Diagnosis casebook

Energy saving / power saving support service

Complimentary Energy
Conservation Audit
Cases in FY2016

The Energy Conservation Center, Japan

CONTENTS
CASE 1

Foodstuffs:

CASE 2

Metals:Company A .................................................................................... Chugoku 6

CASE 3Chemistry:

Company A ...........................................................................................Kinki 8

CASE 4

Chemistry:

Company H ......................................................................................Kyushu 10

CASE 5

Machinery:

Maruyoshi Co., Ltd. ............................................................................. Tokai 12

CASE 6

Electric and Electronic Devices: TEC Corporation ........................................................................... Chugoku 14
Optical Films, Liquid Crystal Films and Electronic Parts

CASE 7

Electric and Electronic Devices: Ketaka Electric Co., Ltd. ................................................................ Chugoku 16
Household Rice Cookers, etc.

CASE 8Printing:

CASE 9Wood and Wooden Products: Kitami Mokuzai Co., Ltd. ...............................................................Hokkaido 20
Wooden Musical Instrument Members, Wood, etc.

Ichinokura Co., Ltd. .......................................................................... Tohoku 4
Japanese Sake

Machined Components

Chemical Treatment Agents

Plastic Products

Development, Design and Construction of Various Automated Systems, and Provision of Technical Service

iword Co., Ltd., Ishikari Factory.....................................................Hokkaido 18
Prints

CASE10 Textile:

Kagawa Seamless Co., Ltd. ............................................................Shikoku 22

CASE11 Service:

Manseikaku Hotels Co., Ltd. .........................................................Hokkaido 24

CASE12 Service:

Tendo Hotel Co., Ltd......................................................................... Tohoku 26

Stockings

Hot Spring Hotel

Hot Spring Hotel

CASE13 Social Welfare and Nursing Care: Social welfare corporation, Kagayakinokai, Ikiikinosato ................... Tohoku 28
General Welfare Facilities

2

CASE14 Public:

Company K.................................................................................... Chugoku 30

CASE15 Other Manufacturing:Company A ......................................................................................... Kanto 32

Welfare Center A and Culture Center B

City Gas3

6. aeration blower

Wastewater treatment system: Inverted-based

Case of Japanese Sake
CASE 1 Manufacturer[Tohoku Area]

Audit case of energy
conservation/power-saving
support services

Two aeration blowers are always operating, but a wastewater discharge volume decreases during the periodof using less water. Accordingly, we proposed introducing an inverter for the blower to reduce an air feed rate
on holidays and during the no-use time (frequency setting 60%), thereby promoting energy conservation.
(Note) A further effect is obtained by attaching a DO meter (Dissolved Oxygen) to continuously measure, andcontrolling an aeration roots blower by an inverter (rotation frequency control by a DO value, lower air
volume) so that the DO value will maintain a standard value.

■ Industry type: Foodstuffs ■ Products: Japanese sake
■ Company name: Ichinokura Co., Ltd.
■ No. of employees: Approx. 150

7. and guide lights

Lighting: Renewal to the higher-efficiency lighting

Conducting energy conservation activities such as introduction of the demand monitoring equipment, Ichinokura Co.,
Ltd. requested for an overall energy conservation audit this time. As a result of the audit, we proposed renewal of the
air-conditioning system, adjustment of the boiler air ratios, enhanced thermal insulation of steam piping, introductionof inverters to the aeration blowers, higher-efficiency lighting and guide lights, conveyor operation control by sensors,and so on.

kL/year

Reduced by

2,600,000

yen/yearAir-conditioning system: Reduction of standby electric power by

Saving: 0.6 kL/year
1. shutting off the power during the no-use period of an outdoor unit Energy
Cost Saving: 32,000 yen/year
The compressor of the outdoor unit is equipped with a crank case heater thatis always left energized. We proposed shutting off the power for the outdoor
unit during the no-use period of an air-conditioner, thereby saving the power.

Facility: 25 outdoor units (crank caseheater: 40 W/unit)

Since the air ratios of two boilers are high (1.8 for the No. 1 boiler and 1.6 for theNo. 2 boiler), we proposed lowering the ratios to the EC Guideline (1.3) based on
the Act on the Rational Use of Energy, thereby reducing heavy oil consumption.

Energy Saving: 10.4 kL/year
Cost Saving: 676,000 yen/year
Facility: 2 boilers (3 t/h/unit, total heavy oil
consumption: 318 kL/year)

2. Boiler: Adjustment of the air ratio

3. Compressor: Reduction of the discharge pressure

Since one of the compressors (multiple units) has a high dischargepressure, we proposed lowering it (from 0.80 to 0.65 Mpa) to reduce power
consumption.

Energy Saving: 1.2 kL/year
Cost Saving: 71,000 yen/year
Facility: 1 compressor (7.5 kW)

Making investments into facilities with higher efficiency (Note) Energy conservation effect is shown in crude oil equivalent.

4. high-efficiency air-conditioner

Air-conditioning system: Renewal to the

The air-conditioning system has been used for 20 years after installation
and aged. The production of a refrigerant (R22) will be discontinued in 2020
as a global warming preventive measure. Accordingly, we proposed
renewing to the latest high-efficiency air-conditioner to conserve energy.
This time, we made a calculation on 4 air-conditioners in the office.

Steam piping: Enhanced thermal insulation of the

We proposed enhancing thermal insulation of the valves and flanges of thesteam piping to decrease heat dissipation, thereby reducing the heavy oil
consumption of the boilers.

4Cold-cathode fluorescent lamp (22 W/unit)
LED lamps (6.9 W/unit)
LED guide lights (2.0 kW/unit)
LED guide lights (2.7 kW/unit)
Total

We proposed renewing the FLR fluorescent lamps to the Hf fluorescentlamps with motion detector/dimming control function to control theilluminance to 100% when someone passes the staircase and dim to 30%
when no one passes, thereby reducing power consumption.

Energy cost

Proposals requiring no cost (Note) Energy conservation effect is shown in crude oil equivalent.

5. steam piping(1) Fluorescent lamps (36 W/unit)(2) Downlights (Compact fluorescent lamps, 13 W/unit)(3) Fluorescent guide lights (15 W/unit)
Fluorescent guide lights (23 W/unit)

Renewal plan

Lighting: Dimming control of the staircase lighting

Energy consumption (crude oil equivalent)

43

Status quo

8. by a motion detector

Effects of the measures (Audit)

Reduced by

We proposed renewing (1) the fluorescent lamps to the low-power consumption(approx. 40% less), long-life (50,000 h.) and inexpensive cold-cathode ones, (2)the downlights (fluorescent lamps) at the entrance to LED lighting, and (3) the
fluorescent guide lights to the LEDs, thereby reducing power consumption.

Energy Saving: 3.1 kL/year
Cost Saving: 181,000 yen/year
CAPEX: 5,280,000 yen
PP: Upon renewing the aged system
Facility: 4 air-conditioners (cooling/heating
capacity: 20/22.3 kW/unit, cooling/heating
COP: 2.8/3.0 to 4.2/4.1)
Energy Saving: 3.5 kL/year
Cost Saving: 228,000 yen/year
CAPEX: 540,000 yen PP: 2.4 years
Facility: Flange type globe valves (3 pcs. for
100A, 10 pcs. for 80A, and 1 pc. for 65A), flanges (1pc. for 200A, 5 pcs. for 80A and 5 pcs. for 50A), etc.

9. sensors

Production system: Conveyor operation control by

The conveyors in a canning factory are running even when there is nothing
to convey. We proposed installing conveyed goods detection sensors tostop the conveyors when there is nothing to convey, thereby conserving
energy.

10. transformers and their integration

Transformer: Renewal to higher-efficiency

We proposed (1) renewing 18-year-old transformers to the high-efficiency
ones and (2) integrating 3 transformers into 2 units, thereby reducing
transformer losses.

Energy Saving: 11.4 kL/year
Cost Saving: 665,000 yen/year
CAPEX: 500,000 yen PP: 0.8 years
Facility: 2 blowers (7.5 kW/unit)

Energy Saving: 5.2 kL/year
Cost Saving: 304,000 yen/year
CAPEX: 4,917,000 yen
PP: Upon renewing the aged system
Facility: Fluorescent lamps, downlights (fluorescentlamps), fluorescent guide lights → Renewal to cold-cathodefluorescent lamps, LED lamps and LED guide lights
Qty.

64
17
125
16
222

Money saved(in ?1,000)426Investment(in ?1,000)
384
136

Payback period(in years)
9.1
22.7

256

4,397

17.2

304

4,917

16.2

Energy Saving: 0.8 kL/year
Cost Saving: 44,000 yen/year
CAPEX: 504,000 yen PP: 11.5 years
Facility: FLR fluorescent lamps (6 units, 85
W/unit) → Renewal to Hf fluorescent lamps
with motion detector (6 units, 65 W/unit)
Energy Saving: 1.9 kL/year
Cost Saving: 108,000 yen/year
CAPEX: 300,000 yen PP: 2.8 years
Facility: 30 conveyors (0.25 kW/unit), 10
conveyed goods detection sensors(installed for every 3 conveyors)
Energy Saving: 5.0 kL/year
Cost Saving: 291,000 yen/year
CAPEX: 3,740,000 yen PP: 12.9 years
Facility: (1) Renewal of the transformers (1ø: 1 unit,
200 → 150 kVA), (2) Integration of the transformers(3ø: 3 units, 500 kVA/unit → 2 units, ø500 kVA/unit)

Major efforts in energy conservation activities
1. Adjusting the boiler air ratios for operational improvement
Concerning adjustment of the boiler air ratios, the setting of the operating requirements has been changed
for the two boilers. Prior to the audit, they were not properly managed due to high air ratios, but energy
conservation effects are now obtained by appropriately lowering air volumes.
2. Utilizing a subsidy to steadily implement an investment-required improvement proposal
Enhanced thermal insulation of the steam piping and energy conservation of lighting by the motion detectors
were implemented starting from what can be done. The inverter-based aeration blowers were materialized
by initially installing a timer to intermittently operating them. Furthermore, since the air-conditioners, which
control the temperature important for brewing, have been installed 20 years and the refrigerant used (R22)will go out of production in 2020, the subsidy was utilized to systematically renew the equipment, realizing
energy conservation and stabilizing the product quality. For lighting, the subsidy was utilized to renew thefluorescent lamps and mercury lamps to the LED lamps, starting from those with longer lighting hours.
3. Continuing the energy conservation measures to deliver quality products
After taking the energy conservation audit, an energy management organization was established topositively promote energy conservation activities. Presently, the boilers are being renewed (heavy oil →gas). From now on, high-efficiency equipment will be continually introduced in line with facility improvement.

5Case of Machined
CASE 2 Components Manufacturer[Chugoku Area]

Audit case of energy
conservation/power-saving
support services■ Industry type: Metals■ Products: Machined components■ Company name: Company A ■ No. of employees: 130

5. the outer periphery of the industrial furnace

Industrial furnace: Enhanced thermal insulation of(1) The average outer peripheral temperature of a reflow electric furnace is high at 80°C,(2) that of a steam dry furnace is high at 55°C, and (3) that of a refining furnace is high at
75°C. We proposed reducing a radiation heat loss by enhanced thermal insulation of theouter peripheries of the furnaces in (1), (2) and (3), thereby realizing energy conservation.

Energy Saving: 14.5 kL/year
Cost Saving: 862,000 yen/year
CAPEX: 373,000 yen PP: 0.4 years
Facility: Reflow furnace, dry furnace andrefining furnace

Avg. outer peripheral
temperature (°C)

Qty.

Total furnace
surface area (m2)

Money saved(in ?1,000)(1) Reflow electric furnace

80

5

8.6

(2) Steam dry furnace

55

1

2.0

(3) Refining electric furnace

75

2

6.0

Total

Company A has been conducting energy conservation activities such as thinning out/turning off unnecessary lighting
fixtures, introducing high-efficiency boilers and utilizing demand monitoring equipment. This time, they requested foran overall energy conservation audit, focusing on the machining facilities. As a result of the audit, we proposed a lower
steam pressure fed to the machining line, utilization of inverter-based exhaust fans, thermal insulation of the steam
piping and the outer periphery of the industrial furnaces, LED-based lighting in the office and the factory, and so on.

6. feed fan

Industrial furnace: Inverter-based dry furnace air

An air feed fan for the dry furnace (electric fan) throttles an air volume to
30% with a damper. Because a throttle resistance loss results from throttlingwith the damper, we proposed encouraging energy conservation by the fully
opened damper plus inverter-based control.

7. factory

Lighting: LED-based lighting in the office and the

Effects of the measures (Audit)
Energy consumption (crude oil equivalent)

Reduced by184

kL/year

We proposed renewing the (1) rapid start type fluorescent lamps in the factoryand office to the straight-tube LEDs and (2) mercury lamps in the factory to thehigh-efficiency metal halide lamps, thereby realizing energy conservation.

Energy cost

Reduced by

14,896,000

yen/year

Proposals requiring no cost (Note) Energy conservation effect is shown in crude oil equivalent.

1.

Air-conditioning system: Easing of the
air-conditioning setting temperature

The standard cooling/heating setting temperature is 28/18°C, but the setting
temperature is not properly controlled for some part of the system. We proposed
easing the cooling/heating setting temperature by 1°C (27/21°C → 28/20°C) andstrictly observing the standard values, thereby reducing power consumption.

Energy Saving: 10.8 kL/year
Cost Saving: 554,000 yen/year
Facility: Air-conditioners (total power
consumption for cooling/heating: approx.
350,000/67,000 kWh/year)

Production system: Utilization of the inverter-based

2. exhaust fans

The exhaust fans in the machining line are continuously running at ratings for 24 hours,
but an air volume can be reduced during a non-production time. We proposed utilizing
the inverters of the exhaust fans in the A- and B-product lines to reduce the air volume
to 50% during the non-production time, thereby lowering power consumption. The
effects were calculated assuming a production time to be 16 hours/day x 245 days.

Energy Saving: 41.6 kL/year
Cost Saving: 2,137,000 yen/year
Facility: 2 exhaust fans (18.5 and 22 kW)

Making investments into facilities with higher efficiency (Note) Energy conservation effect is shown in crude oil equivalent.

3. pressure fed to the machining line

Steam-based system: Reduction of the steam

The steam pressure 0.6 MPa fed to the machining line is high. We proposed
attaching a reducing valve to reduce the steam pressure (0.6 → 0.30 MPa,0.30 MPa less), thereby reducing city gas consumption (by 4.1%).

4. steam piping

Steam piping: Enhanced thermal insulation of the

We proposed enhancing thermal insulation of the steam piping of a boiler
room and the machining line to reduce futile heat radiation, thereby reducing
fuel (city gas) consumption of the boiler.

6

Energy Saving: 35.3 kL/year
Cost Saving: 3,175,000 yen/year
CAPEX: 500,000 yen PP: 0.2 years
Facility: Machining line boiler (13A city gas
consumption: 430,000 m3/year)
Energy Saving: 29.6 kL/year
Cost Saving: 2,663,000 yen/year
CAPEX: 500,000 yen PP: 0.2 years
Facility: Flange type gate valves (2 pieces for
80A, 8 pcs. for 40A), flanges (10 pcs. for 40A,
182 pcs. for 25A), piping (6 pcs. for 40A), etc.

