2011 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 2012

The Energy Conservation Center, Japan

CONTENTS
I.

Outlines of Project ..................................................................................................... 2

II.

Philippines (semiconductor facility, etc.) ............................................................... 4

1. Outlines of Activity .................................................................................................. 4
2. Energy Conservation OJT(Semiconductor Manufacturing Facility-A)................... 5
3. Follow Up Diagnosis .............................................................................................. 14
4? Seminar and workshop.......................................................................................... 16
Pictures of Activities: PROMEEC Industrial Enterprise @Philippines ..................... 19
Material A: Results of Energy Audit OJT at Wacky Corporation............................... 21
Material B: MHI Promotion Document ...................................................................... 25
Material C: ECCJ Expert Presentation Document .................................................... 27
Ⅲ? Indonesia(Thermal Power Plant) ............................................................................ 28
1? Outlines of Activities ............................................................................................. 28
2? Facility Assessment of energy conservation OJT (Thermal Power Plant B) ........ 28
3. Presentation on Revamping of Isogo Thermal Power Plant, etc. .......................... 44
4. Seminar and workshop .......................................................................................... 45
Pictures of Activity: PROMEEC Industrial Entreprixe @Indonesia .......................... 49
Material? D: Results of Energy Audit OJT at B Power Plant ................................... 50
Material? E: J-Power Presentation Document .......................................................... 54

1

I. Outlines of Project
ASEAN nations have experienced rapid economic growth, and current predictions arethat the consumption of energy will also rapidly increase; consequently, the efficientuse of the energy and the prevention of global warming will be necessary
considerations. In this, the 12 th year of the project, the activities of the relevantorganization ACE, as part of the ASEAN nations, are more enhanced and more deeply
rooted. The change in awareness has spread with regard to the reduction in energy
consumption by all nations, which can be attributed to the recent rise in energy prices
as a result of the escalation in oil prices and the enforcement of the Kyoto Protocol of
February 16, 2005. The third year of Phase 3 has been regarded as the year for theenforcement of the protocol and the dissemination of past achievements by more selfreliant efforts, as well as the result of the integrated achievements of activities in thepast 11 years. More specifically, the decision has been made to establish a platform topromote energy conservation and disseminate the achievements of a diagnosis ofenergy conservation conducted in the facilities across 10 business categories for all
ASEAN nations in the past 11 years. In particular, the following activities wereorganized by the Philippines (semiconductors) and Indonesia (thermal power plants).
♦ Instruction in Energy Conservation Assessment
Energy Conservation OJT by a specialist from Japan was provided at a facility thatwanted the transfer of the technology for energy conservation assessment to theplanners of energy conservation policies and to personnel involved in energy
conservation assessment of the visited countries. We reported the results of theassessment of energy conservation to the relevant facilities for use in conserving
energy in the future.
♦ Holding a Seminar or Workshop
With the participation of personnel from the relevant facilities, including personnel
from other industries and related facilities as well as government officials fromother ASEAN nations, a seminar was offered where presentations were maderegarding conservation activities, examples of improvements in disseminating
successful examples, and sharing expertise with ASEAN nations.
♦ Introduction of Energy Conservation Technologies and High Efficiency Facilities inJapanThis is a new enterprise this year. When the results of the assessment of energy
conservation were reported to the facility or during the seminar and workshop, we
introduced Japanese energy conservation technologies and high efficiency facilities
as a contribution to the involved nations for the enhanced efficiency of the use of theenergy.
The Major Industry Project this year is as follows:2

1? Services at site in Philippines: Oct. 10-14, 2011.
(1) OJT in the assessment of energy conservation took place in a semiconductor
facility in Manila, the Philippines. The duration was only two days at the request of
the facility. The assessment team was organized by the persons from the Ministry ofEnergy of the Philippines, and the engineers of the diagnosed facility accompanied
then. The leadership was assumed by the engineer of the Ministry of Energy.
Furthermore, and as a follow up diagnosis, visited the pharmaceutical plant
diagnosed in 2009, and could confirm the satisfactory enforcement of energy
conservation activities.
( 2 ) A follow up assessment was made on the pharmaceutical plant that had anassessment of energy conservation in 2009. The items that were identified for
improvement last time were satisfactorily completed or in the planning stage; wewere able to confirm satisfactory implementation of energy conservation activities.
(3) A total of 74 people participated in the seminar and workshop, and a constructive
exchange of information was made through the presentations below and theconference.
? Presentations from the Philippines and Japan regarding energy conservation
policies and programs.
? Presentation by involved parties from ASEAN nations on the example of
implementation of energy saving? Presentation by the site assessment team on the results of an assessment ofenergy conservation.
? As an attempt to introduce energy conservation technologies and high efficiency
facilities from Japan, started for the first time this year, an introduction wasmade on the high efficiency refrigerator by Mitsubishi Heavy Industries Ltd.,
which belongs to JASE-World.
2? Services on-site in Indonesia: November 21-25, 2011
(1) OJT in the assessment of energy conservation was conducted at the national
thermal power plant located in Jakarta, Indonesia, which uses natural gas. A site
assessment team was organized by the engineers of the Ministry of Energy andMineral Resources and of the relevant facility. The assessment of energy
conservation was led by the engineers of the thermal power plant, and the staff
members of the Institute of the national power company assumed a role in theseminar and workshop held on the last day.
(2) A total of 80 people participated in the seminar and workshop, including theparticipants from the national thermal power plants, in addition to the engineers
above, and a constructive exchange of information was made through the3presentation below and the conference.
? Presentation by Indonesia and Japan regarding the energy conservation policy
and its program.
? Presentation of the results of an assessment of energy conservation by the site
assessment team.
? As the second introduction of energy conservation technology and high efficiency
facilities from Japan, a presentation was made by an invited engineer from JPower, an affiliated company of JASE-World, regarding the high efficiency
operation of similar thermal power plant businesses in Japan.
To conclude, we would like to express our deepest gratitude for the full cooperation by
the related organizations of various nations, ACE, and the personnel from theinvolved companies for this enterprise.

II. Philippines (semiconductor facility, etc.)
1. Outlines of Activity
Among the various projects for Structural Improvement for International Energy
Use, a commissioned project of METI, to implement th e Project for Promotion ofEnergy Conservation for the Major Industries in ASEAN Nations, we visited Manila
in the Philippines from October 9th to 15 th for OJT in the assessment of energy
conservation for a semiconductor manufacturing facility and a follow up assessmentof a pharmaceutical company, as well as to hold a seminar and workshop to exchange
information among the persons from Industries in the Philippines and the ASEAN
nations. A total of 21 engineers from the Ministry of Energy of the Philippines andthe diagnosed facility, ECCJ, and ACE, participated in the energy conservation OJTof the semiconductor manufacturing facility. The satisfactory implementation of theitems that were generally identified was confirmed in the follow-up assessment of
the pharmaceutical facility that had been assessed in 2009. A total of 47 persons
participated in the seminar and workshop and successfully completed it.
Members of the visit:

Tsutomu Okamoto/ Technical Cooperation Dept., ECCJ
Taichiro Kawase, Kazuhide Kunitoku/ Technical Expert

Schedule of activity:

Oct. 10Visit DOE & conference

Oct. 11-12 OJTDiagnosis(Semiconductor

manufacturing

facility A)
Oct. 13

Follow-up diagnosis (Pharmaceutical facility)

Oct. 14

Seminar and workshop

42. Energy Conservation OJT(Semiconductor Manufacturing Facility-A)(1) Attendee: 26 persons
DOE (8 persons): Ms. Genevieve L. Almonares, Mr. Marlon Romulo U. Domingo,
Mr. Maximino G. Marquez, Ms. R. P. Parreno Jn., Ms. Vilma P. Reyes, Ms. Rose
V Sarulory, Mr. Darwin P. Galang, Ms. Einor P. Quinto
Facility-A (13 persons): President Takeo Kikuchi, Adviser Nobuyoshi Suzuki andothersACE (one person): Mr. Junianto M
ECCJ (three persons): Tsutomu Okamoto, Taichiro Kawase, Kazuhide Kunitoku(2) General description of the Facility: Facility-A
This is an affiliate facility of a semiconductor manufacturing company in Japanthat started operation of the first workshop in 1997 and the second in 2007. The
major product is a power semiconductor by purchasing semiconductor chips for thematerial for assembly into a semiconductor product, a so-called downstream
semiconductor manufacturing facility.
On the first day of the visit and workshop, an explanation of the workshop andthe outlines of CSR activities were made by the vice president. Then an explanationof energy conservation activities followed by the director of the facility. Additionally,
this facility won the DOE Energy Conservation Prize of the Philippines in 2010 for
its energy conservation program.
The number of employees is approximately 850, including 12 engineers. Major
posts above the director including the president are occupied by Japanese. It is
continuously operated for 24 hours with two shifts per day. Annual production is35,660,000 pieces, power consumption 17.77 million kWh, equivalent to the scale ofa type-1 designated energy management factory in Japan.
(3) General description of assessment
1) Members of the assessment teamBecause there were only three to four OJT trainees from the DOE and one personfrom ACE, with the short duration of 1.5 days, grouping was not made, and the OJTon energy conservation was conducted with all members as one team. The teamleader was Mr. Maximino G. Marquez / DOE. The assessment team consisted of
total seven or eight persons including an engineer from the facility and three
persons from ECCJ, including the OJT trainees above.
2) The procedure for assessment“Due to the secrecy of the facility, it will not be possible to see the details.” Therewas such anticipation from the e-mail communication between DOE and ACE

