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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #LM0067


Assessment Year 2004
SIC 3462
SIC Description Iron And Steel Forgings
NAICS 332111
NAICS Description Iron and Steel Forging
Principal Product Open/Closed Die and Upset Forging
Sales $ 13,000,000
# of Employees 32
Plant Area (Sq.Ft.) 165,000
Annual Production 70,293 Pieces
Production Hrs. Annual 2,635
Location (State) CA
Yearly Energy Cost $ 397,238

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 840,939 kWh $ 100,178 $ 0.119 /kWh

- Demand Charge

 3,396 kW $ 27,785 $ 8.18 /kW

- Electricity Fees

 - $ 6,559 -

Natural Gas

 41,152 MMBtu $ 262,716 $ 6.38 /MMBtu

TOTAL ENERGY

 49,772 MMBtu $ 397,238 $ 7.98 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 3,016 kWh
21,928 kWh		 $ 652
$ 2,855		 0.65 %
2.85 %		 $ 0.119 /kWh

- Demand Charge

 66 kW
66 kW		 $ 537
$ 537		 1.93 %
1.93 %		 $ 8.18 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 18 MMBtu
18 MMBtu		 $ 114
$ 114		 0.04 %
0.04 %		 $ 6.38 /MMBtu

TOTAL ENERGY

 49 MMBtu
243 MMBtu		 $ 1,303
$ 3,506		 0.33 %
0.88 %		 $ 7.98 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 165 $ 418 0.39
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,367 kWh $ 418 $ 0.119 /kWh

TOTAL ENERGY

 35 MMBtu $ 418 -
02 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 0 $ 1,055 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,492 kWh $ 806 $ 0.119 /kWh

- Demand Charge

 30 kW $ 249 $ 8.18 /kW

TOTAL ENERGY

 67 MMBtu $ 1,055 -
03 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 2,176 $ 1,647 1.32
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 10,382 kWh $ 1,422 $ 0.119 /kWh

- Demand Charge

 28 kW $ 225 $ 8.18 /kW

TOTAL ENERGY

 106 MMBtu $ 1,647 -
04 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 247 $ 272 0.91
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,687 kWh $ 209 $ 0.119 /kWh

- Demand Charge

 8 kW $ 63 $ 8.18 /kW

TOTAL ENERGY

 17 MMBtu $ 272 -
05 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 50 $ 114 0.44
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 18 MMBtu $ 114 $ 6.38 /MMBtu

TOTAL ENERGY

 18 MMBtu $ 114 -
06 view
details		 USE EVAPORATION TO CONCENTRATE MATERIAL 3.3131 N $ 5,500 $ 2,465 2.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -18,912 kWh $ -2,203 $ 0.119 /kWh

TOTAL ENERGY

 -194 MMBtu $ -2,203 -

Other Liquid (haz)

 0 Gal $ 4,668 $ 0 /Gal

TOTAL WASTE

 - $ 4,668 -
07 view
details		 MODIFY WORKLOAD 4.4260 I $ 570 $ 45,760 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 45,760 -

TOTAL PRODUCTON

 - $ 45,760 -
08 view
details		 MODIFY WORKLOAD 4.4260 I $ 5,500 $ 10,652 0.52
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 10,652 -

TOTAL PRODUCTON

 - $ 10,652 -
09 view
details		 MODIFY WORKLOAD 4.4260 I $ 9,400 $ 81,000 0.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 81,000 -

TOTAL PRODUCTON

 - $ 81,000 -
10 view
details		 MODIFY WORKLOAD 4.4260 N $ 500 $ 55,000 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 55,000 -

TOTAL PRODUCTON

 - $ 55,000 -