Status quo

Renewal plan

Lighting hours(h./day)(1) FLR fluorescent lamps (47 W/unit)
FLR fluorescent lamps (115 W/unit)

Straight-tube LED lamps (25 W/unit)
Straight-tube LED lamps (50 W/unit)

24

FLR fluorescent lamps (47 W/unit)
FLR fluorescent lamps (115 W/unit)(2) Mercury lamps (400 W/unit)

Straight-tube LED lamps (25 W/unit)
Straight-tube LED lamps (50 W/unit)
Metal halide lamps (400 W/unit)

Mercury lamps (400 W/unit)

Metal halide lamps (400 W/unit)
Total

8. enhanced control

12
24
12

Demand control: Reduction of demand by

We proposed utilizing the present demand monitoring controller to introduce
automatic demand load control for an air-conditioning load, etc., thereby reducing
maximum power (contract demand) (1,301 to 1,171 kw, 130 kW less). The effects
were calculated on the premise of 10% demand reduction from the present contract,
including demand reduction (approx. 60 kW) by this energy conservation proposal.

Investment(in ?1,000)

Payback period(in years)

419

84

0.2

286

222

0.8

157

67

0.4

862

373

0.4

Energy Saving: 2.0 kL/year
Cost Saving: 101,000 yen/year
CAPEX: 125,000 yen PP: 1.2 years
Facility: 1 fan (3.7 kW)
Energy Saving: 50.4 kL/year
Cost Saving: 2,583,000 yen/year
CAPEX: 7,199,000 yen PP: 2.8 years
Facility: Fluorescent lamps and mercury
lamps → LEDs and metal halide lamps
Qty.

545
67
632
58
11→6
16→8
1,302

Money saved(in ?1,000)

Investment(in ?1,000)

Payback period(in years)

2,323

7,135

3.1

260

64

0.2

2,583

7,199

2.8

Maximum power: 130 kW less
Cost Saving: 2,821,000 yen/year
CAPEX: 1,000,000 yen PP: 0.4 years
Facility: Demand monitoring equipment andautomatic demand load controller

Major efforts in energy conservation activities
1. Promoting energy conservation while assessing an effect on the quality and workability
The inverters have been already utilized for seven of the nine exhaust fans in the machining line. For theremaining two, an effect on the working environment and the quality is being assessed. Thermal insulation
has been firstly enhanced on the dryers, heaters and steam piping within the range of not affecting the
product quality. Thermal insulation of the facilities having an effect on the quality is being carefully carried out.
2. Utilizing a subsidy to realize higher-efficiency air-conditioning and lighting and introduce the EMS
The facilities with large investments were finished by utilizing the “Promotion Project Subsidy for
Investments in Energy Conservation and Productivity Revolution of Small- and Medium-sized Businesses”
and “Promotion Project for Smart Energy Introduction for Business Offices in Okayama City”. The
air-conditioners were renewed to the higher-efficiency ones, the fluorescent lamps and mercury lamps were
replaced by LEDs, and the demand controller was introduced to control an air-conditioning load, etc. The
renewal will be continued step by step.
3. Energy conservation and environmental activities participated by all the employees
They have learned the concept of extracting the problems and the method of calculating cost-effectivenessthrough the energy conservation audit, and a field driving force and management (investments) started
rolling together, achieving significant results. On the other hand, activities have been going on such as
improved work uniforms and reduced industrial waste by thorough sorting, continuing to address new
improvement items by the vitalized company and office.

7

Case of Manufacturer of Surface
CASE 3 Treatment Agents and Adhesive Agents[Kinki Area]

Audit case of energy
conservation/power-saving
support services■ Industry type: Chemistry■ Products: Chemical treatment agents■ Company name: Company A ■ No. of employees: 50

We proposed enhancing thermal insulation of the steam piping fed to thereactors, humidifying storerooms, etc. in the factory, using a thermal
insulation cover, etc., thereby reducing the bunker-A consumption of theboilers.

8. inverter-controlled compressor

Compressor: Renewal to a high-efficiency

A constant-rate compressor is used to control loading/unloading, but it consumes
the electric power even during unloading. We proposed renewing to an
inverter-controlled compressor to reduce power consumption.

Energy consumption (crude oil equivalent)kL/yearThere are many air-conditioners and their outdoor units are installed
outdoors or on the verandas. We proposed shielding the outdoor units fromsolar radiation (with a reed blind, etc.) to inhibit a temperature rise of theheat exchanger fins, etc. in summer and decrease a condenser’s load,
thereby reducing the power consumption for air-conditioning.

Steam piping: Enhanced thermal insulation of theEffects of the measures (Audit)

16

system: Shielding of outdoor units
Energy Saving: 0.6 kL/year
6. Air-conditioning
from solar radiation
Cost Saving: 47,000 yen/year

7. steam piping

Company A has been conducting energy conservation activities such as easing an air-conditioning setting
temperature, thinning out/turning off unnecessary lighting fixtures, and utilizing the demand monitoring equipment.
This time, they requested for an overall energy conservation audit. As a result of the audit, we proposed renewal tohigh-efficiency air-conditioners, lower steam pressure of the boilers, renewal to a high-efficiency inverter-controlled
compressor, LED-based lighting in the office and the factory.

Reduced by

Making investments into facilities with higher efficiency (Note) Energy conservation effect is shown in crude oil equivalent.

(Note) Because the inverter-controlled compressor controls a rotation frequency so as tokeep a constant pressure according to a discharge air rate, power consumption decreases
as the air rate drops, having an energy conservation effect in a partial load.

Energy cost

Reduced by

1,514,000

9. factory

Lighting: LED-based lighting in the office and theyen/year

We proposed renewing the (1) FLR fluorescent lamps of the office and the(2) mercury lamps of the factory to LED-based lighting to save the electric
power.
Status quo

Proposals requiring no cost (Note) Energy conservation effect is shown in crude oil equivalent.

1. Boiler: Reduction of the steam pressure

Steam is used for reactors, etc. Since a reducing valve is used to reduce a pressure, we proposed
lowering the steam pressure (0.70 → 0.60 MPa, 0.1 MPa lower) to reduce bunker-A consumption.

(Note) The boiler has been renewed in the year when the audit was conducted to change
fuels (bunker A → city gas). The effects were calculated with the bunker A because there areno actual fuel consumption data from the previous year.

2. Compressor: Reduction of the discharge pressure

The factory consumes air for the reactor, dissolver’s air cylinder, drum
turnover machine, etc. The discharge pressure of the compressor is high at
rated 0.69 MPa, seemingly reducible. We proposed lowering the dischargepressure by 0.05 MPa to reduce power consumption.

3. Air piping: Air leak prevention

It is difficult to detect a leak from the air piping or know a leak amount, but it is said that theleak amount accounts for 10 to 20% of the air usage of the factory. We proposed decreasing
the leak amount from the air piping to reduce the power consumption of the compressor (theeffects were calculated on the premise of a 10% leak rate and 80% improvement thereof).

4. by utilizing the demand monitoring equipment

Demand control: Inhibition of the maximum power

We proposed utilizing the existing demand monitoring equipment to monitor a changeof the maxim power, and inhibit the maximum power (210 → 200 kW, 10 kW less)such as by stopping predetermined equipment (air-conditioner) and shifting operationof the production system when the maximum power approaches a setting value.

5. high-efficiency automatic vending machines
Automatic vending machine: Renewal to

We proposed renewing automatic vending machines to the latest energy
conservation type (peak-shift automatic vending machines) to reduce power
consumption (58% less).

8

Energy Saving: 0.8 kL/year
Cost Saving: 70,000 yen/year
Facility: 2 boilers (0.8 t/h./unit, total
bunker-A consumption: 52 kL/year)
Energy Saving: 0.3 kL/year
Cost Saving: 28,000 yen/year
Facility: 1 compressor (22.5 kW)

Energy Saving: 0.5 kL/year
Cost Saving: 44,000 yen/year
Facility: 1 compressor (22.5 kW)

Maximum power: 10 kW less
Cost Saving: 139,000 yen/year
Facility: Demand monitoring equipment

Energy Saving: 0.5 kL/year
Cost Saving: 40,000 yen/year
Facility: 2 automatic can/bottle vending
machines (total power
consumption: 3,300 kWh/year)

Renewal plan

(1) FLR fluorescent lamps (79 W/unit)(2) Mercury lamps (310 W/unit)

Straight-tube LED lamps (40 W/unit)
LED lamps (79 W/unit)
Total

dispenser: Suspension of automatic tea
dispensers during an unnecessary time
10. Tea

The automatic tea dispensers in the cafeteria and the office arecontinuously operating for 24 hours. We proposed using a schedule timer toturn them off during a nighttime period (8:00 p.m. to 8:00 a.m.) in which
there are no users, thereby reducing power consumption.

CAPEX: 58,000 yen PP: 1.2 years
Facility: 29 electric HP air-conditioners (total
rated electric power: 97 kW, cooling/heating
COP: 2.3 to 5.0/2.3 to 5.6)
Energy Saving: 6.2 kL/year
Cost Saving: 564,000 yen/year
CAPEX: 1,040,000 yen PP: 1.8 years
Facility: Flange type globe valves (2 pcs. for50A), reducing valves (10 pcs. for 50A), andflanges (40 pcs. for 50A)
Energy Saving: 3.5 kL/year
Cost Saving: 284,000 yen/year
CAPEX: 1,800,000 yen PP: 6.3 years
Facility: 1 compressor (22.5 kW)

Energy Saving: 3.3 kL/year
Cost Saving: 272,000 yen/year
CAPEX: 2,220,000 yen PP: 8.2 years
Facility: FLR fluorescent lamps and mercury
lamps → LED lamps
Qty.

Money saved(in ?1,000)

Investment(in ?1,000)

Payback period(in years)

100
6
106

144
128
272

1,800
420
2,220

12.5
3.3
8.2

Energy Saving: 0.3 kL/year
Cost Saving: 26,000 yen/year
CAPEX: 24,000 yen PP: 0.9 years
Facility: 2 tea dispensers (total power
consumption: 2,400 kWh/year)

Major efforts in energy conservation activities
1. Implementing all the operation improvement proposals as proposed
The operation improvement proposals of “Reduction of the steam pressure” and “Reduction of thedischarge pressure of the compressor” were implemented as proposed. “Air leak prevention” is continuallyinspected by a monthly patrol. The maximum demand has been reduced by promoting “Utilization of thedemand monitoring equipment”, completely stopping the air-conditioning system at the time of alarm, andadopting a work shift system to avoid simultaneous operation of the large facilities. One of the two
automatic vending machine was replaced by an energy conservation type high-efficiency machine.
2. Completed 4 of 5 investment-required improvements and planning to implement the remaining one“Thermal insulation of the steam piping” was enhanced as proposed. In order to “shield the outdoor units
from solar radiation”, their self-made solar radiation covers were attached. For “suspension of automatic tea
dispensers at night”, the dispensers were renewed to those with a timer to automate suspension at night.
For “LED-based lighting”, 100 fluorescent lamps and 6 mercury lamps were replaced by the LEDs. Since
the mercury lamps will go out of production in 2020, the other factories will also replace them by the LEDs.
Because “renewal of the compressor” is a costly investment, a public subsidy will be utilized to introduce aninverter-controlled compressor when renewing an aged one.
3. Developing the voluntary improvement activities other than the proposals
The demand was greatly lowered by avoiding simultaneous operation of two raw material kneading rolls
based on an on-site idea. The boiler fuel was changed (bunker A to gas) from an environmental viewpoint.
The awareness of the employees has been enhanced by putting up an in-house notice, “A wall greening
activity has started with bitter gourds, etc. as a heat island preventive measure and a power-saving
measure in summer”.

9Tuning audit implementedCase of Plastic Products
CASE 4 Manufacturer[Kyushu Area]

Audit case of energy
conservation/power-saving
support services■ Industry type: Chemistry■ Products: Plastic products■ Company name: Company H■ No. of employees: Approx. 50

Effects of the measures (Audit)

kL/yearSteam piping: Enhanced thermal insulation of the

We proposed enhancing thermal insulation of the piping and valves of asteam piping system to decrease futile heat radiation, thereby reducing fuel(city gas) consumption.

We proposed (1) renewing the FLR fluorescent lamps in the factory and the office tothe high-efficiency LED lamps, (2) replacing the FLR fluorescent lamps in a molding
line, boiler room, etc. by the Hf fluorescent lamps, and (3) replacing the mercury
lamps used in the factory and warehouse building and as outside lights by thehigh-efficiency ceramic metal halide lamps, thereby reducing power consumption.
Status quo(1) FLR fluorescent lamps (40 W/2-lamp type, 85 W/unit)

Straight-tube LED lamps (55 W/unit)
Hf fluorescent lamps (65 W/unit)(3) Mercury lamps (415 W/unit)

Ceramic metal halide lamps (208 W/unit)

8. Lighting: LED guide lights

Energy cost

Reduced by

3,561,000

yen/year

Boiler: Reduction of fuel consumption by a lower
air ratio

When a burner’s air ratio is higher than necessary, heat losses by exhaust gas
increase. We proposed correcting an air volume to an appropriate value to lower
the air ratio (1.35 → 1.30, 0.05 lower), thereby realizing energy conservation.

2. Compressor: Reduction of a discharge pressure

Five compressors are running. We proposed reducing the discharge pressure of one(37 kW) of them (0.75 → 0.65 MPa, 0.1 MPa lower) to realize energy conservation. If
the discharge pressure is reduced for all of them, there is the risk of producing
defective products. This time, accordingly, the pressure was reduced for only one ofthem, to be followed by the rest sequentially (the effects were calculated on one unit).

3. Air piping: Enhanced air leak prevention

We proposed enhancing an air leak prevention to realize energy conservation (theeffects were calculated assuming that a 10% air leak rate is improved by 80%).

4. by utilizing the demand monitoring equipment

Demand control: Inhibition of the maximum power

Since the maximum power was increased in last December, we proposed enhancing demand
control to lower the maximum power (367 → 349 kW, 18 kW less). This proposal includes acontribution of power-saving by renewal to higher-efficiency lighting (8 kW less, Proposal 7).

5. packing to a faucet

Sanitary equipment: Attachment of a water-saving

If a packing in a faucet is replaced by a water-saving packing, a flow rate is inhibitedwhen a handle is half-opened, thereby saving water. We proposed attaching thewater-saving packings to the faucets in a washroom, etc. to save water.

Handle opening
90°
Fully open

10

Ordinary packing Water-saving packing
12 L/min.
6 L/min.
21 L/min.
21 L/min.