5regarding this activity; however, just after the greetin g on the first day, themembers became intimate enough to allow admission to all facilities except forthe clean room, whose inside could be seen through the surrounding glass window.
We also received answers to the delivered survey slip before departure fromJapan, which allowed us draft an assessment plan before starting site activities. It
was confirmed that the core facility was excluded from the assessment of energy
conservation, which was limited to the peripheral facilities, i.e., the diagnosis waslimited to the thermal recovery facility, the drying facility, and the refrigerating
facility.
In consideration of the restrictions of only 1.5 days for the OJT this time, theassessment was conducted along with the procedure; the interviews of the energy
conservation program of the facility, the inspection of the workshop facility, the data
gathering from the measurement using the measuring instruments and the recordof operation, the data analysis and planning of energy conservation measures, andthen the report of the assessment to the people of the facility.
3) Preparation of Measuring Instrument
A radiation thermometer from DOE, two contact thermometers from ECCJ, ahygrothermograph, a clamp on power monitor, a thermo camera, and a contact
thermometer: total seven instruments were provided. Pre-instruction was provided
on how to operate the instruments and on the points for use. With regard to theclamps on the power monitor, it was confirmed that special care should be taken,
and the operation should only be made by an engineer from the workshop. All the
prepared instruments were effectively used, and we acquired plenty of data. The
thermometers were utilized for the measuring of temperatures around cold-water
pumps, the cooling tower, and the AHU. The power meter was utilized formeasuring the current of the motor for the pump.
For general facilities, a strong request was submitted to have an oxygen meter for
combustion gas analysis and the hot-wire anemometer or Vane anemometer, in
addition to the power monitor and the thermometer as the required measuring
instruments. These are frequently used instruments and which are absolutely
necessary for the assessment of combustion management and inverter control.
4) Measurement and Data Gathering
Guidance was made to OJT trainees in advance on the purpose of measurement,
the items of measurement, the points of measurement, and the measuring
instruments used. We also tried at the site to conduct the inspection while
explaining the purpose of the inspection for each facility. Through this method, thepoints of OJT and the assessment were well disseminated to the trainees. Data
gathering and data analysis were substantially conducted by the specialists from6

ECCJ, mainly due to the restricted working time. Some part of the measuring work
was conducted by the engineers of DOE and the workshop.
? )Diagnosis of Utility Facilities(i) Water Supply Facility (including refrigerating machine)(i) -1 Rough estimation of COP for No. 3 chiller
Generally, the performance of the cold-water chiller is estimated using COP, aperformance formula defined as below:
Chiller COP = Chiller Cooling Heat (kW) / Chiller input power (kW)= Carnot COP x Efficiency of Actual Cycle x Efficiency of Refrigerating Compressor
where,
Carnot Efficiency = (Evaporating Temp. of Refrigerant)/ (Condensation Temp. of
Refrigerant – Evaporation Temp. of Refrigerant)
The temperature of each refrigerant was estimated using the measured surface
temperature of each exit pipe of the evaporator/condenser because the direct
measurement of the refrigerant evaporation/condensation temperature was notpossible. As a result, th e refrigerant evaporation temperature was estimated as 4
degrees Celsius, and the refrigerant condensation temperature as 50 degrees Celsius.
Carnot COP = (4+273)/((50+273)-(4+273)) = 6.0
Chiller COP (estimated) = 6.0 x 0.81 x 0.8 = 3.9
The difference in the Carnot COP and Chiller COP comes from the efficiency
degradation by the expansion valve, ingress of heat into the refrigeration cycle,
performance of evaporator, performance of condenser, and the efficiency of thecompressor. The next step is the evaluation of COP (user COP) in relation to thecooling heat actually received by the cold-water user side. The user COP is given by
the following equation. It was not possible to measure this due to the shortage of time.
User Cooling Heat (kW) = Cold Water Flow x Specific Heat of Cold Water x (Entry
Temp of Cold Water –Temp of Returning Cold Water)
User COP = User Cooling Heat (kW) / Refrigerator Compressor Motor Input (kW)The difference of Chiller COP and User COP comes from the ingress heat of thecooling water pipe/pressure loss in the cooling pipe. We are awaiting the cause of thedegradation of COP to be clarified and removed.

(i) -2 Evaluation of condenser performance
The heat exchanging performance of the condenser has a significant influence on7the chiller COP. Lowering of condensation temperature of the refrigerant by one
degree results in the rise of COP by 3%, i.e., the compressor power saving by 3% ispossible. Then, it was decided to evaluate the heat exchanging performance of thecondenser. Generally, the performance of the heat exchanger is evaluated as thedifference of the log mean temperature difference (LMTD) of the high temperature
fluid and the low temperature fluid
L MTD = (⊿t1 - ⊿t2) / ln (⊿t1 / ⊿t2)
w here, ⊿t1, ⊿t2 stand for the temperature difference of the two fluids at theentry and the exit of the condenser.

74℃
41℃

refrigerant
⊿t1

⊿t2
air

45℃

31℃

The measured condenser was the air-cooling type. The high temperature fluid was
the refrigerant R410A, and the low temperature fluid was the air. The temperature of
the high temperature fluid was estimated using the surface temperature of the entry
pipe to the expansion valve (supposed to directly measure the fluid temperature).
Meanwhile the temperature of the low temperature fluid was measured by thethermometer directly inserted in the airflow. The exit temperature of the lowtemperature fluid was 45 degrees Celsius, significantly exceeding 41, the entry
temperature of the high temperature fluid. Because such a reverse phenomenon neveroccurs on the condenser, it was considered a measuring error. It was necessary to takethe measurement again by changing the measuring point of the low temperature fluid,
etc.
(i) -3 Improvement of chilled water pump efficiency at part load
Generally, it is possible to significantly save energy by lowering the speed ofrotation, when the rotating machinery, such as the pump/fan, is operated with a low
load. Especially for the centrifugal machinery, the energy saving performance
proportional to the cube of the speed of rotation can be expected.
Then, it becomes necessary to know the load for the cold water pump. Because there
was no in-line flow meter, the opening of the discharge valve was found fully open.
Due to this, the cold water was regarded as flowing at the rated flow. Meanwhile, themeasured temperature of the cold water supply and return at the cold-water header
was 9 and 12 degrees Celsius, respectively. Normally the temperature difference of the8cold water supply and return is designed as 5 degrees, then it was estimated that thecooling load at the process side was 3 degrees/5 degrees x 100 = 60% when measured;
the loading was estimated at approximately 60%. Then, it can be argued that the flowrate could be reduced to 60% if the difference in the supply and return temperatures
is increased to 5 degrees. If the inverter is to be implemented, the speed of rotation
could be lowered to 60%. If the cold water is assumed to flow in a closed system, thepower saving of the pump is roughly estimated as (1- 0.63) x 100 = 78.4%? ? ?Chiller? ?
Cold Water

12℃
9℃? ? ?Header? ? ?
SupplyReturn? ? ? ?Header? ?

? ? ? ? ? Process?
Production?Cold? ?Water? ? ? User
M

? Inverter? ? ? ? ?
(ii) Utility Water Facility(ii) -1 Waste heat recovery to pre-heating RO feed water
The temperature control of material water did not apply to the Reverse Osmosis
Membrane/RO equipment of this facility. Therefore, there was no need to use theexhaust heat of warm water or cold water. However, the temperature of the material
water for RO equipment for the semiconductor facility in Japan is controlled to 24
degrees. This is to maintain the viscosity of water going through the RO film to themost appropriate figure. The recommendation then was for an exchange of opinions
between ORGANO on the need for temperature control of the material water.
(ii) -2 Application of inverter to water pumps
Generally, the quantity of utility water varies corresponding to the demands of theprocess. This variation can be roughly grasped by recording the variation in the
discharge pressure of the pump. Our recommendation was to record the variation bothby day and season.
By adopting PID control using the inverter speed as an operational variable, thepower for pump can be saved by controlling the discharge pressure of pump to a
constant figure. The saved pump power can be estimated if the pressure variation andthe flow are known, as below:

9Concept of Automatic Inverter Control

delta P

automatic control of header pressure(inverter auto of one pump)manual control of header pressure(manual on/off of one pump)Calculation : kW saving = delta P(m) * Q(ton/min)/(6.12 *η)(iii) Compressed Air Facility(iii) -1 Reduce intake air temperature
The required power for the air compressor is proportional to the absolutetemperature of the suction air. If the suction air temperature drops from 20 degrees to
10 degrees Celsius, the required power will decrease by((273? 20)? (273? 10))/(20? 273)x 100 = 3.4? .
The suction air was taken from the wall near the ceiling through the propeller fan
in the compressor room of the first shop. It was the air at higher altitude over 5 m
from the ground level and relatively lower temperature outdoor air.
(iii) -2 Reduce unloaded operation losses
The power is wasted during unloaded running of the air compressor for many
facilities. Especially the screw type compressor will consume 30% of the rated power
during the unloaded running. To quantitatively grasp the unloaded operation loss, themotor power for the compressor was measured every 5 minutes for 24 hours to
calculate the percentage of unloaded time and estimated the energy loss;

loading

100%

Compressor
motor kW
unloading

30%
ti
min

Cumulative unloading time = Σti
To cut down the no-load operation loss, usually multiple operation of smallermachines or an inverter type compressor is employed. If multi-operation is adopted
already, it is enough if only one set of machinery has the inverter function.

