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

Industrial Assessment Centers

Assessment #IA0453


Assessment Year 2010
SIC 3084
SIC Description Plastics Pipe
NAICS 326122
NAICS Description Plastics Pipe and Pipe Fitting Manufacturing
Principal Product Polyethylene plastic pipe
Sales $ 25,000,000
# of Employees 100
Plant Area (Sq.Ft.) 63,000
Annual Production 19,000,000 Pounds
Production Hrs. Annual 6,240
Location (State) NE
Yearly Energy Cost $ 326,599

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 5,745,600 kWh $ 225,686 $ 0.039 /kWh

- Demand Charge

 13,584 kW $ 96,319 $ 7.09 /kW

- Electricity Fees

 - $ 380 -

Natural Gas

 715 MMBtu $ 4,214 $ 5.89 /MMBtu

TOTAL ENERGY

 59,608 MMBtu $ 326,599 $ 5.48 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 531,770 kWh
373,714 kWh		 $ 20,897
$ 14,685		 9.26 %
6.51 %		 $ 0.039 /kWh

- Demand Charge

 152 kW
107 kW		 $ 1,073
$ 757		 1.11 %
0.79 %		 $ 7.09 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 554 MMBtu
207 MMBtu		 $ 3,252
$ 1,215		 77.17 %
28.83 %		 $ 5.89 /MMBtu

TOTAL ENERGY

 6,005 MMBtu
4,038 MMBtu		 $ 25,222
$ 16,657		 7.72 %
5.10 %		 $ 5.48 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 19,968 $ 8,157 2.45
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 201,084 kWh $ 7,902 $ 0.039 /kWh

- Demand Charge

 36 kW $ 255 $ 7.09 /kW

TOTAL ENERGY

 2,061 MMBtu $ 8,157 -
02 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 1,037 $ 1,082 0.96
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 27,517 kWh $ 1,082 $ 0.039 /kWh

TOTAL ENERGY

 282 MMBtu $ 1,082 -
03 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MECHANICAL DRIVE 2.4144 N $ 24,540 $ 5,755 4.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 142,272 kWh $ 5,592 $ 0.039 /kWh

- Demand Charge

 23 kW $ 163 $ 7.09 /kW

TOTAL ENERGY

 1,458 MMBtu $ 5,755 -
04 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 11,586 $ 5,525 2.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 136,626 kWh $ 5,369 $ 0.039 /kWh

- Demand Charge

 22 kW $ 156 $ 7.09 /kW

TOTAL ENERGY

 1,400 MMBtu $ 5,525 -
05 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 25 $ 203 0.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,992 kWh $ 196 $ 0.039 /kWh

- Demand Charge

 1 kW $ 7 $ 7.09 /kW

TOTAL ENERGY

 51 MMBtu $ 203 -
06 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 1,500 $ 2,037 0.74
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 347 MMBtu $ 2,037 $ 5.89 /MMBtu

TOTAL ENERGY

 347 MMBtu $ 2,037 -
07 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 530 $ 570 0.93
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 10,792 kWh $ 424 $ 0.039 /kWh

- Demand Charge

 21 kW $ 146 $ 7.09 /kW

TOTAL ENERGY

 111 MMBtu $ 570 -
08 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 81 $ 678 0.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,487 kWh $ 332 $ 0.039 /kWh

- Demand Charge

 49 kW $ 346 $ 7.09 /kW

TOTAL ENERGY

 87 MMBtu $ 678 -
09 view
details		 IMPROVE AIR CIRCULATION WITH DESTRATIFICATION FANS / OTHER METHODS 2.7243 I $ 3,400 $ 1,215 2.80
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 207 MMBtu $ 1,215 $ 5.89 /MMBtu

TOTAL ENERGY

 207 MMBtu $ 1,215 -