Energy Saving: 2.4 kL/year
Cost Saving: 200,000 yen/year
Facility: 1 boiler (5 t/h., city gas 13A: 850,000
m3/year)
Energy Saving: 3.0 kL/year
Cost Saving: 202,000 yen/year
Facility: 1 compressor (37 kW)

Energy Saving: 4.1 kL/year
Cost Saving: 277,000 yen/year
Facility: 5 compressors (totally 203 kW)
Maximum power: 18 kW less
Cost Saving: 359,000 yen/year
Facility: Demand monitoring equipment

Energy Saving: –Cost Saving: 30,000 yen/year
Facility: 10 faucets

Energy Saving: 18.6 kL/year
Cost Saving: 1,545,000 yen/year
CAPEX: 644,000 yen PP: 0.4 years
Facility: Flange type globe valves (11 pcs.
for 65A), flanges (12 pcs. for 150A) andpiping (44 m for 65A)
Energy Saving: 13.6 kL/year
Cost Saving: 922,000 yen/year
CAPEX: 6,500,000 yen PP: 7.0 years
Facility: FLR fluorescent lamps → (LEDlamps and Hf fluorescent lamps), Mercury
lamps → Ceramic metal halide lamps
Qty.

(2) FLR fluorescent lamps (40 W/2-lamp type, 85 W/unit)

Conventional guide lights (fluorescent lamps) are inefficient because they
use a copper or iron type ballast. We proposed renewing to high-efficiency
LED guide lights to realize energy conservation.
Before renewal

After renewal

Qty.

Guide lights: Fluorescent lamps (15 W/unit)

LEDs (2.0 W/unit)

Guide lights: Fluorescent lamps (23 W/unit)

LEDs (2.7 W/unit)

5
5

Proposals requiring no cost (Note) Energy conservation effect is shown in crude oil equivalent.

1.

Renewal plan

Total

Energy consumption (crude oil equivalent)42

6. steam piping

7. Lighting: Renewal to higher-efficiency lighting

Company H has been conducting energy conservation activities such as easing an air-conditioning setting temperature and thinning
out/turning off unnecessary lighting fixtures. This time, they requested for an overall energy conservation audit. As a result of the audit,
we proposed enhanced thermal insulation of steam piping, renewal to higher-efficiency lighting, reduction of discharge pressure andenhanced air leak prevention for compressors, utilization of demand monitoring equipment to lower the maximum power, and so on.
Six months after the energy conservation audit (December 2014), they took our tuning audit “(1) Measurement of heat radiation fromthe steam piping system and (2) Measurement of a leak from the air piping” to confirm the current losses and improvement effects.

Reduced by

Making investments into facilities with higher efficiency (Note) Energy conservation effect is shown in crude oil equivalent.

100
100
40
240

Lighting hours Money saved(h./year)(in ?1,000)

4,878
4,878
3,415

256
171
495
922

Investment(in ?1,000)

Payback period(in years)

3,500
1,200
1,800
6,500

13.7
7.0
3.6
7.0

Energy Saving: 0.4 kL/year
Cost Saving: 26,000 yen/year
CAPEX: 325,000 yen PP: 12.5 years
Facility: Fluorescent guide lights → LED
guide lights

Results of tuning audit
1. Topics(1) Measurement of heat radiation from the steam piping, valves and flanges (Proposal 6)(2) Identification of the compressed air leaking spots and measurement of a leak amount (Proposal 3)

2. Target facilities(1) Steam piping in the factory, (2) Air piping in the factory

3. Results(1) Heat radiation from non-heat-retained parts of the steam piping system: 73.3 kL/year in crude oil
equivalent (approx. 7.5% of fuel consumption), Saved amount of money, approx. 5,700,000 yen/year(2) Leak amount from the air piping: 7.8 kL/year in crude oil equivalent (5.2% leak rate), Saved
amount of money, approx. 530,000 yen

Major efforts in energy conservation activities
1. Measures for the leak from the air piping and heat radiation from the steam piping in responseto the results of the tuning audit
As a result of the tuning audit, it was found out that the air piping had 87 air leak spots, resulting in an air
leak amount of 77 Nm3/h. The leak spots were immediately repaired. It was also found out that heatradiation from the steam piping accounted for approx. 7.5% of fuel consumption. Renewal of the piping,enhancement of thermal insulation, etc. are planned in line with renewal of a molding machine(steam-based) in the next term.
2. Improving four items in line with operation and investments (except for those associated withthe tuning audit)“Reduction of the compressor’s discharge pressure” and “Reduction of fuel consumption by the lower air
ratio” were conducted in consultation with the relevant manufacturers. Concerning “Replacement of the Hf
mercury lamps by the ceramic metal halide lamps”, a subsidy was utilized to renew many of them. Theenergy for the outside lights (mercury lamps) having short lighting hours was saved by shorting the lighting
hours with a timer. Other fluorescent lamps and guide lights are also being renewed to LED lamps.
3. Developing the voluntary improvement activities other than the proposals
After taking the energy conservation audit, a company-wide energy conservation promotion system wasbuilt, including a management level, to systematically address energy conservation such as making a
medium-/long-term plan for energy conservation investments; the compressors have been already renewed
to the inverter-based one.

11

Case of Manufacturer of
CASE 5 Various Automated Systems[Tokai Area]

Audit case of energy
conservation/power-saving
support services■ Industry type: Machinery■ Products: Development, design and construction of various automated systems,
and provision of technical service■ Company name: Maruyoshi Co., Ltd. ■ No. of employees: Approx. 50

Making investments into facilities with higher efficiency (Note) Energy conservation effect is shown in crude oil equivalent.

3. by affixing the light-shielding sheets to the windows

Air-conditioning system: Lowering of the cooling load

We proposed affixing the detachable light-shielding sheets to the windows
exposed to strong solar radiation (factory: approx. 23 m2 without blind,
office: approx. 16 m2 with blind) to lower the cooling load, thereby reducing
power consumption.

4. LED lamps

Lighting: Renewal of the fluorescent lamps to the

Maruyoshi Co., Ltd. has been taking energy conservation measures such as thinning out/turning off unnecessary
lighting fixtures and renewing to high-efficiency lighting. This time, they requested for an overall energy conservation
audit, focusing on air-conditioning and demand reduction. As a result of the audit, we proposed easing of the setting
temperature of air-conditioners, lowering of a cooling load by affixing light-shielding sheets to the windows expose tostrong solar radiation, replacement of fluorescent lamps by LED lamps, reduction of the maximum power byintroducing a demand monitoring controller, and so on.

Effects of the measures (Audit)

3.4

kL/year

Energy cost

Reduced by

Air-conditioning system: Easing of the setting

1. temperature of air-conditioning

We proposed easing the cooling/heating setting temperature (25/22°C) in
the office and the factory to a government-recommended value (28/20°C) to
reduce power consumption.

456,000

yen/year

Energy Saving: 1.9 kL/year
Cost Saving: 180,000 yen/year
Facility: 10 air-conditioners (totally 81 kW,
cooling/heating power consumption:
16,000/20,000 kWh/year)

OA equipment: Utilization of the sleep mode of theHalf the energy of the PC is consumed by the display. We proposed turning
off the power of the display and setting the PC to the sleep mode whenleaving your seat, thereby reducing power consumption.

12

After renewal

Qty.

FLR fluorescent lamps (85 W/unit)

Straight-tube LED lamps (40 W/unit)

FLR fluorescent lamps (43 W/unit)

Straight-tube LED lamps (20 W/unit)

45
17

5. by introducing the demand monitoring equipment

Proposals requiring no cost (Note) Energy conservation effect is shown in crude oil equivalent.

2. PC

Before renewal

Demand control: Reduction of the maximum power

Energy consumption (crude oil equivalent)

Reduced by

We proposed renewing the fluorescent lamps of the ceiling of the factoryand office to the LED lamps to reduce power consumption.

Energy Saving: 0.1 kL/year
Cost Saving: 10,000 yen/year
Facility: 12 desktop PCs, 3 notebook PCs

We proposed introducing the demand monitoring equipment with a monitor
to (1) automatically stop predetermined equipment (machining center, etc.)
to reduce the maximum power (contract demand) when it is expected to
exceed a demand target value (55 → 45 kW, 40 kW less) and (2) set thedemand target value for each season by “visualization” of the energy usage
status, thereby reducing power consumption throughout the year.

Energy Saving: 0.2 kL/year
Cost Saving: 20,000 yen/year
CAPEX: 39,000 yen PP: 2.0 years
Facility: 10 air-conditioners (totally 81 kW,
cooling/heating power consumption:
16,000/20,000 kWh/year)

Energy Saving: 1.2 kL/year
Cost Saving: 118,000 yen/year
CAPEX: 846,000 yen PP: 7.2 years
Facility: FLR fluorescent lamps →Straight-tube LED lamps

Maximum power: 18 kW less
Cost Saving: 128,000 yen/year
CAPEX: 400,000 yen PP: 3.1 years
Facility: Demand monitoring equipment

Major efforts in energy conservation activities
1. Immediate implementation of operational improvement
All the employees cooperated to immediately ease the temperature setting of the air-conditioners andreduce the standby power of the PCs.
2. Energy conservation by investment in the systems
As a solar radiation control measure, the light-shielding sheets were affixed to the west windows to improvecooling effectiveness, bringing it home to ease the temperature setting of the air-conditioners. Utilization of
a subsidy is being planned to renew the fluorescent lamps to the LED lamps.
3. Promoting a maximum power reduction measure
The demand monitoring equipment was introduced to put demand control into practice according to a
prepared preferential list of stopping the equipment. Demand analysis was started for further improvement.

13Case of Manufacturer of Optical Films,
CASE 6 Liquid Crystal Films and Electronic Parts[Chugoku Area]

Audit case of energy
conservation/power-saving
support services■ Industry type: Electric and electronic devices■ Products: Optical films, liquid crystal films and electronic parts■ Company name: TEC Corporation ■ No. of employees: Approx. 80

Energy cost

Reduced by

Air piping: Enhanced air leak prevention from theair piping

Aged air piping and pneumatic systems were seen here and there. Air leakinspection is conducted, but there is generally a 10 to 20% air leak. We
proposed enhancing an air leak control measure to realize energy
conservation (the effects are calculated on the premise of a 10% leak rate
and 80% improvement thereof).

Air-conditioning system: Renewal of the packaged
air-conditioners

We proposed renewing the aged cooling/heating packaged air-conditioners
in Building A to the higher-efficiency ones to reduce power consumption.

3. Air-conditioning system: Inverted based AHU fans

A fan for an air handling unit (AHU) is continuously running at ratings throughout
the year. Since a thermal load drops at night and on holidays (non-productiontime), we proposed fully opening a damper and introduce an inverter (20% lessair volume by lowering a motor speed), thereby realizing energy conservation.

4. water pump

Air-conditioning system: Inverter-based cooling

A cooling water pump for a chiller is continuously running. We proposed
introducing an inverter to lower a flow rate during a low-load intermediate
period and at night (50% less), thereby realizing energy conservation.

14(1) Lower the discharge pressure of the compressor gradually, while checking
the air-based system (0.63 to 0.65 MPa → 0.5 MPa, 0.1 MPa less). (2) Since
the air pressure of the pneumatic equipment is high, feed the air at an
appropriate pressure (air blow: 0.6 → 0.4 MPa) by a reducing valve. We
proposed adopting the measures (1) and (2) to realize energy conservation.

6,619,000(2) Lower feed pressure to the pneumatic equipment (0.06 to 0.2 MPa less)yen/year

Energy Saving: 9.0 kL/year
Cost Saving: 489,000 yen/year
Facility: 5 compressors (totally 67 kW)

Making investments into facilities with higher efficiency (Note) Energy conservation effect is shown in crude oil equivalent.

2.

Compressor, pneumatic equipment: Lower discharge pressure of the

7. compressor and lower feed pressure to the pneumatic equipment(1) Lower discharge pressure of the compressor (0.1 MPa less)

Proposals requiring no cost (Note) Energy conservation effect is shown in crude oil equivalent.

1.

The roof of the clean room in Building C is lined with a heat-insulating
material, but the rest of the roof is not. We proposed sprinkling water on theroof (reutilizing wastewater from a chiller) to reduce intrusion of heat throughthe roof (15% less), thereby reducing power consumption for air-conditioning.

Item

Energy consumption (crude oil equivalent)kL/year(Note) Since a V-belt with inside notches (energy conservation belt) reduces a “bending
stress” when it is coiled around the pulley, it decreases losses caused by bending andimproves power transmission efficiency from a motor to the drive side, saving the power.

Air-conditioning system: Energy conservation by

Effects of the measures (Audit)

102

The fan for the air handling unit (AHU) has a high motor capacity. We accordingly
proposed remodeling the pulley of the existing system and introducing an energy
conservation belt, thereby reducing power consumption (approx. 5% less).

6. sprinkling water on the roof

TEC Corporation has been conducting energy conservation activities such as thinning out/turning off unnecessary
lighting fixtures and introducing demand monitoring equipment. This time, they requested for an overall energy
conservation audit, focusing on air-conditioners, etc. As a result of the audit, we proposed renewal tohigher-efficiency packaged air-conditioners, inverter-based air-conditioning equipment, reduction of the dischargepressure and the feed pressure to pneumatic equipment for compressors, reduction of the maximum power byintroducing an automatic demand load controller, and so on.

Reduced bysystem: Introduction of an energy
5. Air-conditioning
conservation belt for an AHU fan

Energy Saving: 23.0 kL/year
Cost Saving: 1,253,000 yen/year
CAPEX: 6,000,000 yen PP: 4.8 years
Facility: 3 air-conditioners (total capacity:
154 kW, cooling/heating COP:
2.1/2.4 → 4.2/4.2)
Energy Saving: 18.2 kL/year
Cost Saving: 988,000 yen/year
CAPEX: 675,000 yen PP: 0.7 years
Facility: 3 fans (15 kW/unit)
Energy Saving: 11.8 kL/year
Cost Saving: 644,000 yen/year
CAPEX: 165,000 yen PP: 0.3 years
Facility: 1 pump (11 kW)

8.

Total

Energy Saving: 4.1 kL/year
Cost Saving: 225,000 yen/year
CAPEX: 400,000 yen PP: 1.8 years
Facility: 3 fans (15 kW/unit)

Energy Saving: 0.6 kL/year
Cost Saving: 34,000 yen/year
CAPEX: 50,000 yen PP: 1.5 years
Facility: Roof area (200 m2), air-conditioner(COP: 3.0)
Energy Saving: 21.3 kL/year
Cost Saving: 1,161,000 yen/year
CAPEX: 150,000 yen PP: 0.1 years
Facility: 5 compressors (totally 67 kW), 10
reducing valves

Money saved(in ?1,000)

Investment(in ?1,000)

Payback period(in years)

550
611
1,161

15
15

0.2
-

Compressor: Utilization of the exhaust heat fromthe compressors for heating

The exhaust heat from the compressors is discharged outside through theduct piping. We proposed utilizing this exhaust heat for heating in Building C
to decrease an air-conditioning load, thereby realizing energy conservation.

Replacement of the fluorescent lamps by
9. Lighting:the LEDs

We proposed renewing the fluorescent lamps in a factory tohigher-efficiency, longer-life LED lamps to realize energy conservation. It is
expected to reduce replacement work of ceiling lighting owing to thelonger-life (40,000 h.) LED lamps, but this is not included in the effects.

