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

Industrial Assessment Centers

Assessment #NC0091


Assessment Year 1996
SIC 3690
SIC Description
NAICS
NAICS Description
Principal Product Electric soldering tools
Sales $ 40,000,000
# of Employees 350
Plant Area (Sq.Ft.) 169,000
Annual Production 2,300,000 Pieces
Production Hrs. Annual 6,000
Location (State) SC
Yearly Energy Cost $ 425,978

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 6,913,834 kWh $ 250,725 $ 0.036 /kWh

- Demand Charge

 14,441 kW $ 155,963 $ 10.80 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 3,502 MMBtu $ 15,120 $ 4.32 /MMBtu

Fuel Oil #2

 687 MMBtu $ 4,170 $ 6.07 /MMBtu

TOTAL ENERGY

 75,056 MMBtu $ 425,978 $ 5.68 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 2,293,083 kWh
153,575 kWh		 $ 83,165
$ 5,569		 33.17 %
2.22 %		 $ 0.036 /kWh

- Demand Charge

 3,931 kW
103 kW		 $ 42,449
$ 1,110		 27.22 %
0.71 %		 $ 10.80 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 -4,492 MMBtu
-22 MMBtu		 $ -19,405
$ -96		 -128.34 %
-0.63 %		 $ 4.32 /MMBtu

Fuel Oil #2

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 6.07 /MMBtu

TOTAL ENERGY

 19,011 MMBtu
1,551 MMBtu		 $ 106,209
$ 6,583		 24.93 %
1.55 %		 $ 5.68 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REPLACE ELECTRICALLY-OPERATED EQUIPMENT WITH FOSSIL FUEL EQUIPMENT 2.1311 N $ 132,000 $ 68,531 1.93
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,752,638 kWh $ 63,563 $ 0.036 /kWh

- Demand Charge

 3,450 kW $ 37,260 $ 10.80 /kW

Natural Gas

 -7,475 MMBtu $ -32,292 $ 4.32 /MMBtu

TOTAL ENERGY

 10,490 MMBtu $ 68,531 -
02 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 1,155 $ 946 1.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 17,878 kWh $ 653 $ 0.036 /kWh

- Demand Charge

 36 kW $ 389 $ 10.80 /kW

Natural Gas

 -22 MMBtu $ -96 $ 4.32 /MMBtu

TOTAL ENERGY

 161 MMBtu $ 946 -
03 view
details		 INCREASE INSULATION THICKNESS 2.2512 N $ 195 $ 368 0.53
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,034 kWh $ 254 $ 0.036 /kWh

- Demand Charge

 14 kW $ 151 $ 10.80 /kW

Natural Gas

 -9 MMBtu $ -37 $ 4.32 /MMBtu

TOTAL ENERGY

 63 MMBtu $ 368 -
04 view
details		 INSTALL OUTSIDE AIR DAMPER / ECONOMIZER ON HVAC UNIT 2.7241 I $ 6,000 $ 3,668 1.64
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 101,114 kWh $ 3,668 $ 0.036 /kWh

TOTAL ENERGY

 1,036 MMBtu $ 3,668 -
05 view
details		 RE-USE OR RECYCLE HOT OR COLD PROCESS EXHAUST AIR 2.2443 N $ 56,200 $ 18,922 2.97
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 80,598 kWh $ 2,923 $ 0.036 /kWh

- Demand Charge

 276 kW $ 2,979 $ 10.80 /kW

Natural Gas

 3,014 MMBtu $ 13,020 $ 4.32 /MMBtu

TOTAL ENERGY

 3,840 MMBtu $ 18,922 -
06 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 28,500 $ 9,524 2.99
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 262,603 kWh $ 9,524 $ 0.036 /kWh

TOTAL ENERGY

 2,692 MMBtu $ 9,524 -
07 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 420 $ 802 0.52
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 12,016 kWh $ 434 $ 0.036 /kWh

- Demand Charge

 34 kW $ 368 $ 10.80 /kW

TOTAL ENERGY

 123 MMBtu $ 802 -
08 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 600 $ 884 0.68
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 15,240 kWh $ 554 $ 0.036 /kWh

- Demand Charge

 31 kW $ 330 $ 10.80 /kW

TOTAL ENERGY

 156 MMBtu $ 884 -
09 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 500 $ 1,412 0.35
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 23,447 kWh $ 853 $ 0.036 /kWh

- Demand Charge

 52 kW $ 559 $ 10.80 /kW

TOTAL ENERGY

 240 MMBtu $ 1,412 -
10 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 168 $ 199 0.84
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,172 kWh $ 45 $ 0.036 /kWh

- Demand Charge

 2 kW $ 22 $ 10.80 /kW

TOTAL ENERGY

 12 MMBtu $ 67 -

Ancillary Material Cost

 - $ 132 -

TOTAL PRODUCTON

 - $ 132 -
11 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 980 $ 246 3.98
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,517 kWh $ 125 $ 0.036 /kWh

- Demand Charge

 5 kW $ 51 $ 10.80 /kW

TOTAL ENERGY

 36 MMBtu $ 176 -

Ancillary Material Cost

 - $ 70 -

TOTAL PRODUCTON

 - $ 70 -
12 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 761 $ 909 0.84
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 15,826 kWh $ 569 $ 0.036 /kWh

- Demand Charge

 31 kW $ 340 $ 10.80 /kW

TOTAL ENERGY

 162 MMBtu $ 909 -
13 view
details		 LEASE / PURCHASE BALER; SELL CARDBOARD TO RECYCLER 3.5315 I $ 100 $ 56 1.79
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 3,750 lbs $ 56 $ 0 /lbs

TOTAL WASTE

 - $ 56 -