control system
・ Selection of big and/or small machines
・ Addition of variable flow control (pole change, pulley, fluid
coupling, vane control, inverter)e) Replace tohigh efficiency machine・ To replace to high efficiency machinef) Pause at a resting timein intermittent load・ To replace to motor of high frequency start type・ Addition of soft starter with inverter
・ Addition of fluid coupling
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Delivery pressure(Total pump head)☆Example of Power-saving by Speed Control (1)Resistance curve at flow (Qb)with valve control
PipelineB’resistance curve

HbHaEnergy saving

HvA
Hb
R2
HS

Q-H curve at aspeed (Nn)B

R1

Q-H curveat rated speed(N0)Net pump head
Qb

Qa

FlowQb/Qa = Nn/N0, Hb/Ha = (Nn/N0)2 ,axis power: Lb/La = (Nn/N0)3
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☆Example of Power-saving by Speed Control (２)(1) If there is no valve restriction, pressure is P1r and flow rate isQ1r at a rotation speed of 100％(2) If an additional valve restriction bears a flow rate of Qa, thepump discharge pressure becomes Pa. Therefore, valve
restriction performed until pressure becomes P1 leads to aflow rate of Qa.
(3) If a further rotation speed change leads to a pressure of P1
and a flow rate of Qa, valve restriction will result in greater
energy saving.

P20

P1

1

P10
Flow rate

Qa

Rotation speed andnecessary motive power

esp
noitat
Ro%
90%
80
70 %

e1d:%
00

60 %
50 %

Qa
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P1r

P2

60 %

SystemNecessary motive power(2) Higher pressure of the load side results in smaller energy
saving effect by controlling the rotation speed.

P2r

50 %

System 2:(1) The principle of reducing the necessary motive power is thesame as in item (1) of System 1.

Pa80 %
70 %(4) The figures below show the property of the necessary motive
power at that time.

When the pressure of the load side is higher by P20 than that of thefeeding side, pumps compensate this differential pressure andpiping pressure loss.

Rotation speed: 100%
90 %SystemWhen the pressure of the feeding side is the same as that of theload side and pumps compensate piping pressure loss:PressureSystem 1:

2

Fan properties and system head curves

Q2r Q1r Flow rate

☆Pump efficiency and Selection of pump capacity
Figure (a) shows the curves of specific flow rate topump efficiency for pump A (efficiency : 85%) andpump B (efficiency : 80%).
(1) With respect to the ratio of efficiency at eachflow rate, pump A improves by 5% more thanpump B.

Figure (b) shows the curves of specific flow rate to pumpefficiency for pumps with a capacity of 100, 80, and 50(1) Employ pumps with appropriate capacity
With respect to pump efficiency at a flow rate of 70%, pumps
with a capacity of 80 improve by approx. 10% more thanpumps with a capacity of 100.
(2) Quantity control of pumps

100%

100%

80%

80%
Pump efficiency

Pump efficiency

With respect to pump efficiency at a flow rate of 40%, pumps
with a capacity of 50 improve by approx. 35% more thanpumps with a capacity of 100. Controlling the quantity ofpumps by installing several small capacity pumps in place oflarge capacity pumps results in energy savings.

60%
40%
Pump A (efficiency: 85%)

20%Pump B (efficiency: 80%)

60%
40%

Pumps with a capacity of 100%
Pumps with a capacity of 80%
Pumps with a capacity of 50%

20%

0%
0%

20%

40%

60%

80%

Flow rate

Ｆｉgｕｒｅ (a)ECCJPump efficiency

100%

120%

0%
0%

20%

40%

60%

80%

100%

120%

Flow rate

Figure (b) Selection of pump capacity and quantity control

3.2 Air Compressor
Viewpoint of power-saving

Examples regarding methods of power-savinga) Reduction of necessary air
flow rate・Measures against air leak・ON/OFF control and intermittent operation
・Making nozzles smaller and changing to energy- saving
nozzles・Employing constant pressure discharge blowers, etcb) Reduction of pressure loss

・Employing filters with small pressure loss
・Making tube diameters larger
・Decreasing discharge air pressure, etcC) Correction of specification onpressure requiring excessive
to a more appropriate value

