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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #LL0230


Assessment Year 2005
SIC 3479
SIC Description Metal Coating And Allied Services
NAICS 332812
NAICS Description Metal Coating, Engraving (except Jewelry and Silverware), and Allied Services to Manufacturers
Principal Product Pipe coating
Sales $ 8,000,000
# of Employees 35
Plant Area (Sq.Ft.) 50,000
Annual Production 70,000 Pieces
Production Hrs. Annual 4,992
Location (State) LA
Yearly Energy Cost $ 518,549

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 1,309,680 kWh $ 101,948 $ 0.078 /kWh

- Demand Charge

 3,307 kW $ 1,818 $ 0.55 /kW

- Electricity Fees

 - $ 14,474 -

Natural Gas

 52,098 MMBtu $ 400,309 $ 7.68 /MMBtu

TOTAL ENERGY

 65,522 MMBtu $ 518,549 $ 7.91 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 872,690 kWh
0 kWh		 $ 62,913
$ 0		 61.71 %
0.00 %		 $ 0.078 /kWh

- Demand Charge

 0 kW
0 kW		 $ 0
$ 0		 0.00 %
0.00 %		 $ 0.55 /kW

- Electricity Fees

 - $ 25,293
$ 22,903		 174.75 %
158.24 %		 -

Natural Gas

 332 MMBtu
0 MMBtu		 $ 2,419
$ 0		 0.60 %
0.00 %		 $ 7.68 /MMBtu

TOTAL ENERGY

 9,277 MMBtu
0 MMBtu		 $ 90,625
$ 22,903		 17.48 %
4.42 %		 $ 7.91 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 0 $ 25,864 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 345,637 kWh $ 24,917 $ 0.078 /kWh

- Electricity Fees

 - $ 947 -

TOTAL ENERGY

 3,543 MMBtu $ 25,864 -
02 view
details		 PAY UTILITY BILLS ON TIME 2.8123 I $ 0 $ 22,903 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 22,903 -

TOTAL ENERGY

 0 MMBtu $ 22,903 -
03 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 0 $ 19,048 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 254,556 kWh $ 18,351 $ 0.078 /kWh

- Electricity Fees

 - $ 697 -

TOTAL ENERGY

 2,609 MMBtu $ 19,048 -
04 view
details		 USE PHOTOCELL CONTROLS 2.7134 N $ 0 $ 11,584 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 154,804 kWh $ 11,160 $ 0.078 /kWh

- Electricity Fees

 - $ 424 -

TOTAL ENERGY

 1,587 MMBtu $ 11,584 -
05 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 0 $ 8,309 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 111,035 kWh $ 8,005 $ 0.078 /kWh

- Electricity Fees

 - $ 304 -

TOTAL ENERGY

 1,138 MMBtu $ 8,309 -
06 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 0 $ 2,419 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 332 MMBtu $ 2,419 $ 7.68 /MMBtu

TOTAL ENERGY

 332 MMBtu $ 2,419 -
07 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 0 $ 1,105 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,658 kWh $ 480 $ 0.078 /kWh

- Electricity Fees

 - $ 18 -

TOTAL ENERGY

 68 MMBtu $ 498 -

Personnel Changes

 - $ 607 -

TOTAL PRODUCTON

 - $ 607 -
08 view
details		 INCREASE AMOUNT OF WASTE RECOVERED FOR RESALE 3.5313 N $ 0 $ 9,000 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 9 lbs $ 9,000 $ 0 /lbs

TOTAL WASTE

 - $ 9,000 -
09 view
details		 BEGIN A PRACTICE OF PREDICTIVE / PREVENTATIVE MAINTENANCE 4.6110 N $ 0 $ 15,300 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 12,800 -

One-time Revenue or Avoided Cost

 - $ 2,500 -

TOTAL PRODUCTON

 - $ 15,300 -