10

(iii) -3 Reduce pressure drop between air supply and end user
Compressed air is a costly utility. Normally, the pressure loss between thecompressor room and the end user is designed to be 0.5 bars or less in Japan. For thispurpose, countermeasures can be adopted to replace the small tube with larger ones,
change the piping to a loop system, remove the bypass pipe, and minimize the numberof pressure loss elements such as valves. This shop already adopted the loop type. The
next step to be implemented is the measurement of the pressure at the end user. If it
exceeds 0.5 bars or less, the measures above shall be adopted.
(iii) -4 Minimize air leakage
Air leakage test was already conducted at this shop, and achieved the cut down ofcompressor power.
(iii) -5 Reduce end-user’s air pressure
The purposes of the compressed air at the end user of this shop are for thepneumatic cylinders and for air blowing. The required pressure for the pneumatic
cylinders is 2–3 bars, and that for air blow is 1–2 bars. There is a possibility of
reducing the supply air pressure at the compressor room from 6 bars down toapproximately 4.5 bars. If there is a facility that requires a little higher pressure, forexample 5 bars, a small increaser (booster) can be implemented to increase from 4.5bars to 5.5 bars for the necessary quantity. By adopting this, the supply air pressure
could be left unchanged as low as 4.5 bars.
(iv) Air Conditioner (Outdoor unit only)(iv) -1 Application of inverter to makeup air fan
Three Makeup Air Handlers/MAH are installed in the first shop for supplying thetemperature/humidity controlled air to the many Recycle Air Fan Filter Units/RAFFU
arranged along the side wall of the clean room. MAH has the outdoor air supply fan,which was operated with the constant speed using the commercial frequency of 60 Hz
in the beginning. Now the speed is lowered using 45 Hz by an implemented inverter.
However, even if the Hz is lowered, it is still constant speed operation.
The future subject is the implementation of variable speed operation with regard to
the outdoor air conditions (temperature/humidity). By adopting this, it will be possible
to conduct the energy saving operation with the lowered speed of fan during the dry
season or at night when the latent heat load is low.
(iv) -2 Reduction of reheating losses
The first function of MAH is the dehumidifying of the outdoor air. For thispurpose, it has both cold water and warm water coils to dehumidify the outdoor air by11cooling, and after that, re-heating with the warm water coil. The exhaust heat fromthe molding machine (the hydraulic oil cooler) in the clean room is recovered as warm
water as the heat source for re-heating. The steam is used as the heat source for thewarm water coil in Japan, which raises the energy cost. This is an example of doubleenergy savings that do not require steam and at the same time will decrease the air
conditioning load for the clean room.
Hot water

Chilled water

Hydraulic oil

Makeup Air Handler
Oil cooler
FreshMolding machine(iv) -3 Minimize air conditioning load in clean room
In the downstream process in the semiconductor facility, 45% of the energy
consumption is required for air conditioning the clean room. Therefore, reducing the
air conditioning load in the clean room has a direct impact on energy savings. In thisshop, the measures for reducing the air conditioning load have already been
implemented, such as the heat insulation on the high temperature surface in theclean room or the recovery of the heat generated from the hydraulic oil cooler for thewarm water.
(iv) -4 Review the key operating conditions of clean room
For the clean room, the pressurizing, ventilation, and cleanliness classifications arevery important conditions for operation for reducing the count of microparticles to acertain specified level. It is necessary to set the differential pressure with the next
room to 0.03–0.05 H2O. The airflow necessary for pressurizing is the function of the
opening area of the clean room. The reduction of air flow will result in the energy
saving: for this purpose the opening area such as the crack at the side wall/ceilingconnection, through holes on the side wall for utility pipes/cables, differential pressure
damper, etc. shall be minimized. For ventilation, the frequency of ventilation (airchange) to maintain the cleanliness classification shall be satisfied. If it is the class
10,000, the recommended ventilation frequency is 60–120 times /hour.
If the cleanliness class is too strict, it will waste energy. It is necessary to relax thecleanliness class within the range where the product yield does not drop.
The assessment regarding the relaxing the operating conditions of the clean room
was not taken up because the entrance in the clean room was not allowed at this OJT
diagnosis.
(v) Other Knowledge

12(v) -1 Energy Management Structure
According to the answer to the advance survey slip, the program for energy
conservation of this facility has reached a high level. Specifically, the confirmation has
been made on the assignment of the energy manager, implementation ofmonitoring/recording of energy data, the setting of energy reduction goal, developmentof medium/long term plan for energy conservation, active promotion of small group
activity, and co-working together with the semiconductor group in Japan, etc.
The most impressive was the small group activities, which started from 2007 on theenergy conservation activity by visualization: 64 groups (742 persons) have beenorganized now. The thorough implementation of turning off the lights not only in theoffice, passageway, and cafeteria, but also in the workplace, the partial use of light orturning off using a pull switch was observed.
(v) -2 Maintenance of Utility Facilities
In the shop building, a corridor surrounds the clean room in the center, and outsideof it, AHU, storage house, office, and cafeteria are arranged. The cold water facility
and the air compressor room are outside of the shop building.
The clean room and the corridor are well maintained, and the thorough managementof energy such as turning off the lights was enforced. However, the AHU room and thecold-water facility (outdoors) were not well maintained. For example, the heatinsulated surface of the cold-water header (supply/return) was quite wet with water.
Probably the water penetrated into the insurance layer, i.e., heat penetration occurred.
Besides that, it was supposed that the plate for the heat exchanger to recover theexhaust heat of the molding machine was contaminated, based on the measured data
for temperatures. The overhaul cleaning was necessary because the deterioration wasadvancing on the heat insulation surrounding the heat exchanger. Also, the cold-water
facility installed outdoors had advanced deterioration of the heat radiation fin. The
time to change the heat insulation for the piping had come.
(v) -3 Energy Saving of Lighting Equipment
Thorough measures had been implemented for energy saving regarding the lighting.
The introduction was made on management, such as turning off the lights, but also on
the facility, and the various measures were implemented. For example, theintroduction of ambient task lighting and the transition to the high efficiency
fluorescence light/LED light was in progress. Besides that, it was reported that there
was a plan to lower the height of the ceiling light for energy saving of general lighting.
(4) Data Analysis and the Simplified Report
On the last day, the results of the OJT assessment and problems were reported to the13executives of the facility as a prompt report. This prompt report was presented at theseminar and workshop by Mr. Maximino Marquez, a member of the local team.
(5) Personal Comment
Due to the extremely short period of 1.5 days, the qualitative assessment became
the core of the assessment of energy conservation of semiconductor facility A, which
made me disappointed, because I excitedly made the pre-investigation report as anexpert. The facility had an active small group activity. As soon as I stepped into theshop, I was strongly impressed by the cleanliness and the thorough implementation of
blackout/brownout of the lights. It is undoubtedly the fruit of the visualization activity
launched by the deputy vice president four years ago. Various measures for energy
conservation are taken in this shop; however, those measures are weighted toward
electrical energy. I think the optimum use of energy as a total shop should be pursued
by integrating heat and electricity. Besides that, the maintenance of the utility
facilities looked a little weaker as compared with the production facilities. Especially,
AHU, the air compressor room, the outdoor cold water facility need replacement of theinsulation and repair of the measuring instruments.
3. Follow Up Diagnosis(1) Attendants: 12 persons
Department of Energy/ DOE (three persons): Mr. Maximino G. Marquez, etc.
Facility-B (five persons): Mr. De Leon / General Affairs Manager, etc.
ACE (one persons): Mr. Junianto M
ECCJ (three persons): Tsutomu Okamoto, Taichiro Kawase, Kazuhide Kunitoku(2) The Point of Follow Up Investigation
An OJT assessment was made in 2009 in this facility. This time, the investigation
was made on the status of implementation of the energy conservation measures thatwere suggested and instructed at the OJT last time.
(3) Result of Follow Up
The explanation was provided by the facility manager regarding the activities thattook place after the follow up investigation last time. Out of 10 items, 8 items werealready done, and 2 items were in progress, so the status was worthy of praise.
The major results are listed as below;(i) Cooling Tower
Suggestion 1: To cut down the motor power of IDF fan by raising the cooling watersupply temperature.
Status: Done. The temperature was raised from 31 to 32 degrees Celsius.

14

Suggestion 2: Implement the inverter for the cooling water pump.
Status: Installation under consideration(ii) Chiller for Cold Water
Suggestion: Add a bypass pipe to the primary cold-water pump, and stop theprimary pump.
Status: Done, however changed to the stop of the secondary pump.
(iii) Recovery in Boiler Room/Steam Supply
Suggestion 1: Recover the unrecovered condensate in Boiler Room/the second floor.
Status: Done
Suggestion 2: Repair of the defective steam traps
Status: Done. Ultrasonic leak test is conducted every half year. (Outsourced to
Spirax Sarco Inc.)(iv) Insulation
Suggestion: Repair of the deteriorated insulation of boiler room/the second floor.
Status: Done(v) Compressed Air
Suggestion 1: Low pressure operation when the micronizer is stopped.
Status: Conducted as required
Suggestion 2: Change of compressor setting pressure
Status: Done. The pressure setting of the base machine has been changed to 115
psi/cutout, 105 psi/cut in(vi) Sludge Treatment Equipment
Suggestion 1: Aeration control using the dissolved oxygen meter (DO meter)
Status: Done. Purchased the DO Meter and utilizing it for control.
Suggestion 2: Implementation of inverter for roots blower.
Status: Done. Utilized for aeration control together with DO Meter(vii) Other Activities
Transition from T8 lamp to T5 lamp: 50% done.
Cleaning of AHU filter (backwash)
Re-use of the recovered reject water of CEDI
(4) Personal Comment
It was not possible to take the quantitative back up because the substantial survey
time was only two hours. Though the technical difficulty level of the suggestions was
not very high, its high execution rate looked commendable.