・Making air compressors smaller incapacity and lower inpressure
・Adjusting the opening of inlet side vanesd) Selection of the number ofrunning air compressors or
introduction of variable
discharge flow-rate control
according to the fluctuating load

・Adjusting the number of parallel running air compressor, etc
・Selecting small-capacity air compressor and controlling theiractual operation
・Adjusting the discharge air flow and pressure to appropriate
values by controlling the capacity of air compressor
・Integrating air compressors
・Correcting the capacity of receiver tanks to a appropriate valuee) Enhancement of the function
high efficiency air compressor

・changing to high efficiency air compressor
・Lowering the temperature inlet side airf) Reduction of operating time of
air compressor

・Shutting down air compressor when operation is unnecessary
19・Providing air compressor with automatic start/stop functions

ECCJ(Examples)
Comparison of electricity consumption of the compressor
at variable capacity system
100①：system to adjust
suction valve①, ②
consumption electricity

[%]

80

①60②②：system to adjust
suction valve
and air purge③③：system to change
air load/unload
by air purge④40④：inverter system
200
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204060Quantity of use air[%]

80

10020

3.3 Lighting apparatus
Viewpoint of Power-saving

Examples regarding methods of power-saving

Choice of high efficiency light sources

Choice of high efficiency lamp such as sodium lamp
Choice of Hf fluorescent lamp utilizing inverter
Choice of low loss type stabilizer

Reduction of illumination

Adequacy of lighting standards in workshop
Reduction of whole illumination and use of part illumination
Dimming of lighting through proper lighting control

Reduction of illumination object

Review and reduction of place needing illumination

Choice of high efficiency lamps

Choice of high efficiency lamp, floodlight beams

Improvement of illumination rate

Consideration such as reflection efficiency to lighted
location

Improvement of maintenance rate

Periodical cleaning of lamp
Appropriate exchange of lamps

Reduction of lighting time

Close lights out
Extinguishing of lighting through proper lighting control

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Energy Consumption of Lighting Apparatus
Powerconsumption[kWh]

N =Powerconsumption
per apparatus[kW]

Lightingtime[h]Number ofapparatus
Ｎ [set]E×A

decrease

Φ×U×M

increase

N: Number of lighting apparatus
A: Room space [m2]installed
U: Utilization factor
E: Average luminance on working
M: Maintenance factor
place [LX]
Lighting standards in workshop
Φ: Luminous flux perin JAPAN : ＪＩＳ Ｚ９１１０lighting apparatus [lm]
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Replace with more efficient light
40w×2 tubes
with C &C stabilizer

Light flux

36w×2 tubes
with C &C stabilizer

Light flux

32w×2 tubes
with Inv. stabilizer

Reflection plate

Light flux
Original

ECCJFix a reflection plate

Replace Hf tube

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3.5 Electric Power Distribution Systemmain
transformer

Viewpoint ofpower-saving

Examples regarding
methods of power-saving

Selection ofhigh efficiency
apparatus

Selection of high efficiency
transformer☆

Improvementof power factor

Addition of condenser
for improvement of power
factor ☆
Selection of high powerfactor apparatus ☆

transformer
apparatuswith pause
at a restingtime

StaticCondenser

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Integration and haltof light-load transformers
Pause of fans for transformers
when transformers are loaded
lightly and/or not heated☆：Consider when facilities will be replacedor equipment will be newly installed24

1. Promotion ofEnergy Conservation Activity
2. Viewpoint of Power-saving
3．Methods of power-savingof major electric facilities
4. Power-saving Examples
of existing facilities in Japan
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4. Power-saving Examples of existing facilities in Japan
4.1 Example-1 : Power-Saving regarding Pump
4.1 Power saving on Clinker-cooling-Fan

4.1 Power saving on Clinker-cooling-Fan

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4.2 Example-2 : Power-Saving regarding Brower

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4.３ Example-３ : Power-Saving regarding Ａｉｒ compressor

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4.4 Example-4 : Power-Saving regarding Lighting Equipment

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The END

Thank you !

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