Energy Saving: 4.9 kL/year
Cost Saving: 268,000 yen/year
CAPEX: 300,000 yen PP: 1.1 years
Facility: 5 compressors (totally 67 kW),
air-conditioner (capacity: 6 kW, COP: 3.0)
Energy Saving: 8.7 kL/year
Cost Saving: 472,000 yen/year
CAPEX: 2,490,000 yen PP: 5.3 years
Facility: Hf fluorescent lamps →Straight-tube LED lamps

Status quo

Renewal plan

Rated life
(h.)

Qty.

Money saved(in ?1,000)

Investment(in ?1,000)

Payback period(in years)(1) Hf fluorescent lamps (40-W 2-lamp type, 86 W/unit)(2) Hf fluorescent lamps (110-W 2-lamp type, 230 W/unit)

Straight-tube LED lamps (40 W/unit)
Straight-tube LED lamps (101 W/unit)

12,000→40,000

153
48
201

272
201
473

1,530
960
2,490

5.6
4.8
5.3

10.

Total

Demand control: Reduction of the maximum
power by an automatic demand load controller

We proposed utilizing a demand monitoring controller to control the air-conditioners, AHU fans, etc.
through the automatic demand load controller, thereby reducing the maximum power (contract
demand: 500 → 450 kW, 50 kW less). This proposal includes contributions to power-saving (approx.
43 kW) by replacement of the fluorescent lamps by the LEDs (13 kW, Proposal 9), renewal of the
air-conditioners (10 kW, Proposal 2), improvement of the compressors (12 kW, Proposal 7), and so on.

Maximum power: 50 kW less
Cost Saving: 1,085,000 yen/year
CAPEX: 1,000,000 yen PP: 0.9 years
Facility: Automatic demand load controller

Major efforts in energy conservation activities
1. Promoting the higher-efficiency air-conditioning related system

To promote energy conservation, the greatest challenge was to realize the higher-efficiency of the air-conditioning related
system, which accounted for 70% of the energy used by the business establishment. Utilizing the FY2014 Subsidy for
Introduction of Energy Conservation Facilities for Local Factories, Small- and Medium-sized Businesses and other means,considerable energy conservation related to the air-conditioning system was realized by renewal of the air-conditioning
chiller bodies and packaged air-conditioners, introduction of outdoor air-conditioners for reducing ventilation losses, andintroduction of an inverter system for the air handling unit (AHU) fans and chiller cooling water pumps. In addition,
thorough energy conservation was realized by changing heater-based heating of the air-conditioning system to the heatpump-based heating method, and changing a humidification system from steam to direct spray.

2. Replacing the fluorescent lamps by the LEDs to greatly reduce lighting power consumption

Utilizing the same subsidy, the lighting fixtures of the entire building were renewed to the LEDs, halving lighting power
consumption.

3. Further energy conservation activities

Utilizing the introduced EMS, an optimum control method is being built, aiming at demand control which does not inhibit
production and quality. It is also planned to take measures for the compressed air, which uses the second largest energy.

15Case of Manufacturer of
CASE 7 Household Rice Cookers, etc.

[Chugoku Area]

Audit case of energy
conservation/power-saving
support services■ Industry type: Electric and electronic devices■ Products: Household rice cookers, etc.
■ Company name: Ketaka Electric Co., Ltd. ■ No. of employees: Approx. 280

66

kL/year5,579,000

Air-conditioning system: Appropriate setting

We proposed managing an air-conditioning setting temperature control value (28°C
in summer and 20°C in winter) in a reliable manner to reduce power consumption(the effects were calculated when the setting temperature is eased by 1°C).

system: Thorough cleaning of the
2. Air-conditioning
filters of the indoor units
Many filters of the air-conditioners were found clogged. We proposed
cleaning them periodically to reduce power consumption.

3. Compressor: Lower discharge pressure
We proposed lowering a discharge pressure by 0.1 MPa (0.75 → 0.65 MPa)
through periodic cleaning of the filters, looping of air piping, and so on, toreduce the power consumption of the compressors.

4. Air piping: Air leak prevention
We proposed inspecting and repairing an air leak from the air piping to
reduce the power consumption of the compressors (the effects were
calculated assuming that a 10% air leak rate is improved by 80%).

5. Lighting: Thinning out of ceiling lighting
Task ambient lighting is used in an assembly factory, but ceiling lighting is
excessive. We proposed thinning out lighting (30% less) to lower
illuminance adequately, thereby reducing power consumption.

16

7. Compressor: Introduction of numbers control

The hydraulic pumps for processing machinery always run at a constant speed. During pressure
maintenance and standby, the discharged oil from the pump returns to a tank from a relief valve.
We proposed introducing the inverters for the hydraulic pumps to decrease a discharge oil rateduring pressure maintenance and standby, thereby reducing power consumption.

9. cylinders of the injection molding machines

Production system: Thermal insulation of the

We proposed attaching a heat-retaining cover to the heater (220°C) installed on thecylinder surface of the injection molding machines to reduce the power consumption of
the heater. An indoor environment is also improved by less radiation from the heater.

yen/year

Proposals requiring no cost (Note) Energy conservation effect is shown in crude oil equivalent.

1. temperature

There are multiple assembly lines of different work shifts on the factory floor
and the conditioned air flows into the areas of the suspended assemblylines. We proposed installing partitions with sheets, etc. to lower the
air-conditioning load of the operating lines, thereby reducing power
consumption.

Production system: Introduction of the inverters forEnergy cost

Reduced by

Air-conditioning system: Reduction of the target

8. the hydraulic pumps

Effects of the measures (Audit)

Reduced by

6. area for air-conditioning

Five compressors keep running all the time under a low load of approx.
50%. We proposed controlling the number of compressors operated
according to the required load to increase efficiency, thereby reducing
power consumption and decreasing the contract demand (10 kW less).

Addressing energy conservation as part of management reform activities, Ketaka Electric Co.,
Ltd. has been taking various energy conservation measures in parallel with the activities suchas preparing a list of energy-consuming devices and improving the wiring diagrams. Thistime, they requested for an overall energy conservation audit in order to upgrade the energy
conservation activities. As a result of the audit, we proposed thermal insulation of thecylinders of the injection molding machines, introduction of inverters for hydraulic pumps,
introduction of compressor numbers control, reduction of an air-conditioning area, and so on.

Energy consumption (crude oil equivalent)

Making investments into facilities with higher efficiency (Note) Energy conservation effect is shown in crude oil equivalent.

Energy Saving: 4.0 kL/year
Cost Saving: 229,000 yen/year
Facility: 31 air-conditioners (total rated
power consumption: 200 kW)
Energy Saving: 1.8 kL/year
Cost Saving: 103,000 yen/year
Facility: 31 air-conditioners (total rated
power consumption: 200 kW)
Energy Saving: 8.9 kL/year
Cost Saving: 505,000 yen/year
Facility: 10 compressors (totally 137 kW)

Energy Saving: 6.4 kL/year
Cost Saving: 364,000 yen /year
Facility: 10 compressors (totally 137 kW)

Energy Saving: 5.5 kL/year
Cost Saving: 315,000 yen /year
Facility: Fluorescent lamps (40 W/unit, 866→ 606 units)

Lighting: Replacement of the mercury lamps by

10. the metal halide lamps

We proposed renewing the mercury lamps in the factory to thehigh-efficiency metal halide lamps to reduce power consumption.

11. power by installing the watt-hour meters

Demand control: Reduction of the maximum

We proposed installing the watt-hour meters for the 20-kW or higher
facilities and the compressors to understand and analyze actual powerusage, thereby reducing the maximum power and decreasing the contract
demand (869 → 780 kW, 89 kW less).

Energy Saving: 1.4 kL/year
Cost Saving: 79,000 yen/year
CAPEX: 200,000 yen PP: 2.5 years
Facility: Air-conditioner (totally 64 kW),
air-conditioning area (approx. 960 → 480 m2)
Energy Saving: 2.4 kL/year
Cost Saving: 324,000 yen/year
CAPEX: 900,000 yen PP: 2.8 years
Facility: 5 compressors (totally 63 kW)
Energy Saving: 3.5 kL/year
Cost Saving: 200,000 yen/year
CAPEX: 1,200,000 yen PP: 6 years
Facility: 2 hydraulic pumps (21 kW)
Energy Saving: 28.6 kL/year
Cost Saving: 1,621,000 yen/year
CAPEX: 2,000,000 yen PP: 1.2 years
Facility: 13 units (total surface area: 12.35 m2)
Energy Saving: 3.2 kL/year
Cost Saving: 180,000 yen/year
CAPEX: 560,000 yen PP: 3.1 years
Facility: 56 mercury lamps (300 W/unit) → 56
metal halide lamps (200 W/unit)
Maximum power: 89 kW less
Cost Saving: 1,659,000 yen/year
CAPEX: 1,250,000 yen PP: 0.8 years
Facility: 25 watt-hour meters

Major efforts in energy conservation activities
1. Presenting the on-going waste and the results of efforts to improve the awarenessof the employees −− Make haste to implement energy conservation activities

After the audit, the first implemented activity was to present “on-going waste” to the employees tomake them understand that “the effects result from actions”. Aiming at “reduction of the standby
power”, the waste of power usage on holidays was notified and it was encouraged to turn off the circuit
breakers when leaving the office/factory for weekends. As a result, the power usage on holidays has
been halved compared with before, awakening the employees’ awareness that “they can do it.”

2. Starting to build an energy conservation promotion structure and cultivate human resources tocontinue the activities

The scope of electric power management per department was clarified and an “energy conservation committee” wasset up for auditing electric power, implementing improvements, presenting monthly reports, and so on. Utilizing a
subsidy, 82 watt-hour meters and a data collection system were introduced to “visualize” the power usage status foreach facility, making daily management and confirmation easier.

3. Energy conservation measures with investments which utilized a subsidy and were implemented
systematically

Approx. 30% energy conservation was achieved by utilizing a subsidy to renew the injection molding machines. Making
use of a surplus production capacity generated by high productivity of the new injection molding machines, further
energy conservation effects were obtained by shifting production to the new facility.

17

[Hokkaido Area]

CASE 8

Audit case of energy
conservation/power-saving
support services

Case of Printing Company■ Industry type: Printing ■ Products: Prints■ Company name: iword Co., Ltd., Ishikari Factory■ No. of employees: Approx. 270

Lighting: Renewal of lighting to the LED lamps andStatus quo

Renewal plan

(1) FLR fluorescent lamps (225 W/unit)

LED lamps (118 W/unit)(2) Metal halide lamps (414 W/unit)

LED lamps (119 W/unit)

Energy cost

Reduced by

4,231,000

yen/year1.

Compressor: Cleaning of the compressor’s filter

A contaminated filter adds to a suction resistance, increasing the power. We
proposed cleaning a suction filter periodically to reduce pressure losses,
thereby reducing power consumption (the effects were calculated assumingthat the compressor is constantly operated at a load of 80%).

Energy Saving: 0.2 kL/year
Cost Saving: 16,000 yen/year
Facility: 1 compressor (37 kW)

Making investments into facilities with higher efficiency (Note) Energy conservation effect is shown in crude oil equivalent.

system: Suspension of night-time
2. Air-conditioning
intake of the outside air

Air-conditioning energy is wasted in summer and winter, if an outside air intake
volume is higher than necessary. We proposed suspending intake of the outsideair (outside air intake volume: 17,300 m3/h.) from the midnight to the earlymorning (11:00 p.m. to 5:00 a.m., 2 months in summer and 5 months in winter),during which no problems seem to happen, to realize energy conservation.

3. high-efficiency absorption type water coolers/heaters
Air-conditioning system: Renewal to theIntroduced 17 years ago, the gas absorption water cooler/heater has been
aging. We proposed renewing it to the latest high-efficiency gas absorption
water cooler/heater to realize energy conservation.

18

Energy Saving: 11.6 kL/year
Cost Saving: 967,000 yen/year
CAPEX: 500,000 yen PP: 0.5 years
Facility: 2 absorption type watercoolers/heater (LPG,
cooling/heating COP: 0.9/0.8)
Energy Saving: 9.1 kL/year
Cost Saving: 754,000 yen/year
CAPEX: 24,000,000 yen
PP: Upon renewing the aged system
Facility: Absorption type water cooler/heater(LPG consumption: 70 t/year,
cooling/heating capacity: 422/494 kW,
cooling/heating COP: 0.8/0.8 →1.2/0.84)

Energy Saving: 19.3 kL/year
Cost Saving: 1,374,000 yen/year
CAPEX: 15,260,000 yen PP: 11.1 years
Facility: FLR fluorescent lamps and metal
halide lamps → LED lamps
Qty.

Money saved(in ?1,000)

Investment(in ?1,000)

Payback period(in years)

2,570
1,365→1,108

241
24
265

1,213
161
1,374

14,460800
15,260

11.9
5.0
11.1

Total

Energy Saving: 3.3 kL/year
Cost Saving: 234,000 yen/year
CAPEX: 1,350,000 yen PP: 5.8 years
Facility: Integration of the power transformers (3 units:
totally 1,000 kVA→ 1 unit: 500 kVA), renewal of the electric
light transformer (1 unit: 1ø, 300 kVA → 1 unit: 1ø, 100 kVA)

(1) Of the 5 power transformers, integrate 3 low-load units into one. (2)Renew an electric light transformer (1 unit: 1ø, 300 kVA) to the latest
high-efficiency small transformer (1 unit: 1ø, 100 kVA) because a demand
factor is low. We proposed reducing transformer losses by (1) and (2) torealize energy conservation.

Renewal plan

Money saved(in ?1,000)

Investment(in ?1,000)

Payback period(in years)

Integrated into 1 unit (3ø, 500 kVA)
Renewed to 1 unit (1ø, 100 kVA)

167
67
234

450
900
1,350

2.7
13.4
5.8

Status quo(1) 3 power transformers (3ø, 200 kVA x 1,300 kVA x 1,500 kVA x 1)
(2) 1 electric light transformer (1ø, 300 kVA)

Proposals requiring no cost (Note) Energy conservation effect is shown in crude oil equivalent.

Energy Saving: 5.4 kL/year
Cost Saving: 448,000 yen/year
CAPEX: – PP: Upon renewing the aged system
Facility: 1 vacuum water heater (LPG
consumption: 37 t/year, boiler
efficiency: 80 → 90%)

Lighting hours(h./day)

Transformer: Integration of the transformers andEnergy consumption (crude oil equivalent)kL/year

We proposed renewing the fluorescent lamps in the factory and the metal halide lamps on the ceiling of acargo-handling room to LED lamps, and turning off unnecessary lamps based on the subdivided lighting
segments of the bookbinding factory and the cargo-handling room, thereby realizing energy conservation.
However, the effects have not been calculated on the subdivided lighting segments of the fluorescent lamps.

6. renewal to higher efficiency

Effects of the measures (Audit)

49

Installed 17 years ago, the vacuum water heater may have deteriorated inits efficiency. We proposed renewing to the high-efficiency model to reduce
fuel consumption. Currently, one unit is in operation. In view of the heatingload status and the capacity of the cooler/heater, however, it is also
necessary to consider the idea of installing 2 half-capacity units.