15

4? Seminar and workshop(1)Date and Place
October 14, 2011 08:30 a.m. to 05:00 p.m.
Makati Palace Hotel 3F Convention Hall
(2) Attendants: 74 persons
A total of 74 persons joined including the administrative officials of the Philippine
government such as ECCJ, ACE, DOE, etc. The lecturers were invited also frominside the Philippines, a variety of programs as a whole, and hot discussions
continued until around 5:30 p.m. The outlines of the seminar were as below.
At the beginning of the seminar, Mr. Matanog M. Mapandi, assistant secretary of
DOE, Mr. Junianto M, on behalf of ACE, and Mr. Okamoto, on behalf of thegovernment of Japan, made the opening speech. In the address by ECCJ Mr. Okamoto,he expressed his gratitude for the support from various nations after the March 11
this year.
Shown below is a summary of the presentations made by each presenter at theseminar:(3) Summary of the Presentation
SESSION I: Policies, Programs, and Initiatives on EE&C
(i) Overview of ASEAN EE&C Programs and APAEC 2010-2015
The introduction of ACE, the outlines of APAEC, the role of ACE in it, cooperation
projects of (A) PROMEEC enterprise and MTPEC, (B) AEMAS with EU, andSOME-EU, (C) joint project with USA, award program, and other projects which areproposed by Korea and UNDP now by Mr. Junianto M from ACE. Among those, as aproject with the USA, it was decided at the meeting in Hanoi, Vietnam in December
2011 to support the implementation of a labeling system and testing devices within
the ASEAN area.
(ii) Overview of Energy Efficiency in the Philippines
The presentation was made on the prediction of departmental energy demand of thePhilippines and the Action Plan from this year until 2030 by Ms. Genevieve L.
Almonares/Science Research Specialist of DOE, Energy Efficiency and Conservation
Division.
(iii) Japan’s EC Policy and Measures and EE&C Experiences
In the beginning, PPT material was presented regarding the support from eachcountry after March 11, the description of the extent of damage, and the location of16

the Fukushima Daiichi Nuclear Power Station. Then the presentation followed
regarding the energy conservation policy of Japan and the energy conservation
experience in the industry as below:? The trend in Japanese energy use record, and a comparison of each sector
between the countries.
? The history of energy conservation policies in Japan? How Japanese companies are working on energy conservation.
? Top Runner Program? How to access the AEEC website for checking excellent examples and theintroduction of those examples.
(iv) Results of OJT Energy Audit at Wacky Corporation
The presentation was made on the results of the energy conservation OJT on asemiconductor manufacturing facility by Mr. Maximino G. Marquez/DOE. The
presentation of the company was made with the name Wacky Corporation, and thecomment from Mr. Maximino was added to the last page of the PPT material
prepared by the two experts, Mr. Kawase & Mr. Kunitoku (ref. Material – A)(v) Energy Management Practice
The introduction was made by Mr. Christopher T. Bellaflor regarding the examplesof the Toshiba semiconductor manufacturing facility, which received the two awards
for ASEAN Best Energy Management Practice and ASEAN Best Special Energy
Project. In the presentation, this facility was certificated as No. 2 under the AEMASGold Standard in August this year. An introduction was made on the termination of
the use of three low efficiency refrigerators, new construction of a high efficiency
water-cooling refrigerator, and the integration of refrigerator piping, the adoption of
LED lights, the chemical cleaning of cooling water piping, the recovery of exhaust
heat, and the improvement/small group activities regarding management.
(vi) Energy Conservation activities of semiconductor manufacturers in Japan
The presentation was made by the expert Mr. Kunitoku/ECCJ on the example of the
cut down of standby electricity and the application of the inverter to the fan andmotor, which received the award in Japan as the most excellent example of energy
conservation. Besides that, useful measuring instruments were explained using a
PPT presentation “Recording Instrument in EC activity.”(vii) Training plan for energy management personnel
The explanation was provided by the President Mr. Bernard E. Pacia, Energy
Efficiency Practitioners Association of the Phils., Inc./ENPAP, regarding theoutlines of energy management, the training and certification system of the energy

17consultant in Philippines.
SESSION III: The Way Forward(viii) Updates on the Development of PROMEEC EM Tools
The explanation was provided by Mr. Junianto M/ACE, regarding the status ofdevelopment of the technical directory, in -house database, and ASEAN Energy
Management Service and System.
SESSION IV: EE&C Technologies(ix) Japanese State-of-the-Art Smart Energy Products
As an introduction to a high efficiency product in Japan, Mr. Okamoto/ECCJ
introduced JASE-World, and as an example of technologies, a demonstration and an
explanation was provided on how to access the Centrifugal Chiller of Mitsubishi
Heavy Industries, Ltd. Then, the high efficiency large scale refrigerator of
Mitsubishi Heavy Industries Ltd. was explained using the PDF file “MHI HighEfficiency Centrifugal Chiller” (Attachment-B) from Refrigeration Systems of
Mitsubishi Heavy Industries Ltd., and its supplemental PPT material “Supporting
Technology for High Efficiency Operation of Chilled Water Supply system”(Attachment-C), which was prepared by extracting information from the Mitsubishi
Heavy Industries Technical Review. This is a newly started item this year. Initially
it was planned that the presentation would be made by a specialist from Mitsubishi
Heavy Industries Ltd. (MHI) regarding the High -Efficiency Centrifugal Chiller;
however, he could not come due to the sudden cut down of the time schedule, then aspecialist of ECCJ took over it on a short notice.
The seminar was closed with the greeting by Ms. Evelyn N. Reyes, Director, Energy
Utilization Management Bureau/DOE(4)Personal Comment
When an expert from ECCJ made a presentation using a real measuring device,
questions were asked by the attendants who showed great interest in the real device.
The presentation using a real device worked well. Additionally, it can be said that, asa business related presentation, the explanation on how to make a contact regarding
the High-Efficiency Centrifugal Chiller of MHI using PPT material for introduction of
the Website prepared by JASE-World was meaningful.
Additionally, the time schedule was changed from the plan made by the Inspection
Workshop. The plan was to invite an expert from outside ECCJ to offer meaningful
information to ASEAN nations, however as explained above, the invitation was notpossible. I assume that it was a loss of a very valuable opportunity for this country. I
hope FP will initiate closer coordination of the time schedule etc.

18

Pictures of Activities: PROMEEC Industrial Enterprise @Philippines

2011-10-10 Lecture by an expert at DOE

2011-10-10 Diagnosis by an expert at a
facility

2011-10-11 OJT members at Assessmentof energy conservation, the 2nd day.

2011-10-14 Opening address of Seminar

2011-10-14 Attendants to the seminar

2011-10-14 Presentation by an expert at
the seminar

Attachment (omitted)
Ⅰ: Assessment of energy conservation
1. Briefing of OJT Energy Audit for A-Facory
2. Presentation of Energy Conservation activities of semiconductor manufacturers
in Japan
3. Briefing of Follow-up Survey at Amherst Laboratory194. Tentative Power Recording for Energy Audit
5. FEP ENERGY AUDIT
6. Reply Questionnaire (final)
7. Briefing of OJT Energy Audit
8. Diagnosis Report of A-Facory OJT Diagnosis and B laboratories Follow Up
9. Result of OJT Energy Audit at A-Facory
10. Initial Findings and Recommendations
11. Briefing of Follow-up Survey at B Laboratory
12. Progress in Implementation for proposal of 2009 OJT Audit
Ⅱ: Seminar / Workshop
1. PROGRAM OF ACTIVITIES
2. Overview of ASEAN EE&C Programs and APAEC 2010-2015
3. Overview of Energy Efficiency in the Philippines
4. Japan's EC Policy and Measures and EE&C Experiences
5. Results of OJT Energy Audit at Wacky Corporation
6. ENERGY MANAGEMENT PRACTICE
7. Presentation of Energy Conservation activities of semiconductor manufacturers
in Japan
8. Recording Instrument in EC activity
9. Training plan for energy management personnel
10. Updates on the Development of PROMEEC EM Tools
11. Japanese State-of-the-Art Smart Energy Products & Technologies
12. MHI High-Efficiency Centrifugal Chiller
13. Supporting Technology for High Efficiency Operation of Chilled Water Supply
system20

Material A: Results of Energy Audit OJT at Wacky Corporation

21

22

23

24

Material B: MHI Promotion Document

25

26

Material C: ECCJ Expert Presentation Document

Supporting Technology
for High Efficiency Operationof Chilled Water Supply system

Real-time Achievable COP Display
Achievable COP is usually different from therated COP because operation condition isdifferent from the rated one.

From MHI Technical Report Vol. 48 No.2(2011)• Real-time Display of Achievable COP

If Achievable COP and Measured COP are
known, they help to keep high efficiency
operation.

• Total Operation Controller
for Chilled Water Supply System

Real-time Achievable COP calculation method
was established for both Inverter model and
Non-inverter model.
1

2

Accuracy of COP Estimation
Deviation of Calculated COP and Measured COP is less than 3%
Non-Inverter model

Inverter model

Total Operation Controller
for Chilled Water Supply System

Measured(solid line)

Measured(solid line)“Ene-Conductor”

Calculated(broken line)

Calculated(broken line)

It controls– Chiller unit On/Off and Load allocation– Chilled Water Flow
– Cooling Water Flow
– Cooling Tower Fan Speed

Cooling
water inlet
Cooling
water inlet

In order to maximize
Total System Efficiency
Load

Load
3

Simulation Results
Chiller
Cooling W Pump

Simulation Condition
Centrifugal

No of units

3
1000USRt

Chillers

Capacity(Inverter)

Rated COP

Cooling

No of units

3

TowersFan Power

2 x 7.5kW

Chilled6.1

No of units

3

Water

Input Power

2 x 37kW

Pumps

Pump efficiency

75%

Cooling

No of units

3

Water

Input Power

2 x 45kW

Pumps

Pump efficiency

0.75

Chilled W Pump
Cooling Tower Fan
26% reduction
by Total System
Optimization

Cooling
W PumpChilled Chiller COP
W PumpSystem COP

Chiller

Location: Japan

Without Total
System Control

Total System
Control

5

27

4

Ⅲ? Indonesia(Thermal Power Plant)
1? Outlines of Activities
During November 21–26, the group visited Jakarta/Indonesia for execution of an
Energy Conservation Project, conducted the assessment of energy conservation OJT ofa thermal power plant, and sponsored a seminar and workshop aiming at informationexchange with the related persons from industries in Indonesia and ASEAN nations.
Attendants to the diagnosis OJT were 6 persons from the central government, 16
people from the thermal power plant to be diagnosed, 3 experts from ECCJ, and 2
engineers from ACE: at total of 27 persons attended. For the seminar and workshop, a
total of 80 persons attended from the local industries and involved people from ACE &ECCJ, in addition to the attendants above.
Member Tsutomu Okamoto/Technical Cooperation Division of ECCJ, Sadao Higaki,
Hirokichi Takeda/Technical Expert
Schedule of Activities

