U.S. Department of Energy - Energy Efficiency and Renewable Energy

Industrial Technologies Program

Industrial Assessment Centers

Assessment #AM0566


Assessment Year 2009
SIC 3494
SIC Description Valves And Pipe Fittings, Nec
NAICS 332911
NAICS Description Industrial Valve Manufacturing
Principal Product Plug, butterfly, and ball valves, connectors, pumps
Sales $ 310,000,000
# of Employees 300
Plant Area (Sq.Ft.) 300,000
Annual Production 1,000,000 Pieces
Production Hrs. Annual 3,860
Location (State) TX
Yearly Energy Cost $ 2,128,847

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 18,986,766 kWh $ 1,755,080 $ 0.092 /kWh

- Demand Charge

 65,052 kW $ 328,183 $ 5.04 /kW

- Electricity Fees

 - $ 45,584 -

TOTAL ENERGY

 194,614 MMBtu $ 2,128,847 $ 10.94 /MMBtu

Recommended Reduction in Usage & Costs

Recommended
Implemented
Energy Sources Yearly Savings Yearly Cost % Saved Unit Price

Electricity

 1,215,640 kWh
1,149,440 kWh		 $ 112,280
$ 106,180		 6.40 %
6.05 %		 $ 0.092 /kWh

- Demand Charge

 21,312 kW
3,312 kW		 $ 111,070
$ 17,270		 33.84 %
5.26 %		 $ 5.04 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

TOTAL ENERGY

 12,461 MMBtu
11,782 MMBtu		 $ 223,350
$ 123,450		 10.49 %
5.80 %		 $ 10.94 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 SHIFT FROM DAYTIME TO NIGHTTIME OPERATION 2.3134 N $ 0 $ 59,200 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 18,000 kW $ 93,800 $ 5.04 /kW

TOTAL ENERGY

 0 MMBtu $ 93,800 -

Personnel Changes

 - $ -34,600 -

TOTAL PRODUCTON

 - $ -34,600 -
02 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 111,190 $ 48,230 2.31
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 417,000 kWh $ 38,530 $ 0.092 /kWh

- Demand Charge

 1,296 kW $ 6,750 $ 5.04 /kW

TOTAL ENERGY

 4,274 MMBtu $ 45,280 -

Ancillary Material Cost

 - $ 2,950 -

TOTAL PRODUCTON

 - $ 2,950 -
03 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 1,300 $ 35,170 0.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 330,000 kWh $ 30,500 $ 0.092 /kWh

- Demand Charge

 895 kW $ 4,670 $ 5.04 /kW

TOTAL ENERGY

 3,383 MMBtu $ 35,170 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 3,000 $ 32,100 0.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 295,800 kWh $ 27,300 $ 0.092 /kWh

- Demand Charge

 920 kW $ 4,800 $ 5.04 /kW

TOTAL ENERGY

 3,032 MMBtu $ 32,100 -
05 view
details		 USE SYNTHETIC LUBRICANT 2.4314 I $ 0 $ 6,890 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 63,380 kWh $ 5,860 $ 0.092 /kWh

- Demand Charge

 197 kW $ 1,030 $ 5.04 /kW

TOTAL ENERGY

 650 MMBtu $ 6,890 -
06 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 N $ 0 $ 4,000 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 43,400 kWh $ 4,000 $ 0.092 /kWh

TOTAL ENERGY

 445 MMBtu $ 4,000 -
07 view
details		 INSTALL SKYLIGHTS 2.7145 N $ 2,730 $ 2,100 1.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 22,800 kWh $ 2,100 $ 0.092 /kWh

TOTAL ENERGY

 234 MMBtu $ 2,100 -
08 view
details		 UTILIZE DAYLIGHT WHENEVER POSSIBLE IN LIEU OF ARTIFICIAL LIGHT 2.7121 I $ 0 $ 1,950 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 21,100 kWh $ 1,950 $ 0.092 /kWh

TOTAL ENERGY

 216 MMBtu $ 1,950 -
09 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 0 $ 1,780 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 19,300 kWh $ 1,780 $ 0.092 /kWh

TOTAL ENERGY

 198 MMBtu $ 1,780 -
10 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 380 $ 1,385 0.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,860 kWh $ 260 $ 0.092 /kWh

- Demand Charge

 4 kW $ 20 $ 5.04 /kW

TOTAL ENERGY

 29 MMBtu $ 280 -

Ancillary Material Cost

 - $ 1,105 -

TOTAL PRODUCTON

 - $ 1,105 -