5. turning off based on subdivided lighting segments

iword Co., Ltd., Ishikari Factory has been taking various energy conservation measures such as thinning out/turning
off unnecessary lighting fixtures and stopping unnecessary devices. This time, they requested for an overall energy
conservation audit, focusing on air-conditioning and lighting. As a result of the audit, we proposed suspension ofnight-time intake of the outside air, renewal to high-efficiency absorption type water coolers/heaters, replacement of
the lighting fixtures with the LED lamps, turning off lighting based on subdivided lighting segments, renewal of thevacuum heaters, and so on.

Reduced byheating system: Renewal of a vacuum water
4. WaterheaterTotal

7. monitoring equipment

Demand control: Introduction of the demand

We proposed introducing the demand monitoring equipment with a monitor to“visualize” the energy usage status, and inhibiting the maximum demand
power by suspending predetermined devices or lowering the rotating speed ofa printing machine, thereby decreasing the contract demand (1,215 → 1,190
kW, 25 kW less), when the maximum power is finely monitored on its change
and comes close to a setting value. In addition, we proposed setting a target
value for each season to reduce power consumption throughout the year.

Maximum power: 25 kW less
Cost Saving: 438,000 yen/year
CAPEX: 400,000 yen PP: 0.9 years
Facility: Demand monitoring equipment

Major efforts in energy conservation activities
1. Promoting the energy conservation measures, including utilization of the capital investment
promotion tax system for productivity enhancement
Two air-cooled chiller units were newly installed, which fall under the category of the advanced facilities(latest models, productivity enhancement) in the capital investment promotion tax system for productivity
enhancement. Together with this, a series of energy conservation measures were taken such as improving
the ventilation system of the factory, integrating the transformers as proposed in the energy conservation
audit, and introducing the demand monitoring equipment.
2. Other energy conservation measures
The fluorescent lamps in the factory were renewed to the LED lamps to not only conserve energy, butprevent the insects.
3. Further recognizing the necessity of energy conservation in the wake of the energy
conservation audit
Reliable demand control has been enabled by introduction of the demand monitoring equipment, leading toan enhanced energy conservation management structure.

19

Tuning audit implementedCase of Manufacturer of Wooden
CASE 9 Musical Instrument Members and Wood

[Hokkaido Area]

Audit case of energy
conservation/power-saving
support services■ Industry type: Wood and wooden products manufacturing industry■ Products: Wooden musical instrument members, wood, etc.
■ Company name: Kitami Mokuzai Co., Ltd. ■ No. of employees: Approx. 120

3. Lighting: Renewal to high-efficiency lighting

We proposed renewing the (1) ceiling mercury lamps to the ceramic metal
halide lamps, (2) outside mercury lamps to the high-pressure sodium lamps,and (3) FLR fluorescent lamps to the Hf fluorescent lamps, thereby reducing
energy conservation.

Status quo

Renewal plan

(1) Mercury lamps (415 W/unit)

Ceramic metal halide lamps (208 W/unit)(2) Mercury lamps (310 W/unit)

High-pressure sodium lamps (195 W/unit)(3) FLR fluorescent lamps (40-W 2-lamp type, 85 W/unit)

Kitami Mokuzai Co., Ltd. has been conducting energy conservation activities such as introducing the demand
monitoring equipment and turning off unnecessary lighting fixtures. This time, they requested for an overall energy
conservation audit. As a result of the audit, we proposed lowering a compressor’s discharge pressure, thermal
insulation of the steam piping, and renewal to high-efficiency lighting and high-efficiency transformers.
Approximately 2 years after the energy conservation audit (Oct. 2015), they took our tuning audit “Lower dischargepressure of the compressor” to tune two of three compressors and confirm their tuning method and energy
conservation effects.

Reduced by65

kL/yearRenewal to the high-efficiency
4. Transformer:
transformers

We proposed renewing the aged transformers in a power-receiving cubicle
to the high-efficiency amorphous transformers to reduce power losses.

Energy cost

Reduced by

1,601,000

The discharge pressure (0.69 MPa) is higher than the pressure required(0.4 to 0.5 MPa) for an air cylinder, etc. We proposed lowering the dischargepressure by about 0.1 MPa to reduce the power consumption of thecompressors (9% less).

yen/year

Energy Saving: 4.5 kL/year
Cost Saving: 323,000 yen/year
Facility: 20 compressors (totally 103 kW)

Making investments into facilities with higher efficiency (Note) Energy conservation effect is shown in crude oil equivalent.

2.

Steam piping: Enhanced thermal insulation of thesteam piping (Reduction of waste wood for boiler fuel)We proposed enhancing thermal insulation of the steam piping and thevalves to inhibit radiation losses, thereby reducing a purchase volume ofwaste wood for boiler fuel (104 t/year less, 4.1% less).

Qty.

Money saved(in ?1,000)

Investment(in ?1,000)

Payback period(in years)

7
6
149
162

63
56
117
236

228
130
1,490
1,848

3.6
2.3
12.7
7.8

Energy Saving: 11.0 kl/year
Cost Saving: 786,000 yen/year
CAPEX: – PP: –Facility: Transformers (3ø: 8 units, totally
1,425 kVA, 1ø: 6 units, totally 200 kVA) →Transformers (3ø: 3 units, totally 1,500 kVA,1ø: 2 units, totally 200 kVA)

Results of tuning audit
1. Topics

Lower discharge pressure of the compressors (Proposal 1)

2. Target facilities

Compressors (15 kW x 3 units, discharge pressure: 0.69 MPa), 3 of 20 compressors

3. Results

A discharge pressure setting value was lowered (0.69 → 0.59 MPa) on two of three compressors,and no problems were confirmed.
Energy conservation effect, No. 1 unit: Power reduced by 7.5%, No. 2 unit: Power reduced by 5.0%,
No 3 unit: Reserved
Reason for the reserving one unit: Impossible in the present situation because the pressure drops
greatly when blowing the air to remove polishing abrasive grains, resulting in unstable operation ofother pneumatic devices. A possible measure is to branch the piping for air blow from the low-pressure compressor to feed the air.

4. Expected resultsNo. 1 unit: 48,000 yen/year, No. 2 unit: 46,000 yen/year

Proposals requiring no cost (Note) Energy conservation effect is shown in crude oil equivalent.

1. Compressor: Lower discharge pressure

Hf fluorescent lamps (32-W 2-lamp type, 65 W/unit)

Total

Effects of the measures (Audit)
Energy consumption (crude oil equivalent)

Energy Saving: 3.3 kl/year
Cost Saving: 236,000 yen/year
CAPEX: 1,848,000 yen PP: 7.8 years
Facility: FLR fluorescent lamps → (LEDlamps, Hf fluorescent lamps), mercury
lamps → ceramic metal halide lamps

Energy Saving: 45.6 kL/year
Cost Saving: 256,000 yen/year
CAPEX: 900,000 yen PP: 3.5 years
Facility: Flange type globe valves (10 pcs. for
50 A, 51 pcs. for 32A), flanges (4 pcs. for 200A,
98 pcs. for 50A), piping (7 m for 32A), etc.

Major efforts in energy conservation activities
1. Energy conservation by lowering the setting pressure of the air compressors (including the tuning
audit activities)

After the audit, 5 of 20 units were suspended by rationalization to realize energy conservation. The tuning audit was
conducted on 3 of 4 screw type units, whose output exceeds 15 kW. Based on actual values such as the air pressure
and compressor power, the pressure was lowered by 0.1 MPa on 2 units to realize energy conservation. An additional
measure is being considered as to a system showing an instantaneous decompression by air blow.

2. Energy conservation by renewal to the high-efficiency high-voltage power-receiving system and thehigh-efficiency lighting system

The power-receiving system was renewed to the high-efficiency type. For the lighting system, 12 ceiling mercury lamps,
6 outside mercury lamps and 33 fluorescent lamps with relatively long lighting hours were renewed to the LEDs. In
addition, the fluorescent lamp pull switches were installed at the 256 positions so as to manually turn off theunnecessary fluorescent lamps, thereby realizing thorough energy conservation.

3. Promoting energy conservation of the waste wood-fired boiler

According to the audit, thermal insulation of the steam piping and the valves of the waste wood-fired boiler was
systematically implemented, reducing the fuel consumption of the boiler by a little more than 7% from the previous year.

20

21

5. water by recovering the waste heat from the steam drain Energy Saving: 16.1 kL/year
Steam-based system (Dokigawa): Heating of boiler feed

Case of Stockings
CASE10 Manufacturer[Shikoku Area]

Audit case of energy
conservation/power-saving
support services

We proposed recovering the waste heat from the steam drain of the dyeing machine toheat boiler feed water (27 → 49°C), thereby reducing the boiler fuel (2.4% less). In thiscase, wastewater is fed to a wastewater treatment system after waste heat recovery to
prevent a dye from contaminating boiler feed water when opening the heater.

■ Industry type: Textile industry ■ Products: Stockings■ Company name: Kagawa Seamless Co., Ltd.
■ No. of employees: 160 in the main office/factory, 48 in the Dokigawa Factory

Kagawa Seamless Co., Ltd. requested for an energy conservation audit, focusing on the air-conditioners and lighting
in the main office/factory, and we proposed enhancing utilization of outside air cooling, controlling the number ofcompressors, renewing to high-efficiency lighting, and so on. Three years later, they requested for another energy
conservation audit, focusing on waste heat recovery and the air-conditioners in the Dokigawa Factory, and we
proposed heating of boiler feed water by waste heat recovery from steam drain and hot wastewater, renewal of the
air-conditioners, renewal of the compressors, inverter-based aeration blowers, and so on.

Effects of the measures (Audit)
Energy consumption (crude oil equivalent)

Reduced by147

kL/year9,301,000

As an air source for automatic sewing machines, automatic knitting machines, and so on, fourconstant-speed compressors are used to feed air. Since the sewing machines stop at night, airconsumption decreases, resulting in unloading operation. We proposed controlling the number ofcompressors to automatically stop the compressors at night, thereby reducing energy consumption.

Compressor (Dokigawa): Renewal to an

7. inverter-controlled screw compressor

One screw compressor and two reciprocating compressors are estimated to haveaged because they were introduced approx. 30 years ago. We proposed renewing
to the latest high-efficiency inverter-controlled screw compressor to reduce power
consumption. After renewal, the existing machine will be used a spare unit.

(Note) A conventional suction valve throttling compressor does not reduce much power consumption
because if an air volume decreases and a discharge pressure increases, it throttles the suction valve
to control the pressure. Since the inverter-controlled type controls a rotation frequency so as tomaintain the constant discharge pressure according to a flow rate, power consumption decreases
according to the flow rate, having greater energy conservation effects than the conventional type.

Wastewater treatment system (Dokigawa):

8. Inverted-based aeration blowers

Energy cost

Reduced by

6. Compressor (Main office): Numbers control

yen/year

Two aeration blowers at a wastewater treatment plant are continuously operatingfor 24 hours by turns regardless of a treatment volume. We proposed introducing
inverters to operate the blowers according to the treatment volume (working days)(lower air volume on holidays: 30% less), thereby reducing power consumption.

(Note) Substantial energy conservation is expected by continuously measuring the DO (Dissolved Oxygen) value ofcontaminated water in an aeration tank and controlling the rotation frequency of the blowers based on that numerical value.

Production system (Dokigawa): Introduction of a heat

Proposals requiring no cost (Note) Energy conservation effect is shown in crude oil equivalent.
Air-conditioning system (Main office): Enhanced utilization

1. of outside air cooling in the intermediate period

Because a formulation room has high indoor heat generation, it is cooled
except for January and February. On the other hand, an outside air inlet valve
is fully closed in summer, fully opened in January and February, and manually
adjusted as to its opening in the intermediate period. We proposed increasing
an outside air inlet volume in the intermediate period to lower a cooling load.

Energy Saving: 5.0 kL/year
Cost Saving: 276,000 yen/year
Facility: Air-conditioner (COP: 4.3, capacity:
447 kW)

Making investments into facilities with higher efficiency (Note) Energy conservation effect is shown in crude oil equivalent.

2. high-efficiency refrigerators

Air-conditioning system (Main office): Renewal to the

Of the two air-conditioning refrigerators in the formulation room, we
proposed renewing one of them with lower COP to the high-efficiency typeto reduce power consumption.

3.

Air-conditioning system (Dokigawa): Renewal to ahigh-efficiency packaged air-conditioner

Installed 28 years ago, a packaged air-conditioner for Rooms A and B has aged.
Heating is done with steam, but the thermal efficiency of steam is lower than thatof a heat pump (HP). We proposed renewing to the latest high-efficiency packaged
cooling/heating air-conditioner to realize energy conservation. Power consumption
increases because of steam heating through the electric heat pump, but there will
be no fuel (LPG) consumption, resulting in energy conservation as a whole.

Boiler (Dokigawa): Heating of boiler feed water by

4. recovering the waste heat from overflowing hot water
Well water is heated by the waste heat of hot wastewater from a dyeing
machine and stored in a hot water tank to be reused by a heater for thedyeing machine, but surplus water is discharged (overflow). We proposed
utilizing this overflowing hot water to heat boiler feed water (27 → 43°C) to
reduce the boiler fuel (1.9% less).

22

Energy Saving: 26.7 kL/year
Cost Saving: 1,471,000 yen/year
CAPEX: 8,000,000 yen PP: 5.4 years
Facility: Refrigerators (119 kW, COP: 2.9 →6.0)Energy Saving: 3.5 kL/year
Cost Saving: 232,000 yen/year (431,000 yen/year

less for LPG, 199,000 yen/year more for electric power)

CAPEX: 3,000,000 yen PP: 12.9 years
Facility: 1 air-conditioner (capacity: 52 kW, cooling COP:

2.9, boiler steam used for heating) → 1 air-conditioner(capacity: 52 kW, cooling/heating COP: 3.3/3.4)

Energy Saving: 12.7 kL/year
Cost Saving: 915,000 yen/year
CAPEX: 1,000,000 yen PP: 1.1 years
Facility: 3 boilers (2.5 t/h./unit)

9. pump into a feed water heater by waste heat recovery

A heater for the dyeing machine heats feed water (well water → 45°C) withoverflowing hot water. We proposed introducing a heat pump (HP) into thisfeed water heater to further heat hot water (45 → 60°C), thereby reducing
steam consumption for heating.

10. lighting (LEDs)

Lighting (Main office): Renewal to high-efficiency

We proposed renewing the fluorescent lamps in the formulation room tohigh-efficiency LED lighting to reduce power consumption. Heat generation
decreases along with energy conservation of the lighting fixtures, lowering
an air-conditioning load.