Nov. 21- 24 Diagnosis OJT and the report of its result
Nov. 25

Seminar and workshop

2? Facility Assessment of energy conservation OJT (Thermal Power Plant B)(1) Attendants for the first day of diagnosis: 32 persons
Member (6 persons): Ms. Ani, Ms. Dewi, Mr. Dedi Suntoro, Mr. Andriyanto
Ms. Endang Widayati, Mr. Sonden Winarto
PT PLN HQ (4 persons): Mr. Basuki Siswanto, Ms. Tiva Winahyu DH
Mr. Alsusilo Handoko, Mr. Arif Susetyo
Thermal Power Plant B(10 persons): Mr. Rizki Dwi Kusworo, Mr. Arief Teguh andother members
PT PJB / excluding Thermal Power Plant B (4 persons) & others (3 persons)
ACE (2 persons): Mr. Pham, Mr. Bernard,
ECCJ (3 persons): Tsutomu Okamoto, Sadao Higaki, Hirokichi Takeda(2) Outlines of the Facility Thermal Power Plant B
Thermal Power Plant B belongs to PT PLN/PERSERO, a national power company ofIndonesia, whose total power generation capacity is 1,650 MW. It has nine power
generation units now, and two units of them (No.4 & No.5) are for steam power
generation, and the rest of the seven are gas turbines for combined cycle power
generation, a modern power plant as a whole. It started operation in 1981, and its
initial generation facilities were supplied by GE, and however Mitsubishi Heavy
Industries Ltd. took over all its new installation, revamping, and rehabilitation. The

28

table below shows the power generation capacity and the list of generators in thefacility.
For information, the power generation facility subjected to the assessment of energy
conservation OJT this time, was the No. 5 power generation facility built by MHI in1982 in the table below. It is a normal circulation water-tube type boiler of
evaporation speed 636 t/h, and gas / heavy oil combined combustion, combined /extracting / re-heating / condensing turbine with the power generating capacity of
200 MW.
The personnel organization of the power plant is seven managers for operation,
maintenance, shift, human resources, engineering etc., and a general manager(Plant Chief) above them. Those facilities built before 2000 are called “Block 2” andoperated with 10 personnel per shift, a total of 300 employees work in the whole
power plant; and the affiliate / subcontracting companies, other than that.
Year of
Installation

Total Generating
Power/TypePower Generation
Capacity x Number of
Units

1982

400 MW/ STG

200 MW/ST x 2

1993

500 MW/ CCGT

Fuel

Gas ?
Heavy OilGas

Supplier ofMain Equipment

MHI, MELCO

107 MW/GT x 3
GE+ 185 MW/ST x 1
2010
750 MW/ CCGT270 MW/GT x 3
Gas
MHI, MELCO+ 70.6 MW/ST x 3(STG: Steam Turbine Generator, CCGT: Combined Cycle Gas Turbine)(MHI: Mitsubishi Heavy Industries, Ltd, MELCO: Mitsubishi Electric Corp.)(3)Outlines of Diagnosis
1) Member of Assessment team
From the attendants listed above, 16 persons participated in the assessment ofenergy conservation OJT, excluding experts from ACE and ECCJ. It consisted offour persons from MEMR, three from thermal power plant B, six from the national
power company other than the thermal power plant B, and three from other parties.
The 16 persons were divided into two groups for the assessment of energy
conservation OJT on the thermal energy facility and the electrical energy facility. A
leader and a secretary were selected from each group. Staff of thermal power plant
B was selected for the leader for each group. A doctor from the research institute of
the national power company was selected as the reporter for the seminar on the last
day.

29

2) Procedure for Diagnosing
The diagnosis was conducted in accordance with the following procedures: thehearing of the energy conservation activities of the facility, inspection of the shop
facility, measurement using the measuring instrument and the data collection fromthe record of operation, data analysis and planning of energy conservation measure,and reporting the result of the diagnosis to the related people in the facility. At eachpoint of diagnosing work, the meaning of each work was explained to theattendants; and the midway data analysis was made, and the process of data
analysis was explained and instructed. In order to ensure the interactive
explanation and instruction, ingenuity was made by explaining to the attendants infront of a whiteboard to measure and record by the attendants themselves.
3) Measuring Instrument
The instruction was provided for the six measuring instruments from Japan
regarding the purpose and methods of taking measurements. At the practicalmeasuring, an expert showed an example of measuring, and then let the attendants
measure and record it.
No.
1

2
3
4

?
?

Name of
Instrument
Thermo Camera

Manufacturer, Type No., Spec.

NEC AVIO Infrared Technologies
Co., Ltd.
Type No.: F30W
Spec.: Measuring Temp.: -20? 350?
Contact-type
TESTO
thermocouple
Type No.: 905-T2
thermometer
Spec.: Range: -50°C to 350?
Radiation
CUSTOM
Thermometer
Type No.: IR-303
Spec.: Range: -55°C to 350?
Ultrasonic
Leak EXAIR
Detector
Type No.: ULD
Spec.:Detect the leakage ofcompressed air, etc. as far as max.
6.1 m away.
Listening Rod
A long screw driver was used.
Luxmeter/
Thermometer/
Hygrometer/
Anemo-multimeter

Manufacturer: MK Scientific
Corporation
Type No.: LM8000
Spec.: Temp. Range: 0°C to 50ºC
Humid. Range: 10% to 90%RH
Lux. Range: 0–20,000 Lx

PurposeMeasuring the surface
temperature ofmachinery, piping, etc.
Measuring the surface
temperature ofmachinery, piping, etc.
Measuring the surface
temperatureofmachinery, piping, etc.
? Checking the leakageof compressed air? Checking the operationof steam trap
Checking the operationof stem trap
? Checking the Air
Conditioning? Checking the Lighting4) Facility Subjected to the Energy Conservation OJTThe number 5 power generation facility, which was subjected to the energy
conservation OJT diagnosis this time, is equipped with a normal circulation water-

30

tube boiler, which mainly uses heavy oil as fuel, but also natural gas can be
combusted. However, when the OJT was made, only the heavy oil was used. A
combined/extracting/re-heating/condensing turbine, the startup was in 1982, themanufacturer was Mitsubishi Heavy Industries, Ltd. The design conditions, and theoperating conditions at the OJT diagnosis with ( ), are indicated as below;
Steam Generation: 636 t/h (624 t/h)
Steam Temp. /Pressure of Turbine: 12.65 MPaG/538℃ (127 MPaG/541℃)
Output of Steam Turbine Generator: 200 MW (201 MW)
5) Contents of Assessment of energy conservation OJTDue to time restrictions, the following was focused on as the contents of the
instruction of assessment of energy conservation at this power plant.
(i) The calculation of the efficiency of boiler, the efficiency of steam turbine
generator, and the total efficiency of power plant facility(ii) Confirmation of lagging/insulation status of machinery and piping(iii) How to check the operation of steam traps(iv) Compressed air system for control(v) Illumination inspection of lighting equipment by sampling(vi) Other electrical equipment
6) Result of Assessment of energy conservation OJT(i) -1 The instruction for calculation of boiler efficiency, the efficiency of steam turbine
generators, overall efficiency of power generating facilities
The instruction was provided by having the attendants calculate the efficiency
based on the acquired data, besides instructing them on how to calculate efficiency.
The following was also taught:-

The O2 percentage in the exhaust gas is automatically controlled: the labo test
showed 1% to 2% of O2 content, which was the no-problem level for a boiler
whose major fuel is the heavy oil.

-

The equation of each efficiency is as below, however the reheated calorie wasadded to the boiler output heat, and the reheated calorie of boiler was added tothe steam turbine input heat, because the steam turbine was the re-heating
type.

31

[Equation of Boiler Efficiency][Equation of Steam Turbine Generator][Equation of Overall Efficiency of Power Plant][Result of Calculation]
The results of each efficiency calculation were as follows, and the figures werereasonable for a power plant with this class of steam condition.

32

Boiler Efficiency
Energy output
Live steam output
Reheat steam output
Auxiliary steam
Blow down
Total energy output
Energy input
Heavy Fuel Oil HHV
Fuel mass FlowHeat input
Boiler efficiency based on HHVSteam Turbine Generator Efficiency
Energy output
Generation Power
Energy input
Main steam input
Reheat steam Energy input
Total energy input
Steam turbine generator efficiency

Power Plant Overall Efficiency
86.89×41.45

GJ/h
GJ/h
GJ/h
GJ/h
GJ/h

1,500.73
237.93
1,738.67

kJ/kg
kg/h
GJ/h
%

43,324.14
46,188.00
2,001.06
86.89

kWh
GJ/h

200,200
720.72

GJ/h
GJ/h
GJ/h
%

1,500.73
237.93
1,738.67
41.45

%

36.0

(ii) Confirmation and Instruction for lagging/insulation
Pictures around the two boilers with thermal mode and normal mode are takenusing a thermo camera. The thermo camera is a very effective tool for confirmation of
lagging/insulation status as one of the measuring instrument for assessment of energy
conservation because it can quantitatively figure out the surface temperature
distribution in a wide range. Some part of the boiler side wall showed a little higher
temperature (max. 65 degrees Celsius); however, generally the temperature was low
and considered to have no problem regarding the insulation status. Furthermore, thethermal insulation of the main steam pipe was good enough, while the defect ininsulation was found where the surface temperature of the peripheral two-inch pipes
showed a high of approximately 120 degrees Celsius. For the thermo camera and themeasuring examples, please refer to the report for the seminar.
(iii) Instruction for Checking Steam Trap
Not very many steam traps were used in this power plant; however, the major placesof use were the heavy oil steam heater for the heavy oil burner and the steam transfer
piping, etc. Instruction was provided for checking one of the steam transferring pipes,
using a listening rod. (The operating condition was normal.) At the same time, an

33

explanation was provided on the need for a periodic check of the steam trap.
(iv) Compressed Air System for Control
The compressed air system for control of units 4 and 5 was the dual air compressor
type, with continuous operation of one set. (Changeover of No. 1-main and No. 2 standby)
The volume control is by load/unload; the on load/unload pressure was set to0.74[MPa]/0.86[MPa] for No. 1 machine, controlled based on the outlet pressure of the
air compressor. The year of revamping was relatively recent 2002; however, theinverter was not used. (It is indeed an important factor for the energy conservation
measure to consider the implementation of energy conservation equipment atrevamping.)

