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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #LE0207


Assessment Year 2005
SIC 3317
SIC Description Steel Pipe And Tubes
NAICS 331210
NAICS Description Iron and Steel Pipe and Tube Manufacturing from Purchased Steel
Principal Product Wlelded Steel Tubing
Sales $ 35,600,000
# of Employees 290
Plant Area (Sq.Ft.) 249,953
Annual Production 151,803 Thousand Feet
Production Hrs. Annual 6,120
Location (State) PA
Yearly Energy Cost $ 1,292,476

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 8,712,000 kWh $ 469,024 $ 0.054 /kWh

- Demand Charge

 23,952 kW $ 148,797 $ 6.21 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 91,796 MMBtu $ 674,655 $ 7.35 /MMBtu

TOTAL ENERGY

 181,094 MMBtu $ 1,292,476 $ 7.14 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 519,733 kWh
432,706 kWh		 $ 28,834
$ 23,534		 6.15 %
5.02 %		 $ 0.054 /kWh

- Demand Charge

 719 kW
719 kW		 $ 4,462
$ 4,462		 3.00 %
3.00 %		 $ 6.21 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 14,316 MMBtu
14,316 MMBtu		 $ 183,019
$ 110,077		 27.13 %
16.32 %		 $ 7.35 /MMBtu

TOTAL ENERGY

 19,643 MMBtu
18,751 MMBtu		 $ 216,315
$ 138,073		 16.74 %
10.68 %		 $ 7.14 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REPLACE BOILER 2.1224 I $ 9,760 $ 109,438 0.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 14,229 MMBtu $ 109,438 $ 7.35 /MMBtu

TOTAL ENERGY

 14,229 MMBtu $ 109,438 -
02 view
details		 PURCHASE GAS DIRECTLY FROM A CONTRACT GAS SUPPLIER 2.8113 N $ 500 $ 72,942 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 0 MMBtu $ 72,942 $ 7.35 /MMBtu

TOTAL ENERGY

 0 MMBtu $ 72,942 -
03 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 I $ 8,300 $ 21,328 0.39
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 352,686 kWh $ 19,045 $ 0.054 /kWh

- Demand Charge

 368 kW $ 2,283 $ 6.21 /kW

TOTAL ENERGY

 3,615 MMBtu $ 21,328 -
04 view
details		 INSTALL TIMERS AND/OR THERMOSTATS 2.7261 N $ 4,500 $ 5,300 0.85
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 87,027 kWh $ 5,300 $ 0.054 /kWh

TOTAL ENERGY

 892 MMBtu $ 5,300 -
05 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,000 $ 5,115 0.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 60,562 kWh $ 3,271 $ 0.054 /kWh

- Demand Charge

 297 kW $ 1,844 $ 6.21 /kW

TOTAL ENERGY

 621 MMBtu $ 5,115 -
06 view
details		 INSTALL TIMERS AND/OR THERMOSTATS 2.7261 I $ 500 $ 1,341 0.37
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 9,900 kWh $ 702 $ 0.054 /kWh

Natural Gas

 87 MMBtu $ 639 $ 7.35 /MMBtu

TOTAL ENERGY

 188 MMBtu $ 1,341 -
07 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 500 $ 851 0.59
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 9,558 kWh $ 516 $ 0.054 /kWh

- Demand Charge

 54 kW $ 335 $ 6.21 /kW

TOTAL ENERGY

 98 MMBtu $ 851 -