Cost Saving: 1,167,000 yen/year
CAPEX: 5,000,000 yen PP: 4.3 years
Facility: 3 boilers (2.5 t/h./unit)
Energy Saving: 31.8 kL/year
Cost Saving: 1,754,000 yen/year
CAPEX: 500,000 yen PP: 0.3 years
Facility: 5 compressors (totally 37 kW/unit)

Energy Saving: 3.5 kL/year
Cost Saving: 276,000 yen/year
CAPEX: 2,000,000 yen PP: 7.2 years
Facility: 1 screw compressor (22 kW,
loading/unloading control), 2 reciprocating
compressors (7.5 kW/unit, on/off control) → 1
inverter-controlled screw compressor (22 kW)

Energy Saving: 4.4 kL/year
Cost Saving: 355,000 yen/year
CAPEX: 300,000 yen PP: 0.8 years
Facility: 2 roots blowers (15 kW/unit)

Energy Saving: 7.1 kL/year
Cost Saving: 661,000 yen/year
CAPEX: 7,500,000 yen PP: 11.3 years
Facility: Heat pump (heating capacity: 65
kW, COP: 3.9)
Energy Saving: 20.8 kL/year
Cost Saving: 1,151,000 yen/year
CAPEX: 6,000,000 yen PP: 5.2 years
Facility: 236 fluorescent lamps (88 W/unit) →236 LED lamps (46 W/unit)

Major efforts in energy conservation activities
1. Addressing energy conservation in the main office/factory

Conventional activities have included introduction of the inverters into the pumps and the fans, and introduction of
the demand monitoring equipment. Along with the proposals in the energy conservation audit, the 236 fluorescentlamps in the formulation room have been replaced by the LED lamps, and “Enhanced utilization of outside air
cooling in the intermediate period” and “Renewal to the high-efficiency refrigerators” are examined. In addition,
the pull switches (string) have been attached to the lighting fixtures to frequently turn off unnecessary ones. The
fans are also effectively utilized to lower a feeling temperature during cooling and stir the air during heating.

2. Addressing energy conservation in the Dokigawa Factory

Conventional activities have included renewal to the high-efficiency boilers, introduction of the waste heatrecovery equipment, and so on. In response to the proposal “Renewal to the high-efficiency packaged
air-conditioner (PAC)”, the PAC has been renewed to obtain energy conservation effects. In addition, theproduction processes have been reviewed and improved to not only reduce water and steam consumptions, butenhance manufacturability.

23

[Hokkaido Area]

CASE11

Audit case of energy
conservation/power-saving
support services

Air-conditioning system: Installation of the curtains overCase of Hot Spring Hotel■ Industry type: Service industry■ Products: Hot spring hotel■ Company name: Manseikaku Hotels Co., Ltd

Air-conditioning system: Adoption of an energy

Since an air-conditioner’s fan in a main kitchen is continuously running
throughout the year, we proposed replacing it by an energy conservation
belt to reduce power consumption. The effects do not include reduction ofmaintenance expenses due to enhanced durability.

■ No. of guests: 600

Effects of the measures (Audit)

kL/year

Reduced by

Hot water system: Lower air ratio of the vacuum

1. water heaters

Two vacuum water heaters are alternately operating to supply hot water. Since both ofthem have a high air ratio, we proposed adjusting it to the standard value provided by
the Act on the Rational Use of Energy (1.9 → 1.3) to realize energy conservation.

Automatic vending machine: Renewal to thehigh-efficiency automatic vending machines

We proposed renewing automatic vending machines of beverages (cannedand bottled) to the high-efficiency ones to reduce energy consumption (36%less).

4,985,000

yen/year

Energy Saving: 12.8 kL/year
Cost Saving: 1,019,000 yen/year
Facility: 2 vacuum water heaters (total
bunker-A consumption: 360 kl/year)
Energy Saving: 3.2 kL/year
Cost Saving: 213,000 yen/year
Facility: 39 air-conditioners (total power
consumption: 35,000 kWh/year)

Making investments into facilities with higher efficiency (Note) Energy conservation effect is shown in crude oil equivalent.

3. water pump

Air-conditioning system: Inverter-based cold/hot

A cold/hot water pump for air-conditioning a banquet hall is adjusting a flow rate by throttlingwith a valve. We proposed fully opening the valve and controlling the pump with an inverter(lower a rotation frequency to the required flow rate) to reduce power consumption. In thiscase, as it is necessary to generate a pressure for an actual pump head, and so on, theeffects were calculated under the condition that the pump head is lowered to 1/2.

4. of the air-conditioning indoor units for the guest rooms

Air-conditioning system: Cleaning of the heat exchangers

The heat exchangers of the air-conditioning indoor units (FCU: Fan Coil
Units) for the guest rooms are contaminated here and there. We proposed
recovering heat exchange efficiency by cleaning to reduce fuelconsumption. The effects were calculated assuming a 5% energy
conservation rate by cleaning.

24

We proposed installing simple heat-retaining sheets on the water surface of a
hot water swimming pool at night during the winter to inhibit evaporation of thewater content and lowering a water temperature, thereby reducing the fuelconsumption of a boiler. Specific measures include spreading foaming resin
sheets, insulating boards, etc. on the surface of the indoor swimming pool.

We proposed enhancing thermal insulation of a hot water piping system in amachine room to decrease radiation losses, thereby reducing the bunker-A
consumption of the hot water boiler.

Proposals requiring no cost (Note) Energy conservation effect is shown in crude oil equivalent.

2.

Hot water swimming pool: Reduction of heat dissipation

7. from the surface of a hot water swimming pool
8. hot water piping system

Energy cost

Energy Saving: 32.7 kL/year
Cost Saving: 2,160,000 yen/year
CAPEX: 2,500,000 yen PP: 1.2 years
Facility: 1 pump (30 kW)

Energy Saving: 9.1 kL/year
Cost Saving: 729,000 yen/year
CAPEX: 3,180,000 yen PP: 4.4 years
Facility: Indoor units (FCU: 318 units, totalheat quantity of cooling/heating: 550/960 kW)

Energy Saving: 0.7 kL/year
Cost Saving: 52,000 yen/year
CAPEX: 1,000,000 yen
PP: Upon renewing the aged system
Facility: Window glasses (area: 225 m2, room
temperature at night: 22°C, outside air: 1°C)
Energy Saving: 0.4 kL/year
Cost Saving: 25,000 yen/year
CAPEX: 17,000 yen PP: 0.4 years
Facility: 1 exhaust fan (22 kW)(Note) Because a V-belt with inside notches (energy conservation belt) reduces a “bending
stress” when it is coiled around a pulley, it decreases losses by bending and improves powertransmission efficiency from a motor to the drive side, saving the power.

Hot water piping: Enhanced thermal insulation of aEnergy consumption (crude oil equivalent)70

In a restaurant and a lounge, heating is suspended at night during the winter (outside thebusiness hours), and the heat is radiated and lost from the window glasses due to a high room
temperature. Because an overnight radiation amount cools down a building and is added to aheating load next day, we proposed installing the curtains over the window glasses to prevent
lowering of the room temperature, thereby reducing bunker-A consumption for heating.

6. conservation belt for an air-conditioning fan

The hotel run by Manseikaku Hotels Co., Ltd. has been conducting the energy conservation activities such as thinning
out/turning off unnecessary lighting fixtures, renewing to high-efficiency lighting, and introducing and utilizing thedemand monitoring equipment. This time, they requested for an overall energy conservation audit. As a result of theaudit, we proposed an inverter-based cold/hot water pump for air-conditioning, cleaning of the heat exchangers of the
air-conditioning indoor units for the guest rooms, lower air ratio of vacuum water heaters, enhanced thermal insulationof the hot water piping, and so on.

Reduced by

5. the window glasses of a restaurant and a loungeLighting: Renewal of the fluorescent guide lights to

9. the LED lamps

The fluorescent guide lights consume less power, but has high annual
power consumption because they are left turned on for 24 hours. We
proposed replacing them by the high-efficiency LED guide lights to reduce
power consumption.

10. refrigerators when the rooms are not occupied

Electric outlet load: Power-off of the guest-room

We proposed installing the electric outlets with switch to turn off the indoor
small refrigerators when the rooms are not occupied, thereby reducing
power consumption resulting from futile operation.

Energy Saving: 4.1 kL/year
Cost Saving: 330,000 yen /year
CAPEX: 200,000 yen PP: 0.6 years
Facility: Hot water swimming pool (surface area: 100
m2, water temperature: 31°C, ambient temperature: 28°C)
Energy Saving: 1.9 kL/year
Cost Saving: 151,000 yen/year
CAPEX: 380,000 yen PP: 2.5 years
Facility: Flange type globe valves (3 pcs. for 150A),
flanges (3 pcs. for 150A, 14 pcs. for 80A, 6 pcs. for65A), piping (1 m for 80A, 1 m for 50A), and so on
Energy Saving: 1.8 kL/year
Cost Saving: 121,000 yen/year
CAPEX: 1,368,000 yen PP: 11.3 years
Facility: 40 fluorescent guide lights (23W/unit) → 40 LED guide lights (2.7 W/unit)
Energy Saving: 2.8 kL/year
Cost Saving: 185,000 yen/year
CAPEX: 10,000 yen PP: 0.1 years
Facility: 320 small refrigerators(17 kWh/month/unit)

Major efforts in energy conservation activities
1. Implementing all two operational improvement proposals
The air ratio of the vacuum water heaters was adjusted and two automatic vending machines were
integrated into one high-efficiency model.
2. Utilizing a subsidy to implement the proposed investment-required improvements, obtaining
substantial energy conservation effects
The proposal “Inverter-based cold/hot water pump” was expanded to all 12 units by utilizing the 2014
Subsidy for Introduction of Energy Conservation Facilities for Local Factories, Small- and Medium-sizedBusinesses, obtaining substantial effects. “Cleaning of the heat exchangers of the air-conditioning indoor
units for the guest rooms”, “closing of the gaps of the restaurant and lounge doors (prevention of entry of theoutside air)” and “enhanced thermal insulation of the hot water piping” were also implemented. “Renewal of
the guide lights to the LED lamps” is being sequentially implemented, beginning with the burnt-out ones.
3. Developing the improvement activities other than the proposals
A cold/hot water generator was renewed by adopting a combination of a hot spring heat-based heat pump (heating)and a cooling tower (cooling), intended for utilization of the hot spring heat, and utilizing the 2014 Subsidy for
Introduction of Energy Conservation Facilities for Local Factories, Small- and Medium-sized Businesses, including
primary heating of hot water feed by the hot spring heat, thereby greatly reducing the fuel heavy oil.

25

[Tohoku Area]

CASE12

Audit case of energy
conservation/power-saving
support services

Boiler: Reduction of fuel consumption by lowering

Case of Hot Spring Hotel■ Industry type: Service industry ■ Products: Hot spring hotel■ Company name: Tendo Hotel Co., Ltd.
■ No. of guests: Approx. 210 on weekdays and 300 on holidays

6. the air ratio

The air ratio of individual boilers has not been measured and understood,
but are estimated high. We proposed adjusting it (1.8 → 1.3) to reduce
bunker-A consumption.

7. steam piping

Steam piping: Enhanced thermal insulation of the

We proposed enhancing thermal insulation of the steam piping and valves
to reduce the heavy oil consumption of the boilers (feasible by thermal
insulation work by the employees).

Water heating system: Introduction of exclusive small

Tendo Hotel Co., Ltd. has been conducting the energy conservation activities such as suspending the air-conditioners
during the intermediate period, replacing the lighting fixtures by the LEDs, and educating the employees about energy
conservation. This time, they requested for an overall energy conservation audit. As a result of the audit, we proposedwater-saving in the washrooms and bathrooms, inverter-based pumps for an air-conditioning system, adjustment of aboiler’s air ratio, reduction of the maximum power by introduction of the demand monitoring equipment, and so on.

Two bathtub filtration pumps (5.5 kW/unit) are running. Since contamination isless at midnight, we proposed installing exclusive small filtration pumps andswitching them over with a timer to reduce power consumption. Since the numberof filtration pumps is added to, they will be a backup in the case of failure.
(Note) It is also possible to detect free residual chlorine concentration in bathtub water tocontrol the filtration pump with an inverter, allowing further energy conservation.

Sanitary system: Replacement of the shower heads

Energy consumption (crude oil equivalent)

Reduced by65

kL/year

We proposed changing the shower heads in the bathrooms from theconventional type to the water-saving type to save water and reduce
bunker-A consumption.

Energy cost

Reduced by

6,650,000

10. lighting in the restrooms

Lighting: Introduction of the motion detectors foryen/year

Proposals requiring no cost (Note) Energy conservation effect is shown in crude oil equivalent.

1.

Freezer/refrigerator: Consolidation of the
prefabricated refrigerators and freezers for kitchen

Many refrigerators and freezers are installed for kitchen use, but the utilization factors ofindividual units seem low and there is room for consolidation of the numbers. The
refrigerators and freezers consume the power not only for the compressors, but for ancillaryfacilities such as frozen door preventive heaters, defrosting heaters and internal lighting.
We proposed consolidating the number of working units to realize energy conservation.

system: Adjustment of the hot water
2. Sanitary
volume in the washrooms

Since a face-washing hot water discharge rate is high, we proposed (1)using a stop cock for a hand-washing faucet to reduce by 75% and (2)introducing a super water-saving shower to save water and reduce thebunker-A consumption of the boiler.

3. Lighting: Power-saving of the fluorescent lamps

We proposed replacing the FLR fluorescent lamps in the backyard such as
an office and a kitchen by the power-saving fluorescent lamps to reduce
power consumption.

Energy Saving: 1.5 kL/year
Cost Saving: 101,000 yen/year
Facility: Reduction of the refrigerators andfreezers (3 units, 2.2 kW/unit)

Energy Saving: 22.2 kL/year
Cost Saving: 2,806,000 yen/year
Facility: Hot water reduced by 3,300 m3/year,
hand-washing water reduced by 2,200 m3/year
Energy Saving: 0.7 kL/year
Cost Saving: 49,000 yen/year
Facility: 180 FLR fluorescent lamps (40 W/unit)→ 180 fluorescent lamps (36 W/unit)

Making investments into facilities with higher efficiency (Note) Energy conservation effect is shown in crude oil equivalent.

Saving: 4.9 kL/year
4. high-efficiency inverter-controlled freezing machine Energy
Cost Saving: 329,000 yen/year

Air-conditioning system: Renewal to a

Installed about 28 years ago, a water-cooled chiller has aged. We proposed
renewing it to a high-efficiency inverter-controlled freezing machine to
reduce power consumption.

5.

Air-conditioning system: Inverter-based secondary
hot water pumps

Two secondary hot water pumps (No. 2 and No. 3) in the new building have an
excessive capacity and are operated by throttling with a valve. (35% for No. 2 and
70% for No. 3). We proposed fully opening the valve and control them with inverters(lower flow rate by controlling a motor speed) to reduce power consumption.

26

CAPEX: 27,650,000 yen
PP: Upon renewing the aged system
Facility: 1 water-cooled chiller (cooling
capacity: 247 kW, COP: 4.1 →5.1)
Energy Saving: 4.2 kL/year
Cost Saving: 283,000 yen/year
CAPEX: 600,000 yen PP: 2.1 years
Facility: 2 pumps (11 kW, 3.7 kW)

Energy Saving: 3.3 kL/year
Cost Saving: 250,000 yen/year
CAPEX: 1,300,000 yen PP: 5.2 years
Facility: Flange type globe valves (15 pcs. for80A), flanges (50 pcs. for 100A, 50 pcs. for 65A)

8. pumps for midnight use into a bathtub filtration system Energy Saving: 2.2 kL/year

9. in the bathrooms by the water-saving type

Effects of the measures (Audit)

Energy Saving: 7.2 kL/year
Cost Saving: 550,000 yen/year
CAPEX: 400,000 yen PP: 0.7 years
Facility: 4 boilers (0.9 t/h./unit, total heavy
oil consumption: 176 kl/year)

There are many lighting fixtures in the restrooms in the public areas, buteffective lighting control cannot be easily done by manual flashing. We
proposed installing the motion detectors to turn off lighting when there is
nobody, thereby reducing power consumption.