System Configuration of Unit 4, 5 Air Compressor Systems for Control-

Receiver tank capacity : 2 [m3] ×2 [set]-Dryer : type : Refrigerated type ×4 [set]-Number of current operating machine : 1[set]-Automatic control : Start / stop operation : manual operation at control room

Automatic on load / unload change control: yes-

Setting value of load / unload pressure of each air compressor

AC #1: on-load: 0.74 [MPa], unload: 0.86 [MPa]Specifications and Status of Use of Unit No. 4 &5 Air Compressor for Control

34

Facility
name
ATLAS
COPCO 1, 2

Air Compressor

Motor

Type

Capacity control[m3/min]

[MPa]

[kW]

[V]

[A]

[rpm]

Screw

On-load /unload

15

1.0

121

380

125.6

2,980

(iv) -1 Measurement of Unloading Rate
[Table 2.1.2-3 Measurement of Unloading Rate of Air Compressor No.1]
Measured data by audit members
Measurement term : abt. 6 min ? Data interval : 1 [sec], number of data : 6
Nov. 22, 2011
FacilityName
ATLAS COPCO 1

On load

Un loadAve. [kW]

[sec]

[%]

Ave. [kW]

[sec]

[%]

128.3

177

51

27.3

169

49

(Remarks) (a) Calculation of Input Power (Only current and voltage are measured)
Loading Power : v3 ×0.38[kV] ×216.6[A] ×0.9 = 128.3[kW]Unloading Power : v3 ×0.38[kV] × 63.8[A] ×0.65 = 27.3[kW]The need for acquiring performance test data on the motor was explained because theefficiency/power-factor varies in accordance with the loading factor. Ideally, long termmeasuring is required including all the loading conditions of compressed air; however,this time it was not possible to make long-term chronological data collection because
the measurement was made by a measurer on-site using a clamp type ampere meterand a watch. The measured unloading rate showed approximately 49%, whichindicated the occurrence of large unload loss. Furthermore, the frequent onload/unload was observed (approx. 31 times/hr), which indicated that the capacity of
the air compressor largely surpassed the air consumption.
(iv) -2 Confirmation of Pressure of Air Compressor System-

Receiver Tank: 8.5[kg/cm2], After Dryer: 8.2[kg/cm2], Before Control Valve:
8.0[kg/cm2]-

Control Valve Pressure (Output of Reducing Valve ): 18 ? 38[psig](0.12 ?
0.26[MPa])(Sampling Check)

The discharge pressure of the air compressor was approximately 0.8 [MPa] (averageof unload/on-load pressure), comparatively higher than normal.
-

The required pressure at the end user of the compressed air was one of thesurvey items; however, it was unconfirmed because an interview was notconducted. This is a required item of the survey, for reducing the discharge

35pressure of the air compressor.
(iv) -3 Measurement of Air Leakage
The plan was to survey the air leakage of each worksite using the air leak checker
carried by the experts; however, it was not possible due to the shortage of time. For
information, it seems the periodical air leakage check is not conducted at this plant.
(iv) -4 Temperature Data
Temperature Data of Air Compressor
Facility name of AC

ATLAS COPCO 1

Intake air

Ambient

Different temperature

Ti [? ]

Ta [? ]

?T [? ]

34.3

33.0

1.3

Although the installation of the air compressor was indoors, its inlet air temperature
was close to the room temperature of the building because it was the water coolingtype whose temperature difference was not at problematic level.
(iv) -5 Confirmation of Result of Survey Using a Check List
Check List of Energy Conservation of Air Compressor

36

(iv) -5 Estimation of Energy Conservation EffectBecause the number of data acquired was small, they were only for reference;
however the quantification of the effect of energy conservation was tried.
a) Cut down of Unload Lossa)-1 Energy Conservation by Implementation of Inverter to the Unit 4 & 5 AC forControlPresent loading is input power 128.3[kW] and loading rate 51[%], while the average
power consumption of 65.4[kW] and inverter efficiency of 95[%] at the time when
the inverter was implemented; it is assumed that the motor efficiency isapproximately equal.
(a) Power saving by Cut down of Unload Loss
?kWh 1 = [(128.3 kW × 0.51 + 27.3 kW × 0.49)–(128.3 kW × 0.51 / 0.95)] × 8,760 [h/y]= (78.8 -68.9) × 8,760[h/y] = 86,724 [kWh/y](b) Power saving by Lowering the Discharge Pressure
It is assumed that the discharge pressure is controlled to the present on-loadpressure setting of 0.74 [MPa] by implementation of the inverter.
Reduction of Pressure: “ 0.8 [MPa] ⇒ 0.74 [MPa]” (? 0.06 [MPa])- Cut down Rate of Power Consumption
W2/W1 = {(0.74+0.1013) / 0.1013} 0.4/1.4-1] / [{(0.8+0.1013) / 0.1013} 0.4/1.4-1]= 0.831 / 0.867 = 0.958(Note) 1.4 : insulation factor of air- ?kWh 2 = 128.3[kW]×(1–0.958)× 8,760[h/y]×0.51 = 24,074 [kWh/y]c) The Overall Power Cut down
?kWh 1+ ?kWh 2 = 86,724 + 24,074 = 110,798 [kWh/y]a)-2 Cut down of Unload Loss by Downsizing of Unit 4,5 AC for Control
The energy conservation effect was estimated regarding the change of the relevant air
compressor to 75 kW, given that a standard specification machine is chosen.
The unloading rate of 49% of this machine downs to approximately 21% when the 75
kW machine operates. However, the input power to the air compressor wasapproximately proportional to its capacity, and the motor efficiency to be 0.9.
Furthermore, it was assumed that the power consumption rate of 75 kW machineduring unloading was equivalent to the relevant machine.
?kW = (128.3 kW × 0.51 + 27.3 kW × 0.49) – (83.3 kW × 0.79 + 17.7 kW × 0.21) ×
8,760 h/y
= (78.8 – 69.5) × 8,760 h/y = 81,468 [kWh/y]Power-Saving percentage = 9.3 / 78.8×100 = 11.8 [%]b) Reduction of Discharge Pressure of Air Compressor
The average discharge pressure of present air compressor 0.8 [MPa] is higher thannormal having the possibility of realizing the energy saving by the discharge pressure

37

down. This time, the energy conservation effect was estimated based on a certain
precondition, because it was not possible to make clear about the pressure distributionof each part, and the minimum required pressure at the end user.
- Reduction of Discharge Pressure
Load/Unload average pressure: Present 0.8 [MPa] (0.74/0.86[MPa] ⇒ temporarily
assumed as 0.66 [MPa] (0.6/0.72)
0.6 [MPa]: assumed that, pressure loss of dryer 0.05 + pressure loss of piping 0.05
+ minimum required pressure 0.5
W2/W1 = {(0.66+0.1013)/0.1013}0.4/1.4-1]/[{(0.8+0.1013)/0.1013} 0.4/1.4-1]= 0.779 / 0.867 = 0.899?kW = 128.3 kW × (1-0.899) × 8,760 h/y × 0.51 = 57,893 [kWh/y](iv) -6 Recommended Items for Future Energy Conservation Plan
The diagnosis this time was a simplified one for OJT; however, it is necessary toacquire the data for a certain period that will allow covering all the loading conditions
for the air compressor for conducting the actual energy conservation measure.
Furthermore, it is recommended to accurately grasp going forward the various
quantities such as the maximum air consumption, the average unloading rate, andthe pressure drop, etc., necessary for the investigation of energy conservation.
(a) Reduction of Unload Loss of Air Compressor
The unloading ratio of this machine was 49 [%], which was so large that the energy
saving effect by reducing this figure is expected. In addition, the AC for units 4 and 5
also has the high unloading rate of approx. 54 [%], under similar conditions as theabove.
- Implementation of Inverter Type Air Compressor
The investment efficiency is the subject of future investigation; it is better toinvestigate at the time of replacement of the old one or when revamping.
- Change to Smaller Size Air Compressor
For the purpose of reducing the unloading ratio, we will recommend an
investigation to change to a small capacity air compressor, after grasping the
maximum required capacity of compressed air. If there is an existing idle machine,
it is desirable to make use of it than newly implementing.
(b) Reducing the Discharge Pressure of Air Compressor
After this, we recommended a gradual reduction in the discharge pressure by settinga certain target for a new discharge pressure after the investigation of the pressure
distribution of each place and the minimum required pressure for the load side, etc.

38

(c) Reducing the Air Leakage
It is necessary to continuously know the location of air leakage by daily and periodical
checks and by the air leak test during the plant shut down maintenance, and then to
make repairs.
(d) Future Investigation for Integration of Air Compressor
The air compressors are installed unit by unit, or use by use; however, the energy
saving effect such as the reduction of the number of operated units or unload loss, etc.
can be expected by integrating these units. The integration of the air compressors
between the units 4 and 5 and the block I and II is a future subject. Because thecontrol room under control is separate, it seems a little difficult to integrate the units
4 and 5 and block I and II; therefore, it should be planned to integrate the aircompressors for control of the units 4 and 5 and for units 4 and 5 for the plant. Bothare located near each other, and their specifications and the applied pressures areapproximately the same and have the interconnecting pipin g. The multiple unit
control system seems to be necessary for the integration of air compressors.
(v) Sampling Illumination Check of Lighting Equipment
The lighting equipment was not considered as the object of the energy conservation
OJT in the beginning; however, unnecessary lighting or too bright lighting was foundduring the walk through on the first day, it was then decided to conduct a simplified
diagnosis on a very short notice.
(v) -1 Viewpoint of Energy Saving(a) Drastic Management of Black Out
Black out of lights when unnecessary and when no one is present.
(b) Proper Illumination Management
Drawing up of a proper illumination standard, reduction of the too bright lighting.
(c) Change to a High Efficiency Lighting Instrument(v) -2 Result of Survey
The fluorescent lamp (40 W x 2) was the major indoor lighting combined with thenatural lighting near the windows, excluding the turbine floor. On the turbine floor,
the high-pressure mercury vapor lamp (250 W) area and the high-pressure Natrium
lamp (250 W) share the area.
(a) Status of Management of Blackout
The management of blackout was not enough because the lights of theentrance/exit area were not turned off when no one was present or during fairweather, while the lights in some areas were partially turned off.

