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U.S. Department of Energy Energy Efficiency and Renewable Energy
IAC Field Managers

Industrial Assessment Centers

Assessment #AM0603


Assessment Year 2012
SIC 3398
SIC Description Metal Heat Treating
NAICS 332420
NAICS Description Metal Tank (Heavy Gauge) Manufacturing
Principal Product storage tanks
Sales $ 30,000,000
# of Employees 205
Plant Area (Sq.Ft.) 110,000
Annual Production 50,000,000 Pounds
Production Hrs. Annual 3,146
Location (State) TX
Yearly Energy Cost $ 731,305

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 1,457,403 kWh $ 138,519 $ 0.095 /kWh

- Demand Charge

 13,101 kW $ 66,002 $ 5.04 /kW

- Electricity Fees

 - $ 15,735 -

Fuel Oil #1

 19,079 MMBtu $ 511,050 $ 26.79 /MMBtu

TOTAL ENERGY

 34,018 MMBtu $ 731,305 $ 21.50 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 -5,505,080 kWh
-5,521,540 kWh		 $ -401,865
$ -403,070		 -290.12 %
-290.99 %		 $ 0.095 /kWh

- Demand Charge

 -1,304 kW
-2,088 kW		 $ -8,880
$ -14,250		 -13.45 %
-21.59 %		 $ 5.04 /kW

- Electricity Fees

 - $ 1,684
$ 1,684		 10.70 %
10.70 %		 -

Fuel Oil #1

 19,079 MMBtu
19,079 MMBtu		 $ 511,050
$ 511,050		 100.00 %
100.00 %		 $ 26.79 /MMBtu

TOTAL ENERGY

 -37,349 MMBtu
-37,517 MMBtu		 $ 101,989
$ 95,414		 13.95 %
13.05 %		 $ 21.50 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE RADIANT HEATER FOR SPOT HEATING 2.7231 I $ 66,160 $ 80,070 0.83
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -5,660,930 kWh $ -413,250 $ 0.095 /kWh

- Demand Charge

 -2,592 kW $ -17,730 $ 5.04 /kW

Fuel Oil #1

 19,079 MMBtu $ 511,050 $ 26.79 /MMBtu

TOTAL ENERGY

 -38,946 MMBtu $ 80,070 -
02 view
details		 REPLACE EXISTING EQUIPMENT WITH MORE SUITABLE SUBSTITUTES 4.652 I $ 2,320 $ 30,000 0.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

Administrative Changes

 - $ 30,000 -

TOTAL PRODUCTON

 - $ 30,000 -
03 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,000 $ 4,750 0.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 47,900 kWh $ 3,500 $ 0.095 /kWh

- Demand Charge

 183 kW $ 1,250 $ 5.04 /kW

TOTAL ENERGY

 491 MMBtu $ 4,750 -
04 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 N $ 9,440 $ 4,730 2.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 691 kW $ 4,730 $ 5.04 /kW

TOTAL ENERGY

 0 MMBtu $ 4,730 -
05 view
details		 USE PHOTOCELL CONTROLS 2.7134 I $ 260 $ 2,890 0.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 31,500 kWh $ 2,300 $ 0.095 /kWh

- Demand Charge

 86 kW $ 590 $ 5.04 /kW

TOTAL ENERGY

 323 MMBtu $ 2,890 -
06 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,000 $ 2,080 0.48
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 21,000 kWh $ 1,530 $ 0.095 /kWh

- Demand Charge

 80 kW $ 550 $ 5.04 /kW

TOTAL ENERGY

 215 MMBtu $ 2,080 -
07 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 500 $ 2,040 0.25
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 19,700 kWh $ 1,440 $ 0.095 /kWh

- Demand Charge

 75 kW $ 600 $ 5.04 /kW

TOTAL ENERGY

 202 MMBtu $ 2,040 -
08 view
details		 PAY UTILITY BILLS ON TIME 2.8123 I $ 0 $ 1,684 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 1,684 -

TOTAL ENERGY

 0 MMBtu $ 1,684 -
09 view
details		 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 2.7124 N $ 0 $ 1,655 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 13,900 kWh $ 1,015 $ 0.095 /kWh

- Demand Charge

 93 kW $ 640 $ 5.04 /kW

TOTAL ENERGY

 142 MMBtu $ 1,655 -
10 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 3,110 $ 1,180 2.64
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,890 kWh $ 870 $ 0.095 /kWh

- Demand Charge

 45 kW $ 310 $ 5.04 /kW

TOTAL ENERGY

 122 MMBtu $ 1,180 -
11 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 20 $ 720 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,400 kWh $ 540 $ 0.095 /kWh

- Demand Charge

 35 kW $ 180 $ 5.04 /kW

TOTAL ENERGY

 76 MMBtu $ 720 -
12 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 N $ 0 $ 190 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,560 kWh $ 190 $ 0.095 /kWh

TOTAL ENERGY

 26 MMBtu $ 190 -