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

Industrial Assessment Centers

Assessment #MA0547


Assessment Year 2004
SIC 2241
SIC Description Narrow Fabric Mills
NAICS 313221
NAICS Description Narrow Fabric Mills
Principal Product Natural fiber fabric
Sales $ 32,000,000
# of Employees 195
Plant Area (Sq.Ft.) 542,304
Annual Production 5,500 Thousand Feet
Production Hrs. Annual 6,000
Location (State) CT
Yearly Energy Cost $ 1,116,771

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 8,060,028 kWh $ 450,221 $ 0.056 /kWh

- Demand Charge

 23,874 kW $ 213,188 $ 8.93 /kW

- Electricity Fees

 - $ -6,785 -

LPG

 8,475 MMBtu $ 98,707 $ 11.65 /MMBtu

Fuel Oil #2

 36,265 MMBtu $ 261,229 $ 7.20 /MMBtu

Fuel Oil #6

 17,270 MMBtu $ 100,211 $ 5.80 /MMBtu

TOTAL ENERGY

 144,625 MMBtu $ 1,116,771 $ 7.72 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 1,079,600 kWh
0 kWh		 $ 59,780
$ 0		 13.28 %
0.00 %		 $ 0.056 /kWh

- Demand Charge

 2,490 kW
0 kW		 $ 20,592
$ 0		 9.66 %
0.00 %		 $ 8.93 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

LPG

 -78 MMBtu
0 MMBtu		 $ -1,009
$ 0		 -1.02 %
0.00 %		 $ 11.65 /MMBtu

Fuel Oil #2

 8,134 MMBtu
0 MMBtu		 $ 63,910
$ 0		 24.47 %
0.00 %		 $ 7.20 /MMBtu

Fuel Oil #6

 8,073 MMBtu
0 MMBtu		 $ 54,186
$ 0		 54.07 %
0.00 %		 $ 5.80 /MMBtu

TOTAL ENERGY

 27,196 MMBtu
0 MMBtu		 $ 197,459
$ 0		 17.68 %
0.00 %		 $ 7.72 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 CLEAR AND RENT EXISTING SPACE 4.5210 N $ 398,000 $ 200,000 1.99
Energy Sources Yearly Reduction Yearly Savings Unit Price

By-product Production

 - $ 200,000 -

TOTAL PRODUCTON

 - $ 200,000 -
02 view
details		 USE EXISTING DAM TO GENERATE ELECTRICITY 2.3322 N $ 210,000 $ 50,195 4.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 774,300 kWh $ 42,332 $ 0.056 /kWh

- Demand Charge

 2,160 kW $ 17,863 $ 8.93 /kW

TOTAL ENERGY

 7,937 MMBtu $ 60,195 -

By-product Production

 - $ -10,000 -

TOTAL PRODUCTON

 - $ -10,000 -
03 view
details		 INSULATE STEAM / HOT WATER LINES 2.2131 N $ 24,670 $ 43,010 0.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Fuel Oil #2

 4,033 MMBtu $ 31,659 $ 7.20 /MMBtu

Fuel Oil #6

 1,867 MMBtu $ 11,351 $ 5.80 /MMBtu

TOTAL ENERGY

 5,900 MMBtu $ 43,010 -
04 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 78,000 $ 34,463 2.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 47,600 kWh $ 2,561 $ 0.056 /kWh

Fuel Oil #2

 4,064 MMBtu $ 31,902 $ 7.20 /MMBtu

TOTAL ENERGY

 4,552 MMBtu $ 34,463 -
05 view
details		 USE HOT PROCESS FLUIDS TO PREHEAT INCOMING PROCESS FLUIDS 2.2444 N $ 44,000 $ 14,711 2.99
Energy Sources Yearly Reduction Yearly Savings Unit Price

Fuel Oil #6

 1,874 MMBtu $ 14,711 $ 5.80 /MMBtu

TOTAL ENERGY

 1,874 MMBtu $ 14,711 -
06 view
details		 INSTALL TIMERS AND/OR THERMOSTATS 2.7261 N $ 4,020 $ 14,705 0.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Fuel Oil #6

 2,125 MMBtu $ 14,705 $ 5.80 /MMBtu

TOTAL ENERGY

 2,125 MMBtu $ 14,705 -
07 view
details		 USE MINIMUM STEAM OPERATING PRESSURE 2.2163 N $ 0 $ 13,419 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Fuel Oil #6

 2,207 MMBtu $ 13,419 $ 5.80 /MMBtu

TOTAL ENERGY

 2,207 MMBtu $ 13,419 -
08 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 6,600 $ 7,117 0.93
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 125,400 kWh $ 7,117 $ 0.056 /kWh

TOTAL ENERGY

 1,285 MMBtu $ 7,117 -
09 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 10,950 $ 3,321 3.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 54,800 kWh $ 3,321 $ 0.056 /kWh

TOTAL ENERGY

 562 MMBtu $ 3,321 -
10 view
details		 REPLACE ELECTRICALLY-OPERATED EQUIPMENT WITH FOSSIL FUEL EQUIPMENT 2.1311 N $ 7,475 $ 2,829 2.64
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 18,300 kWh $ 1,109 $ 0.056 /kWh

- Demand Charge

 330 kW $ 2,729 $ 8.93 /kW

LPG

 -78 MMBtu $ -1,009 $ 11.65 /MMBtu

TOTAL ENERGY

 110 MMBtu $ 2,829 -
11 view
details		 ADD AREA LIGHTING SWITCHES 2.7131 N $ 2,400 $ 1,964 1.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 36,500 kWh $ 1,964 $ 0.056 /kWh

TOTAL ENERGY

 374 MMBtu $ 1,964 -
12 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 825 $ 1,376 0.60
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 22,700 kWh $ 1,376 $ 0.056 /kWh

TOTAL ENERGY

 233 MMBtu $ 1,376 -
13 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 1,400 $ 349 4.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Fuel Oil #2

 37 MMBtu $ 349 $ 7.20 /MMBtu

TOTAL ENERGY

 37 MMBtu $ 349 -