39

(b) Standard for Shop Illumination
It seems that there was no definite standard, and so JIS Z 9110 was introduced as
requested to offer a lighting standard from Japan.
(c) Measurement of Lighting Intensity
Sampling measurement of lighting intensity was conducted by the team members,
using the lux meter brought by the specialists.
Sampling Measurement Data of Lighting Intensity at Various Places
Room nameTurbine FloorPlace
3rd floor

Control RoomTime zone Condition Lux Std

Illumination [lx]10.00

cleaning

70-15087

86

57

3rd floor

10.15

529

491

539

MCC Room

2nd floor

10.30

cleaning 300-750
cleaning 150-300

65

112

116

Swich Gear

2nd floor

11.00

cleaning 150-300

26

73

148

75-150

250

234

213

75-150

90

215

20

cleaning 150-300
cleaning 75-150

300

699

414

191

115

117

BFP
(Boiler
feed 2nd floor
pump)CP(Condensate
1 floorPump)
2nd floor
Relay HouseAUX Cooling Water

1 floor

11.15
11.30
13.00
11.45

cleaning
cleaning(Remarks): JIS Z 9110 was applied for ”Lux Std.” with adjustment. “Condition”
indicates the status of stain on the lighting equipment (lamp, reflector)
As compared to the lux standard, some of the lights show overs and shorts on thelighting intensity. Most of the areas with shortage of intensity were non-resident;
therefore, it was not problematic except when there is a worker; however, the overlighting areas need the reduction of intensity for energy saving regardless ofwhether manned or unmanned.
(d) Confirmation of Result of Survey using a Check List
Check List for Energy Saving on Lighting Equipment

40

(v) -3 Recommended Items for Future Energy Conservation Plan
The status of energy saving on the lighting equipment is considered to be one of theindexes of the implementation status of the energy conservation activities of the
facility. For this point, the status of energy saving at this plant looks like there issome room for improvement.
(a) Drastic Management of Blackout- To enforce the careful blackout for unnecessary areas and unpeopled areas.
- Implementation of automatic switching of lights: Installation of the motion sensor to
the walkway, etc. introduction of lux meters in the area with natural lighting- Implementation of individual switch for lighting: To install a switch for the lighting
at the entrance of Relay House etc. that turns on when necessary, and controls theblackout when no one is present.
(b) Proper Management of the Lighting Intensity- Planning of a proper lighting intensity standard- Removing the unnecessary lighting instrument- Re-arrangement of the existing lights- Adoption of Task-Ambient Lighting: Install fluorescent lights along the walkway andrecommend turning off all the ceiling light under normal conditions.
(c) Change to the High Efficiency Lighting Instrument- Addition of High Efficiency Reflector (mirror type): Fluorescent Light (40 W × 2)
⇒ (40 W × 1): Energy saving by approx. 50[%]- Change to the Hf type Fluorescent Light: Fluorescent Light (40 W)⇒(32 W):
Energy saving by approx. 20[%]- Change of Mercury Lamp to Natrium Light, etc.: Mercury Lamp for Turbine
Floor, etc. Energy saving by approx. 30% to 50[%]

41

- Introduction of LED Lights: Fluorescent light substitute: Energy saving by
approx. 50 [%]: The introduction was made on an example of energy saving inJapan using the LED light.
(vi) Pump, Fan & Blower Facility
The pump, fan, and blower facility was not diagnosed due to the shortage of time;
however, it is hoped that the Indonesia side will further continue the activities
because there are still many facilities targeted for an assessment of energy
conservation in this plant. The pump, fan and blower facilities other than thefollowing are unconfirmed.
(a) Pump Facility? The Cooling Sea Water Pump (710 kW x 9) are confirmed at site, when it wasreported that the discharge valve was fully opened because the load side does nothave a flow control valve; therefore, it is assumed that there is still some room foradjustment through the proper grasping of the flow rate.
? The speed of the boiler feed water pump is controlled using the fluid coupling.
? The present status has not been grasped yet on the wash water pump.
(b) Fan & Blower Facility? It was reported that the inverter was implemented and the suction damper was
fully opened for operation of GRF, FDF (2 sets) for unit 4; however, it was notconfirmed about GRF, FDF for unit 5 and the block I and II. It remains as a subject
for investigation in the future because there is the possibility of the energy saving if
the damper control is still used.
The subjected facilities this time are only part of all; however, the effect oftransferring the result of the detailed investigation for both the compressed air
system and the lighting facility is expected.
Subjected
FacilityComp.
Air
SystemLighting
Facility

Table of Energy Conservation Reviewing Plans
Suggested Energy Conservation Itemsa)-1 Energy saving by implementing the inverter machinefor the AC for control of Unit 4 & 5a)-2 Cut down of unloading loss by downsizing of AC forcontrol of Unit 4 & 5b) Reduction of discharge pressure of AC for control of Unit
4 & 5 (Temporarily: ? 0.14 MPa)c) Cut down of air leakaged) Future investigation for integration of air compressorsa) Management of blackout of lighting when unnecessary(Auto-on/off, installation of individual on/off switches)

42

EnergySaving[%]
16

EnergySaving[kWh/y]110,798

12

81,468

8.4

57,893--b) Adequate management of lighting intensity (Developing
the Lux Standard, Removing unnecessary lights, Rearrangement of layout)c)-1 Implementation of High efficiency reflectorc)-2 Change to the Hf type fluorescent lightc)-3 Change of Mercury light to Natrium light, etc.
c)-4 Introduction of LED light(Fluorescent light substitute)--

approx.
50
20
30-50
approx.
50-7) Questions and Answers(Q) Effect of implementation of inverter: (A) The explanation was provided regarding
the effect of speed control using the inverter, taking the constant dischargepressure control of pump as an example.
(Q) Harmonic of inverter and Hf fluorescent light: (A) AC reactor or DC reactor isconnected to PWM inverter. No problem of harmonic if the Hf fluorescent light ismanufactured in accordance with JIS.
(4) Personal Comments
The No. 5 power plant, subjected to energy conservation OJT, has been operated forapproximately 29 years; however, maintenance and rehabilitation are properly andadequately conducted because the facility looked to be in good condition, and the
instruments were updated to new ones. Also, regarding the status of operation, where
the steam condition of the boiler is dominant to the overall efficiency of steam power
generation facility, the following other various factors that influence efficiency were
well managed.
The various instruments were prepared for this assessment of energy conservation,and instruction was provided for its use: since these instruments are highly effective
as they allow quantitative assessment, it is hoped that the assessment of energy
conservation is conducted making use of these within the extent only where absolutely
no adverse influence is observed on the operation of the facility. The trainee showed astrong interest especially in the thermo camera, which is easy to use because of its
small size, and which makes it possible to easily and quantitatively diagnose thelocation of defective lagging and thermal insulation.
All the team members from Indonesia, which were composed of eight persons
mainly from PT. PJB, worked diligently. I expect good work in the future because thetechnical level of the attendants from Indonesia side was fairly high, and theirawareness of energy conservation was also high. However, they did not appear to havemuch experience in assessment of energy conservation; occasionally the uncertainnessof collected data or waiting for instruction approach was observed. It is required for43-the team members to accumulate actual work experience by further conducting theassessment of energy conservation. To this point, I am very sure that the OJT
diagnosis was very meaningful because the attendants from Indonesia actually joinedand voluntarily participated in the diagnosis.

3.

Presentation on Revamping of Isogo Thermal Power Plant, etc.
Following the presentation by the energy conservation OJT Groups 1 & 2, apresentation was made by J-POWER, regarding the efficient operation and revampingof the facility of Isogo Thermal Power Plant, along with the attachment C (ref.
Attachment-E). The active questions and answers were made regarding thispresentation. The following is a summary of it;(Q) What is the difference in IGCC and the conventional coal thermal power
generation? (A) The efficiency of most advanced USC/Isogo is 43%, the power
generation efficiency of IGCC is 50%, and that of IGFC is 60%. This is an important
advantage. It is a facility under testing, and now under investigation for expansion.
JP has a plan to construct a 200 MW scale plant.
(Q) Is it necessary to have an activated coal facility for the dry-desulphurization? (A)The activated coal facility is not located near the power plant. Occasionally, coal from
China is used. Initial charge of the activated coal is 4,000 to 5,000 t/unit, and its
yearly quantity for supplementing is 3,000 to 4,000 t/h/y (per unit).
(Q) Who owns the intellectual property of USC, Mitsubishi, or JP? (A) The
development of USC has been undertaken by JP with support from the government.
All the heavy industrial machinery suppliers in Japan joined this development. Eachsupplier has been making an effort to develop unique material and designs, then it
can be said that it belongs to the intellectual property of each supplier, but USC itself
does not belong to someone in the suppliers.
(Q) Does the government pay all the technical development costs of IGCC? (A)The
government supports the cost, but the developers (e.g. JP) also bear the cost.
(Q) What is the coal type used for USC, calorie? (? ) Indonesian coal is also burned.
Generally, high quality coal of over 6,200 kcal/kg.
(Q) What happens if low quality coal is used for USC? The boiler size becomes larger,
for example? (? ) Exactly. Technically, it is no problem. The subbituminous coal isplanned to be used for a 200 MW coal thermal plant project of JP proceeding now inthe central Java.
(Q) How high is the operating rate of coal thermal power plant? (? )Depends on thesituation, but possibly over 90%. The average operating rate of Takasago was about
80% in 40 years, but influenced by the power demand or law (frequency and durationof periodical checks).

