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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #IC0149


Assessment Year 2008
SIC 3613
SIC Description Switchgear And Switchboard Apparatus
NAICS 335313
NAICS Description Switchgear and Switchboard Apparatus Manufacturing
Principal Product Protective Relay Panels
Sales $ 70,000,000
# of Employees 200
Plant Area (Sq.Ft.) 100,000
Annual Production 3,540 Pieces
Production Hrs. Annual 7,344
Location (State) MI
Yearly Energy Cost $ 259,719

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 1,711,800 kWh $ 69,989 $ 0.041 /kWh

- Demand Charge

 3,738 kW $ 13,377 $ 3.58 /kW

- Electricity Fees

 - $ 42,849 -

Natural Gas

 15,264 MMBtu $ 133,504 $ 8.75 /MMBtu

TOTAL ENERGY

 32,810 MMBtu $ 259,719 $ 7.92 /MMBtu

Water Disposal

 505,648 Gal $ 3,053 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 427,008 kWh
288,690 kWh		 $ 18,366
$ 12,419		 26.24 %
17.74 %		 $ 0.041 /kWh

- Demand Charge

 1,569 kW
1,354 kW		 $ 20,761
$ 17,914		 155.20 %
133.92 %		 $ 3.58 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 4,818 MMBtu
4,818 MMBtu		 $ 42,158
$ 42,158		 31.58 %
31.58 %		 $ 8.75 /MMBtu

TOTAL ENERGY

 9,196 MMBtu
7,778 MMBtu		 $ 81,285
$ 72,491		 31.30 %
27.91 %		 $ 7.92 /MMBtu

Water Disposal

 0 Gal
0 Gal		 $ 0
$ 0		 0.00 %
0.00 %		 $ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 9,635 $ 4,460 2.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 70,770 kWh $ 3,045 $ 0.041 /kWh

- Demand Charge

 160 kW $ 2,114 $ 3.58 /kW

TOTAL ENERGY

 725 MMBtu $ 5,159 -

Administrative Changes

 - $ 417 -

Ancillary Material Cost

 - $ -1,116 -

TOTAL PRODUCTON

 - $ -699 -
02 view
details		 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 2.7111 N $ 18,015 $ 6,168 2.92
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 95,397 kWh $ 4,102 $ 0.041 /kWh

- Demand Charge

 156 kW $ 2,066 $ 3.58 /kW

TOTAL ENERGY

 978 MMBtu $ 6,168 -
03 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 7,381 $ 1,470 5.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 16,783 kWh $ 723 $ 0.041 /kWh

- Demand Charge

 57 kW $ 747 $ 3.58 /kW

TOTAL ENERGY

 172 MMBtu $ 1,470 -
04 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 I $ 2,040 $ 3,526 0.58
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 403 MMBtu $ 3,526 $ 8.75 /MMBtu

TOTAL ENERGY

 403 MMBtu $ 3,526 -
05 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 0 $ 141 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,280 kWh $ 141 $ 0.041 /kWh

TOTAL ENERGY

 34 MMBtu $ 141 -
06 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,610 $ 2,594 0.62
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 60,265 kWh $ 2,594 $ 0.041 /kWh

TOTAL ENERGY

 618 MMBtu $ 2,594 -
07 view
details		 UPGRADE OBSOLETE EQUIPMENT 2.4321 I $ 210 $ 19,706 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 130,392 kWh $ 5,606 $ 0.041 /kWh

- Demand Charge

 1,065 kW $ 14,100 $ 3.58 /kW

TOTAL ENERGY

 1,337 MMBtu $ 19,706 -
08 view
details		 INSTALL VINYL STRIP / HIGH SPEED / AIR CURTAIN DOORS 2.7447 I $ 29,280 $ 37,783 0.77
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 4,318 MMBtu $ 37,783 $ 8.75 /MMBtu

TOTAL ENERGY

 4,318 MMBtu $ 37,783 -
09 view
details		 ENHANCE SENSITIVITY OF TEMPERATURE CONTROL AND CUTOFF 2.2223 I $ 0 $ 849 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 97 MMBtu $ 849 $ 8.75 /MMBtu

TOTAL ENERGY

 97 MMBtu $ 849 -
10 view
details		 CONSERVE ENERGY BY EFFICIENT USE OF VENDING MACHINES 2.6211 I $ 0 $ 1,263 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,200 kWh $ 310 $ 0.041 /kWh

- Demand Charge

 72 kW $ 953 $ 3.58 /kW

TOTAL ENERGY

 74 MMBtu $ 1,263 -
11 view
details		 TURN OFF EQUIPMENT DURING BREAKS, REDUCE OPERATING TIME 2.6212 N $ 0 $ 2,626 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 42,921 kWh $ 1,845 $ 0.041 /kWh

- Demand Charge

 59 kW $ 781 $ 3.58 /kW

TOTAL ENERGY

 440 MMBtu $ 2,626 -