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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #NC0268


Assessment Year 2003
SIC 3444
SIC Description Sheet Metalwork
NAICS 332322
NAICS Description Sheet Metal Work Manufacturing
Principal Product Accessory products for building industry
Sales $ 68,000,000
# of Employees 290
Plant Area (Sq.Ft.) 450,000
Annual Production 17,000,000 Pounds
Production Hrs. Annual 6,000
Location (State) NC
Yearly Energy Cost $ 424,614

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 4,716,960 kWh $ 228,091 $ 0.048 /kWh

- Demand Charge

 11,383 kW $ 55,880 $ 4.91 /kW

- Electricity Fees

 - $ 9,138 -

LPG

 16,290 MMBtu $ 131,505 $ 8.07 /MMBtu

TOTAL ENERGY

 64,639 MMBtu $ 424,614 $ 6.57 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 70,800 kWh
79,200 kWh		 $ 3,115
$ 3,485		 1.37 %
1.53 %		 $ 0.048 /kWh

- Demand Charge

 108 kW
158 kW		 $ 552
$ 808		 0.99 %
1.45 %		 $ 4.91 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

LPG

 2,505 MMBtu
0 MMBtu		 $ 20,216
$ 0		 15.37 %
0.00 %		 $ 8.07 /MMBtu

TOTAL ENERGY

 3,231 MMBtu
812 MMBtu		 $ 23,883
$ 4,293		 5.62 %
1.01 %		 $ 6.57 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 AUTOMATE FINISHING PROCESS 4.4460 N $ 26,350 $ 29,974 0.88
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -8,400 kWh $ -370 $ 0.048 /kWh

- Demand Charge

 -50 kW $ -256 $ 4.91 /kW

TOTAL ENERGY

 -86 MMBtu $ -626 -

Personnel Changes

 - $ 33,600 -

Administrative Changes

 - $ -3,000 -

TOTAL PRODUCTON

 - $ 30,600 -
02 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT INCOMING FLUIDS 2.2427 N $ 8,000 $ 9,563 0.84
Energy Sources Yearly Reduction Yearly Savings Unit Price

LPG

 1,185 MMBtu $ 9,563 $ 8.07 /MMBtu

TOTAL ENERGY

 1,185 MMBtu $ 9,563 -
03 view
details		 REDUCE COMBUSTION AIR FLOW TO OPTIMUM 2.1113 N $ 2,000 $ 10,491 0.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

LPG

 1,300 MMBtu $ 10,491 $ 8.07 /MMBtu

TOTAL ENERGY

 1,300 MMBtu $ 10,491 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 500 $ 693 0.72
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 79,200 kWh $ 3,485 $ 0.048 /kWh

- Demand Charge

 158 kW $ 808 $ 4.91 /kW

TOTAL ENERGY

 812 MMBtu $ 4,293 -

Personnel Changes

 - $ -2,400 -

Administrative Changes

 - $ -1,200 -

TOTAL PRODUCTON

 - $ -3,600 -
05 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 329 $ 162 2.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

LPG

 20 MMBtu $ 162 $ 8.07 /MMBtu

TOTAL ENERGY

 20 MMBtu $ 162 -
06 view
details		 USE COUNTER CURRENT RINSING TO REDUCE WASTE WATER 3.4153 N $ 300 $ 1,012 0.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 120,000 Gal $ 1,012 $ 0 /Gal

TOTAL WASTE

 - $ 1,012 -