44

(Q) What is SCR? It is not familiar in Indonesia. Is it related to Kyoto Protocol? FGD
is the wet type. (A) It stands for Selective Catalytic (NOx) Reduction, familiar inJapan and other European countries and the US. Its contribution is the reduction ofNOx, which is the reduction of influence to the regional environment, rather than to
the global environment. The decision of SCR can be adopted or not will depend on the
figures in the regulations. The wet type requires a large quantity of water for FGD,
which would tell that Isogo would require twice as much water for twice as muchoutput if the wet type were applied; for the purpose of saving the industrial water, thedry type was adopted.
(Q)Please explain about the combustion management system. (A) The explanation
was provided on the combustion simulation in the presentation. This was applied forsolving the problems in the boiler for the National Thermal Power Corporation
Ltd/NTPC, and the suggestion was the re-arrangement of the boiler panel. This was aspecial example. As normal management of combustion, the central supervisory
instrument for metal temperature and exhaust gas temperature, and the analyzed
figures of non-combusted material in the ash, the burning condition observed throughthe inspection window during operation are watched for the overall judgment. The
report will be found if the “JICA Study” is searched on the website.
(Q) How much was the cost for construction of Isogo? (A) Approximately JPY 0.2
mil/kW for 1 & 2
4. Seminar and workshop(1) Date and Place
November 25, 2011 8:30 a.m. to 5:00 p.m.
Bidakara Hotel 3F Convention Hall
(2)Attendants: 80 persons(3)Summary of Presentation
The chair of the seminar was Mr. Oscarlito C. Malvar/ACE. The opening address
was made by Ms. Indarti, Chief of EEC, MEMR, New and Renewable Energy andEnergy Conservation/NREEC, the greetings for holding a conference from Ms.
Maureen/ACE, and Mr. Okamoto/ECCJ. In the greeting message by Mr.
Okamoto/ECCJ, the gratitude was expressed to the support from various countries
after the March 11. The summary of the presentation made by each presenter islisted below.
SESSION I: Policies, Programs and Initiatives on EE&C
(i) Overview of ASEAN EE&C Programs and APAEC 2010-2015: The introduction of
ACE, the outlines of APAEC, in which the role of ACE, PROMEEC project and45

MTPEC were introduced by Ms. Maureen/ACE. The material for this presentation
was equivalent to that presented in Manila.
(ii) OVERVIEW OF ENERGY EFFICIENCY AND CONSERVATION ACTIVITIESIN INDONESIA: The introduction was made on the energy demand record of2010 in Indonesia, demand prediction until 2025, history and plans of EC policies
and the status of the overseas aid by Ms. Andria Feby Misna/ FP.
(iii) Japan’s Energy Conservation Policy and Measures and EE&C Experiences: The
introduction was made on Japanese history of energy consumption, remedy to theenergy conservation law, Top Runner Program and how to access the excellent
examples in the website of AEEC by Mr. Okamoto/ECCJSESSION II: EE&C Best Practices in Industries(iv) On the Job Training ENERGY AUDIT IN POWER PLANT: The introduction
was made on the result of the assessment of energy conservation OJT conductedon the power generating plant by Dr. Tiva Winahyu/National Power
Company/Research Institute. (Ref. Attachment-D)(v) Case Study of Successful EE&C Countermeasures: The introduction was madeon three examples of energy conservation conducted at a power plant in Japan by
an expert Mr. Higaki/ECCJ.
(vi) Energy Conservation Successful Cases in Japanese Power Plants (Electrical
Equipment): The introduction was made mainly on the twelve examples of theenergy conservation conducted at thermal power generation plant in Japan,
which got the prize for the excellent energy conservation in Japan by Mr. Takeda,
an expert from ECCJ. These examples of power saving are the summary of theabstract from the presentation made at the national convention of energy
conservation from 1999 to 2008 for the presentation of excellent examples by
ECCJ. The following one question was asked.
(Q)Regarding the prevention of accident of transformer (A) The tendency
management using the analysis of the gas in the oil of the transformer has been
conducted in Japan since more than 30 years ago. The standard for the
diagnosis is defined by each company. (e.g., Oita Works has the standard for the
judgment of transformer deterioration established in 1973.) For example, if
acetylene is detected, the burn out of the insulator inside is suspected.
(Furfural, CO + CO2, etc. are adopted for lifetime diagnosis) Regarding thedetails of the gas analysis, it was recommended to consult a power company in46

Indonesia who is probably conducting it.
SESSION III: The Way Forward(vii)Updates on the Development of PROMEEC EM Tools: The explanation wasprovided regarding the status of development on the Technical Directory, In-house
Database, and ASEAN Energy Management Service and System by Mr.
Pham/ACE.
SESSION IV: EE&C TECHNOLOGIES(viii)Japanese State-of-the-Art Smart Energy Products & Technologies: As theintroduction of high efficiency product in Japan, the introduction of JASE-World
was made, and as an example of technical database, instruction was provided foraccessing the Centrifugal Chiller of Mitsubishi Heavy Industries, and theacquired information was displayed and explained by Mr. Okamoto/ECCJ.
(ix)The Latest and High Performance Coal-fired Power Generation: Asked Mr.
Shimizu/J-Power to make a similar presentation made at the thermal power
plant yesterday. (Ref. Attachment-E) The active questions and answers are listed
below:(Q)Do not know the details about IGCC/IGFC, but they seem to be the
combination power plant. Probably they are different from the conventional coal
thermal power plant, but how high is their efficiency? (A) IGCC/IGFC does nothave a combustion furnace; they have a gasification furnace. IGCC is the dual
combined cycle system in which the generated gas burns in GT, then its exhaustgas generates the steam in HRSG, and then power is generated at ST. On theother hand, IGFC is a triple combined cycle system in which part of the generated
gas goes through the FC for power generation, and then generates power together
with the remaining generated gas in GT⇒HRSG ⇒ST. The power generation
efficiency of IGCC 1500-degree class GT is 51% to 53%. That of IGFC is over 60%,
Isogo is 43%.
(Q)How is the quality of coal for IGCC/IGFC(? )The high quality imported coal ofover 6200 kcal/kg is used in Japan. It seems IGCC/IGFC also uses this type ofcoal. The gasification furnace has the structure in which the molten ash drops tothe bottom, therefore suitable for the coal with ash with low melting point;
however, the test is made also on the coal with high melting point ash for
widening the range of coal type.
(Q)Is IGCC a commercially operated?(? )It is now under verification test, not acommercial operation.
(Q) Surprised at the cut down of NOx at Isogo. 159 ppm ⇒ 13 ppm. It was
explained that it was achieved by SCR, but is there another way for a cut down?

47

(A) Previously Isogo was using the Low NOx burner and the two stage combustion
for a cut down of Nox. However, by adopting SCR, NOx can be significantly cut
down. This method is to pour in the ammonia to reduce the NOx to N2 gas andwater (steam) by catalyzers.
(Q): A question to Mr. Takeda/Experts of ECCJ, regarding the judgment criteriaon the efficiency (soundness) of the transformer / Sometimes the transformer will
breathe fire when the operation is continued not knowing the condition of thetransformer.) (A: The supplementary explanation by an engineer of J-Power) The
explanation was provided regarding JICA Study in this presentation; in it, RLA(Remaining Life Assessment) was conducted for transformers. By searching a
Study Title in the JICA website, information can be acquired at no charge, suchas CO/CO2 analysis, Furfural Analysis, DP (Degree of Polymerization) for
insulation paper important for soundness assessment.
The seminar was closed with the address made by Ms. Indarti, Director ofConservation of NREEC, MEMR.
(4) Personal Comment
The attendants to the OJT were asked to make a presentation, on the result of theassessment of energy conservation OJT, similarly as the activities in the Philippines.
The material and the presentation was a sophisticated one. It was difficult to say thatthe contents of the diagnosis was sufficient due to the limited time; however, we hope
those materials handed over to them and the explanation during OJT will be fully
utilized, and used for the assessment of energy conservation in the future. As a firsttrial, asked to make a presentation by a similar thermal power plant regarding thestatus of Japanese high efficiency operation etc. at the last day in the shop and during
the seminar. It was easily guessed that it was a good chance to listen to the very
meaningful presentation, for Indonesia side, as it appeared like in the hot discussion
at the presentation.
The schedule of this activity became different from the one decided at the Inspection
Workshop. From this year, planned to invite the experts from outside ECCJ to join, for
supplying the meaningful information for the ASEAN nations, and enforced it.
Therefore, I would like FP to more closely exchange information regarding theschedule etc.

48

Pictures of Activity: PROMEEC Industrial Entreprixe @Indonesia

2011-11-21 First day of the assessment ofenergy conservation/ Explanation ofoutlines of the facility

2011-11-23 Inspection of the function of
the steam trap

2011-11-23 Instruction of Group 1 by the
specialist

2011-11-22 Instruction of Group 2 by the
specialist

2011-11-25 Meeting place for seminar

2011-11-25 Scene from the seminar (lastpresentation)

Attached Materials(omitted)
1: Outlines of Muara Karang Power Plant
2: Company Organization Chart
3: Questionnaire
4: Report of Expert Mr. Higaki: Report of OJT Assessment of energy conservation of49

Muara Karang Thermal Power Plant
5. Report of Specialist Mr. Takeda: Report of Electrical Energy Conservation
Regarding Thermal Power Plant in Indonesia/ Site Visit
6. Energy Audit Plan of Facilities Related to Thermal Energy
7. Briefing of Energy Audit for Air Compressor
8. Instruments for Energy Audit
9. On the Job Training ENERGY AUDIT IN POWER PLANT
10. Presentation by J-Power: The Latest and High Performance Coal-fired Power
Genera.
11: Report of Business Trip by Mr. Shimizu/J-Power: The Energy Conservation
Survey of Muara Karang Thermal Power Plant of Indonesia National Power
Company PT. PLN(Persero), etc.
12. SEMINAR AGENDA
13. Overview of ASEAN EE&C Programs and APAEC 2010-2015
14. OVERVIEW OF ENERGY EFFICIENCY AND CONSERVATION ACTIVITIESIN INDONESIA
15. Japan's EC Policy and Measures and EE&C Experiences
16. Case Study of Successful EE&C Countermeasures
17. Energy Conservation Successful Cases in Japanese Power Plants (Electrical
Equipments)
18. Updates on the Development of PROMEEC EM Tools
19. Japanese State-of-the-Art Smart Energy Products & Technologies
Material? D: Results of Energy Audit OJT at B Power Plant

50

51

52

53

Material? E: J-Power Presentation Document

54

55

56

57