11. lights by the LED lamps

Lighting: Replacement of the fluorescent guide

We proposed renewing the fluorescent guide lights to the LED lamps with low
power consumption to reduce power consumption.

(Note) When renewing to the LED guide lights, it is necessary to notify to a competent firestation in advance.
Category(1) Class-A guide lights (40 W)(2) Class-A guide lights (35 W)(3) Class-B guide lights (Class BH)(4) Class-C guide lights (20 W)(5) Class-C guide lights (10 W)
Total

Power consumption (W)Fluorescent lamp

49
44
25
25
13

LED

10.5
10.5
3.6
2.0
2.0

12. monitoring equipment

Qty.

Fluorescent lamp

22
26
90
1
57
196

Cost Saving: 151,000 yen/year
CAPEX: 240,000 yen PP: 1.6 years
Facility: Two pumps (2.2 kW/unit) added tothe existing two pumps (5.5 kW/unit)

Energy Saving: 6.0 kL/year
Cost Saving: 810,000 yen/year
CAPEX: 2,800,000 yen PP: 3.5 years
Facility: 40 shower heads
Energy Saving: 0.6 kL/year
Cost Saving: 39,000 yen/year
CAPEX: 176,000 yen PP: 4.5 years
Facility: 8 restrooms, fluorescent lamps (27 W/unit:
14 units, 12 W/unit: 8 units), 8 motion detectors (1master device + 2 slave devices/location)
Energy Saving: 9.7 kL/year
Cost Saving: 654,000 yen/year
CAPEX: 8,500,000 yen PP: 13 years
Facility: Fluorescent guide lights → LED
guide lights

LED

48
91
1
56
196

Demand control: Introduction of the demand

We proposed introducing the demand monitoring equipment to monitor the change of the maxim power,
and suspending operation of the premeditated systems when the maximum power approaches a setting
value, thereby inhibiting the maximum power (contract demand: 720 → 693 kW, 27 kW less). The
systems to be suspended include kitchen equipment (convection oven, dish washing machine), sauna,change of the defrosting time of the freezers and refrigerators, electric water heaters, and so on.

Electric outlet load: Power-off of the guest-room

13. refrigerators when the rooms are not occupied

The refrigerators are installed in the guest rooms. They are left turned on all
the time, consuming the standby power. We proposed utilizing extension
cords with switch, etc. to turn off the power when the rooms are notoccupied, thereby realizing energy conservation.

Maximum power: 27 kW less
Cost Saving: 437,000 yen/year
CAPEX: 400,000 yen PP: 0.9 years
Facility: Demand monitoring equipment

Energy Saving: 2.8 kL/year
Cost Saving: 191,000 yen/year
CAPEX: 116,000 yen PP: 0.6 years
Facility: 116 small refrigerators(180 kWh/unit㺃year)

Major efforts in energy conservation activities
1. Implementing the management proposals requiring no investments in advance“Adjustment of the hot water volume in the washrooms” has been put into practice and is being promoted because it brings about great
effects. For “Power-saving of the fluorescent lamps”, the employees have been voluntarily replacing the burnt-out fluorescent lamps by
the power-saving type.

2. Implementing easily practicable investment-required proposals in advanceThe deteriorated bathroom faucets were renewed according to the proposal. When this was done, 20 shower heads were replaced by thelatest water-saving type capable of lowering a water rate without changing a pressure, thereby substantially reducing water-heating energy.

3. Utilizing a subsidy to replace the guide lights by the LED lamps

The Subsidy for Eco-Renovation Promotion Model Project in Yamagata Prefecture was utilized to replace all fluorescent guide lights by
the LED lamps, which had been left turned on all the time.

27

Case of General Welfare
CASE13 Facilities[Tohoku Area]

Audit case of energy
conservation/power-saving
support services■ Industry type: Social welfare and nursing care ■ Products: General welfare facilities■ Company name: Social welfare corporation, Kagayakinokai, Ikiikinosato■ No. of users: 500

Making investments into facilities with higher efficiency (Note) Energy conservation effect is shown in crude oil equivalent.

6. of the valves, flanges and a filtration tank

Water heating system: Enhanced thermal insulation

We proposed enhancing thermal insulation of the valves and the flanges of
the hot water feed/heating piping, and the filtration tank to decrease heatdissipation, thereby realizing energy conservation.

Water heating system: Inverter-based hot spring

Ikiikinosato has been taking the energy conservation measures such as thinning out/turning off unnecessary lighting
fixtures and changing a cooling/heating setting temperature. This time, they requested for an overall energy
conservation audit, focusing on reduction of a boiler fuel. As a result of the audit, we proposed the lower air ratio of acold/hot water generator for air-conditioning, a measure to control heat radiation from the surface of the baths and aswimming pool when they are not in use, enhanced thermal insulation of hot water piping and a tank, power-saving ofan antifreeze heater, integration of transformers, and so on.

Reduced by87

kL/year

Energy cost

Reduced by

8,767,000

yen/year

Proposals requiring no cost (Note) Energy conservation effect is shown in crude oil equivalent.

1.

Air-conditioning system: Reduction of fuelconsumption (LPG) by the lower air ratio

We proposed lowering the air ratio of the cold/hot water generator for
air-conditioning (1.60 → 1.30) to decrease heat losses by an exhaust gas,
thereby realizing energy consumption.

Energy Saving: 2.5 kL/year
Cost Saving: 236,000 yen/year
Facility: 2 absorption type cold/hot water
generators (cooling/heating capacity: 633/736
kW/unit, LPG consumption: 100 t/year)

Air-conditioning system: Power-off of the

2. air-conditioners during their non-operating period
Since the air-conditioners are left turned on all the time, the crank case heaters consume
the standby power when air-conditioning is not used (4 months/year). We proposed
turning off the circuit breakers during that period to realize energy conservation.

(Note) The crank case heater is a facility to prevent mixture of a refrigerant and a lubricant anddoes not need to be energized when the air-conditioners are not operating. Its manufacturer
recommends turning on the main power a couple of hours before using the air-conditioners.

Plumbing equipment: Power-saving of the

3. antifreeze heater

We proposed (1) adjusting the setting temperature of the piping antifreeze panel
heater for a fire-fighting system (20 → 5°C) and (2) removing the power wiring of theincorporated antifreeze heater of an electric valve because there is no fear of
freezing of the piping (hot water) of a filtration pump, thereby reducing power-saving.

4. monitoring equipment

Demand control: Utilization of the demand

A possible cause for higher maximum power (demand) is heater operation
for the vaporizers (3 LPG vaporizers, totally 78 kW) and the tablewarestorages (2 units, totally 27 kW). We proposed utilizing the demand
monitoring equipment to monitor the change of the maximum power, andstop the predetermined devices (vaporizers, etc.) to inhibit the maximum
power (221 → 180 kW, 41 kW less) when it approaches a setting value.

5. conservation type

Automatic vending machine: Renewal to the energy

Specified as the specially designated secondary device of the Act on the Rational Use of Energy, theautomatic beverage vending machines have enhanced the energy conservation performance year
after year. We proposed renewing them to the energy conservation type to reduce power consumption.

28

Since the valve of a hot spring circulation pump is narrowed, a required flowrate is lower than the rated flow rate of the equipment. Accordingly, we
proposed fully opening the valve and controlling the pump by an inverter toadjust the flow rate, thereby reducing power consumption.

Other facilities: Measure to control heat radiation from the surface

8. of the baths and the swimming pool when they are not in use

We proposed covering the water surface with a simple heat-retaining sheet(3-layer bubble wrap, foamed polyethylene sheet, etc.) to inhibit moistureevaporation and a water temperature fall during a time period (14 h./day x
365 days) when the indoor baths, outdoor bath and hot water swimming
pool are not used, thereby reducing boiler fuel consumption.

Effects of the measures (Audit)
Energy consumption (crude oil equivalent)

7. circulation pump

9. Lighting: Higher-efficiency mercury lamps

We proposed renewing the outside mercury lamps (lighting hours: 3.5
h./day x 365 days) to the high-efficiency ceramic metal halide lamps (withan exclusive stabilizer) to realize energy conservation.

Transformer: Integration of the transformers in

10. two electrical rooms

Five transformers in two electrical rooms are lightly loaded. We proposed
integrating them into two transformers in the first electrical room
(suspension of 3 units and removal of the primary-side wiring) to decreasetransformer losses, thereby realizing energy conservation. In this case,cabling is required from the first to the second electrical room.
Status quo

Energy Saving: 1.1 kL/year
Cost Saving: 83,000 yen/year
Facility: 50 air-conditioners (crank caseheater: 30 W/unit)

1st electrical 3ø transformer (1 unit: 300 kVA)room
1ø transformer (2 units: 200 kVA/unit)
2nd electrical 3ø transformer (1 unit: 200 kVA)room
1ø transformer (1 nit: 200 kVA)

Energy Saving: 9.2 kL/year
Cost Saving: 866,000 yen/year
CAPEX: 413,000 yen PP: 0.5 years
Facility: Flange type gate valves (10 pcs. for
80A, 10 pcs. for 65A, 20 pcs. for 50A), flanges(20 pcs. for 80A, 20 pcs. 65A, 40 pcs. for 50
A), 1 filtration tank (ø1.5 m, 3.0 m high)Energy Saving: 0.9 kL/year
Cost Saving: 70,000 yen/year
CAPEX: 70,000 yen PP: 1.0 year
Facility: 1 pump (2.2 kW)
Energy Saving: 68.6 kL/year
Cost Saving: 6,459,000 yen/year
CAPEX: 2,900,000 yen PP: 0.4 years
Facility: 2 indoor baths (total surface area:
101 m2, 40°C), outdoor bath (23 m2, 40°C), hotwater swimming pool (approx. 200 m2, 30°C)
Energy Saving: 0.3 kL/year
Cost Saving: 26,000 yen/year
CAPEX: 350,000 yen PP: 13.5 years
Facility: 7 mercury lamps (400 W/unit) → 7
ceramic metal halide lamps (250 W/unit, withstabilizer)
Energy Saving: 3.5 kL/year
Cost Saving: 260,000 yen/year
CAPEX: 1,000,000 yen PP: 3.8 years
Facility: 3ø transformers (2 units,300 kVA +200 kVA → 1 unit, 300 kVA), 1ø transformer(3 units, 200 kVA/unit → 1 unit)

Renewal plan
Integrate into;- 3ø transformer (1 unit: 300 kVA)
- 1ø transformer (1 unit: 200 kVA)in the 1st electrical room.

Major efforts in energy conservation activities
Energy Saving: 0.8 kL/year
Cost Saving: 58,000 yen/year
Facility: 1 panel heater (1.0 kW/unit),
4 electric valves (15 W/unit)
Maximum power: 41 kW less
Cost Saving: 685,000 yen/year
Facility: Demand monitoring equipment

Energy Saving: 0.3 kL/year
Cost Saving: 24,000 yen/year
Facility: 2 automatic vending machines(totally 3,020 → 1,754 kW/year)

1. Implementing four operational improvement proposals requiring no investments
Energy conservation activities were immediately put into practice for operational improvement, such as
lowering the air ratio of the cold/hot water generators for air-conditioning and the gas type water boiler,
suspending surplus antifreeze heaters, renewing to the energy-conserving automatic vending machines,
and utilizing the existing demand monitoring equipment to inhibit the maximum power.
2. Implementing two relatively easy investment improvement proposals for management
Thermal insulation of the valves and flanges for the hot water piping, and the filtration tank was enhanced,
and the mercury lamps for the indoor hot water swimming pool were renewed to the high-efficiency lighting
fixtures to obtain the energy conservation effects.
3. Enhancing the energy conservation management structure and promoting their own measures
Having understood the necessity of the management structure after the audit, an organizational structure
was established with a managing director at the top plus mangers and their subordinates to continuously
promote energy conservation. In addition, a water-saving tool was introduced, small humidifiers wererenewed to large ones (mist fans), and one vaporizer was suspended as their voluntary measures to realize
energy conservation. Also, it is planned to renew two hot water boilers by utilizing the Promotion Project
Subsidy for Investments in Energy Conservation and Productivity Revolution of Small- and Medium-sizedBusinesses of the FY2015 supplementary budget.

29

Case of Welfare Center and
CASE14 Culture Center[Chugoku Area]

Audit case of energy
conservation/power-saving
support services■ Industry type: Public ■ Products: Welfare center, culture center■ Company name: Company K■ Total floor area: 4,056 m2 for the welfare center A, 6,700 m2 for the culture center B

Company K has been taking the energy conservation measures such as thinning out unnecessary lighting fixtures andsuspending unnecessary air-conditioning at the welfare center A and culture center B which are the designatedadministrator facilities. This time, they requested for an overall energy conservation audit, focusing on air-conditioning
and lighting. As a result of the audit, we proposed easing the setting temperature of air-conditioning, controlling an
air-handling unit for air-conditioning and a pump through an inverter, lowering an outside air inlet volume, renewing tohigh-efficiency lighting, and so on.

Effects of the measures (Audit)
A.

Energy consumption (crude oil equivalent)
Reduced byB.

20 kL/year

Energy cost

Reduced by

Energy consumption (crude oil equivalent)
Reduced by

36 kL/year

2,441,000 yen/year
Energy cost

Reduced by

4,039,000 yen/year

Lighting (Welfare center): Thinning out of lighting of

5. the corridor in the public area

Lighting of the corridor in the public area has been already thinned out, but
illuminance was 150 to 250 lx at the time of audit (3rd floor), brighter than the
JIS illuminance standard 100 lx. We proposed thinning out lighting on the 3rd
and 4th floors to realize energy conservation.

Making investments into facilities with higher efficiency (Note) Energy conservation effect is shown in crude oil equivalent.

6. by installing the sunshades for the outdoor units

Air-conditioning system (Welfare center): Power-saving

The outdoor units for the air-conditioners are installed on the west side of the 1 and 2
floors and on the rooftop, and subjected to the direct sunshine. We proposed making
shades for the outdoor units with “reed screens”, etc. to block solar insolation, thereby
lowering the temperature of the outdoor units (condensers) to save the power.
stnd

Air-conditioning system, hot water swimming pool (Culture

7. center): Inverter-based AHU, cold/hot water pump, etc.

(1) The fans of the air-handling units (AHUs) for air-conditioning throttles damper
opening to 50% to adjust an air volume. The secondary cold/hot water pump for
air-conditioning and the secondary hot water pumps throttle the discharge valves
to about 30% opening. By fully opening the damper and introducing an inverter,
accordingly, reduce the motor speed to lower the air volume/flow rate. (2) A water
circulation pump for the swimming pool keeps running at a constant speed at night
after business hours. Introduce an inverter to lower the pump rotation frequency
during the less contaminating nighttime, thereby reducing a circulation water rate
(70% less). We proposed saving the power by taking the measures (1) and (2).

1. inlet volume for an atrium and a hot water swimming poolAir-conditioning system (Culture center): Lower outside air(1) Since a CO2 concentration (490 ppm) in the atrium is low and the outside air inlet volume is too high,lower the outside air inlet volume to a control value (900 ppm). (2) The CO2 concentration of the hotwater swimming pool has not been measured. Lower the outside air inlet volume to the required volume
at the CO2 concentration control value (900 ppm) obtained from the number of users at the peak time.
We proposed reducing power consumption for air-conditioning by taking the measures (1) and (2).

(1) A jacuzzi pump is continuously running while the hot water swimming pool is utilized, but
the utilization frequency of the pump seems low. We proposed running it only during usageof the jacuzzi to reduce power consumption. Specifically, have users turn on the start switchof the jacuzzi pump and use a timer to stop the pump automatically, or install a motion
detector at the upper part of the jacuzzi to run the pump automatically. (2) We proposed
replacing the conventional shower heads in a shower room with the water-saving type tosave water and reduce the power consumption of a hot water heat pump chiller.

9. high-efficiency lighting(1) We proposed renewing the (1) downlights in the restrooms(incandescent lamps), (2) mercury lamps in a gymnastic meeting room, (3)multi-halogen lamps in the atrium, and (4) fluorescent guide lights to thehigh-efficiency models to reduce power consumption.
Status quo

Renewal plan

(1) Downlights (incandescent lamps, 40 W/unit)

LED lamps (5.2 W/unit)(2) Mercury lamps (300 W/unit)

Ceramic halide lamps (190 W/unit)

Item

Energy conservation effect

Cost reduction(3) Multi-halogen lamps (430 W/unit)

Ceramic halide lamps (250 W/unit)

17,073 kWh/year

487,000 yen/year(2) Lower outside air inlet volume for the hot water swimming pool

11,210 kWh/year

319,000 yen/year(4) Fluorescent guide lights (98 W/unit)
Fluorescent guide lights (49 W/unit)

LED guide lights (3.5 W/unit)
LED guide lights (3.5 W/unit)

28,283 kWh/year

806,000 yen/year2.

Air-conditioning system (Welfare center): Easing of
the setting temperature of air-conditioning

We proposed easing the setting temperature of (1) a GHP air-conditioner fora public area and (2) an EHP air-conditioner for tenants (cooling/heating:
24/24°C → 26/22°C) to realize energy conservation.

Air-conditioning system (Welfare center): Delayed

3. air-conditioner start time at the front entrance

Two indoor units for the front entrance are activated 1 hour earlier thanother 6 outdoor units. We proposed delaying their start time to the sametime as the other units to reduce fuel consumption and power consumption
for the GHP.

Ventilation system (Welfare center): Change of the exhaust

4. fan setting temperature of an elevator machine room

The Enforcement Order of the Building Standards Act and the JIS“Inspection Standards for Elevators” stipulate that the temperature of themachine room should be maintained at 40°C or lower as a rule. We
proposed easing the exhaust fan setting temperature 20°C (during the audit)
to 35°C to save the power.

Energy Saving: 5.6 kL/year
Cost Saving: 487,000 yen/year
Facility: GHP air-conditioner (city gas
consumption: 12,000 m3/year), EHP
air-conditioner (power consumption: 57,000
kWh/year)
Energy Saving: 2.4 kL/year
Cost Saving: 224,000 yen/year
Facility: GHP air-conditioner (city gas
consumption during cooling/heating:44.3/43.8 m3/h.)
Energy Saving: 0.3 kL/year
Cost Saving: 22,000 yen/year
Facility: 1 exhaust fan (250 W/unit)

Energy Saving: 20.7 kL/year
Cost Saving: 2,300,000 yen/year
CAPEX: 2,138,000 yen PP: 0.9 years
Facility: 4 AHU fans (totally 37 kW), 1
cold/hot water pump (5.5 kW), 2 secondary
hot water pumps (2.2 kW/unit), 3 circulation
pumps (totally 10.5 kW)

Hot water swimming pool (Culture center): Improvement of a(1) Lower outside air inlet volume for the atrium
Total

30

Energy Saving: 7.3 kL/year
Cost Saving: 806,000 yen/year
Facility: Air-conditioner (cooling/heating
COP: 2.6/3.3)

Energy Saving: 0.8 kL/year
Cost Saving: 64,000 yen/year
CAPEX: 400,000 yen PP: 6.3 years
Facility: 10 air-conditioners (compressors:
65 kW in total)

8. jacuzzi pump operating method and water-saving of showers Energy Saving: 1.7 kL/year

Lighting (Culture center, welfare center): Renewal to

Proposals requiring no cost (Note) Energy conservation effect is shown in crude oil equivalent.

Energy Saving: 0.4 kL/year
Cost Saving: 33,000 yen/year
Facility: Fluorescent lamps (4 units, 40 W
paired lamps/unit)

10.

Cost Saving: 302,000 yen/year
CAPEX: 270,000 yen PP: 0.9 years
Facility: 1 pump (2.2 kW), 8 shower heads

Energy Saving: 6.0 kL/year
Cost Saving: 526,000 yen/year
CAPEX: 1,957,000 yen PP: 3.7 years
Facility: Incandescent lamps → LED lamps;
Mercury lamps, halogen lamps → Ceramic halide
lamps; Fluorescent guide lights → LED guide lights

Lighting hours(h./year)

Qty.

4,485
828
3,926

20
20→15
8
11
6
45

Total

Demand control (Welfare center): Introduction of
the demand monitoring equipment

We proposed introducing the demand monitoring equipment to monitorchanges of the maximum power, and suspend the air-conditioning system orthin out lighting as set in advance when approaching a setting value, thereby
inhibiting the maximum demand power (142 → 130 kW, 12 kW less).

8,760

Money saved Investment Payback period(in 1,000 yen) (in 1,000 yen) (in years)

66
55
161

50
675
280

0.8
12.3
1.7

244

952

3.9

526

1,957

3.7

Maximum power: 12 kW less
Cost Saving: 253,000 yen/year
CAPEX: 400,000 yen PP: 1.6 years
Facility: Demand monitoring equipment

Major efforts in energy conservation activities
1. Purpose of utilizing the complimentary energy conservation audit at the public facilities

Under the stern financial circumstances, Company K has been making efforts for efficient management of thedesignated administrator facilities. In the meantime, they have utilized the complimentary energy conservation audit
system to consider the energy conservation measures for the welfare center A and the culture center B, and steadily
implemented them, focusing on the operational improvement proposals requiring no investments.

2. Implementing the investment-required improvements

On the other hand, the investment-required improvements cannot be easily implemented by the designatedadministrator alone. Eyeing utilization of a national subsidy system, they have been deliberating with the related parties
so as to implement them in a municipal mid-term plan. They have already renewed to high-efficiency lighting.

31

Tuning audit implementedCase of City Gas Manufacturing
CASE15 and Supply Company[Kanto Area]

Audit case of energy
conservation/power-saving
support services■ Industry type: Other manufacturing ■ Products: City gas■ Company name: Company A■ No. of employees: Approx. 200 on weekdays and approx. 30 on holidays

Company A has been conducting the energy conservation activities such as thinning out/turning off unnecessary lighting
fixtures and renewing them to high-efficiency ones at the main office building. This time, they requested for an overall
energy conservation audit, including an absorption type water cooler/heater. As a result of the audit, we proposed easing a
cooling start time and a cooling setting temperature, easing the cold water temperature of the absorption type watercooler/heater, utilizing an inverter for a cooling water pump, replacing mercury lamps and guide lamps by high-efficiency
lamps, turning off lighting thoroughly outside the business hours, and so on. Half a year after the energy conservation audit(Dec. 2014), they had our tuning audit to measure various data and confirmed a tuning method and energy conservation
effect as to “full opening of the flow rate control valve of the cooling water pump and tuning by inverter control”.

Effects of the measures (Audit)
Energy consumption (crude oil equivalent)

Reduced by5

kL/year404,000

Lighting: Thorough lights out outside the business

A power monitor tells that lighting of the 2nd and 3rd floors of the new building
has been turned on from an early time before the business hours. We
proposed turning it off outside the business hours to reduce the lighting
power except when it is inevitable.

yen/year

Energy Saving: 0.04 kL/year
Cost Saving: 4,000 yen/year
Facility: Hf fluorescent lamps (10 units,
lighting hours outside the business hours:
65 W/unit x 1 h./day)

Making investments into facilities with higher efficiency (Note) Energy conservation effect is shown in crude oil equivalent.

7. parking lot to the high-efficiency lamps

Lighting: Renewal of the mercury lamps of a

We proposed renewing the outdoor mercury lamps of the parking lot tohigh-efficiency ceramic metal halide lamps to reduce the lighting power.

8. lamps

Lighting: Renewal of the guide lights to the LED

The guide lights of the new building are all LED lamps, but those of the mainbuilding are almost fluorescent lamps. We proposed replacing the guidelights by the LED lamps at the timing of their renewal to reduce power
consumption. When renewing to the LED guide lights, it is necessary to
notify a competent fire station in advance.

Energy cost

Reduced by

6. hours

Energy Saving: 0.2 kL/year
Cost Saving: 15,000 yen/year
CAPEX: 90,000 yen PP: 6.0 years
Facility: Mercury lamps (2 units, 210 W/unit)→ Ceramic metal halide lamps (2units, 128 W/unit)
Energy Saving: 0.2 kL/year
Cost Saving: 14,000 yen/year
CAPEX: 130,000 yen PP: 9.3 years
Facility: Fluorescent guide lights → LED
guide lights

Before renewal

After renewal

Qty.

Guide lights: Fluorescent lamps (15 W/unit)

LED lamps (2.0 W/unit)

Guide lights: Fluorescent lamps (23 W/unit)

LED lamps (2.7 W/unit)

2
2

Results of tuning audit
Proposals requiring no cost (Note) Energy conservation effect is shown in crude oil equivalent.

1.

Air-conditioning system: Easing of a coolingstart-up time

It is estimated that cooling starts at 6:00 a.m. during summer. We proposeddelaying the start-up time by one hour to realize energy conservation
because there is an enough time before the working hours.

Energy Saving: 1.7 kL/year
Cost Saving: 143,000 yen/year
Facility: 5 GHP air-conditioners (total
capacity: 256 kW, cooling COP: 1.2)

Air-conditioning system: Easing of the cooling

2. setting temperature (GHP)

We proposed easing the cooling setting temperature of a new building by
1°C (26 → 27°C on the average) to realize energy conservation.

3.

Air-conditioning system: Easing of the cold watertemperature of the absorption type water cooler/heater

Because a load is low during a cooling period (June, half of September, andOctober) except during the maximum load, we proposed raising the cold
water temperature from the water cooler/heater (7 → 9°C) to enhance theefficiency of the water cooler/heater, thereby improving fuel (city gas 13A)
consumption efficiency.

Energy Saving: 1.2 kL/year
Cost Saving: 101,000 yen/year
Facility: 5 GHP air-conditioners (total
capacity: 256 kW, cooling COP: 1.2)
Energy Saving: 0.4 kL/year
Cost Saving: 37,000 yen/year
Facility: Absorption type water cooler/heater(city gas consumption during the target
period: 6,500 m3/year)

Air-conditioning system: Utilization of the inverter

4. for the cooling water pump

The discharge valve of the cooling water pump (CWP-1) is opened
approximately 50%. We proposed fully opening the valve and adjusting
inverter setting (already installed, lower pump rotation frequency) to reduce
pump power.

5. Lighting: Thinning out of lighting

The illuminance (1,100 to 1,200 lx) of the 2nd and 3rd office floors of the
new building is high, leaving room for reduction with respect to the JIS
standard (750 lx). We proposed thinning out lighting to reduce the lighting
power.

32

Energy Saving: 0.5 kL/year
Cost Saving: 51,000 yen/year
Facility: 1 pump (5.5 kW)
Energy Saving: 0.4 kL/year
Cost Saving: 39,000 yen/year
Facility: Hf fluorescent lamps (65 W/unit, 46→37 units)

1. Topics

Tuning by fully opening the flow rate control valve of the cooling water pump and adjusting the inverter (Proposal 4)

2. Target facilities

Gas-fired absorption type water cooler/heater (cooling/heating: 352/329 kW), cooling water pump (1 unit, 5.5 kW)

3. Results

We confirmed the methods for measuring the cooling water inlet/outlet pressure of the water cooler/heater, coolingwater volume and pump power.
We confirmed the effects of full opening of the valve and inverter adjustment (48 Hz) under the equivalentconditions to conventional throttling of the discharge valve (50% opening).
Power consumption: 8.8% less, Crude oil equivalent: 0.2 kL/year, Effects: 21,000 yen/year
We confirmed the effects, assuming that an inverter frequency is 48 Hz during summer (same as the above) and 35
Hz during the intermediate period when the outside temperature is low (cooling water volume: 30% less than thesummer).
Power consumption: 38% less, Crude oil equivalent: 1.0 kL/year, Effects: 91,000 yen/year

Major efforts in energy conservation activities
1. Utilizing the inverter to realize energy conservation (including the tuning audit activities)

In order to utilize the inverter for the cooling water pump as proposed, they had a tuning audit after the energy
conservation audit to learn a method to collect the data for preparing the relationship diagrams of “frequency vs. flow
chart” and “frequency vs. electric power”. After that, they voluntarily applied it to not only the measured cooling water
pump, but a cold/hot water circulation pump to obtain more energy conservation effect.

2. Implementing the six operational improvement proposals requiring and not requiring investments(other than those related to the tuning audit)

For the improvement proposals not requiring investments, they implemented “easing of the cooling setting temperature(26 → 28°C)” and “easing of the cold water temperature of the absorption type water cooler/heater (7 → 9°C)”. For the
improvement proposals requiring investments, they invested in the sensors, LEDs and LEDs with sensor to respond to
the proposals, “thinning out of lighting” and “thorough lights out outside the business hours”. For the “mercury lamps ofthe parking lot” and “guide lights”, they are renewing them to the LED lamps successively.

3. Developing the voluntary improvement activities other than the proposals

They have utilized the waste heat by cogeneration, renewed the air-conditioners and introduced solar power generation(subsidy utilized) to realize 15% energy conservation across the building.

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Complimentary Energy Conservation Audit Cases
in FY2016

The Energy Conservation Center, Japan
Energy Audit Department/Energy Audit Technology Department
Igarashi Building, 2-11-5 Shibaura, Minato-ku, Tokyo 108-0023

Phone: +81-3-5439-9732 Fax: +81-3-5439-9738
E-mail: ene@eccj.or.jp

http://shoene-portal.jp/
Unauthorized reproduction prohibited, all rights reserved.
The Energy Conservation Center, Japan* This project is subsidized by the Ministry of Economy,
Trade and Industry, Agency for Natural Resources and Energy.

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2016.10

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