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

Industrial Assessment Centers

Assessment #NC0460


Assessment Year 2012
SIC 2273
SIC Description Carpets And Rugs
NAICS 314110
NAICS Description Carpet and Rug Mills
Principal Product Carpeting
Sales $ 110,000,000
# of Employees 375
Plant Area (Sq.Ft.) 530,000
Annual Production 60,000 Thousand Feet
Production Hrs. Annual 6,240
Location (State) NC
Yearly Energy Cost $ 3,721,531

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 19,370,580 kWh $ 1,198,695 $ 0.062 /kWh

- Demand Charge

 38,423 kW $ 220,784 $ 5.75 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 72,955 MMBtu $ 423,234 $ 5.80 /MMBtu

Coal

 397,623 MMBtu $ 1,878,818 $ 4.73 /MMBtu

TOTAL ENERGY

 669,128 MMBtu $ 3,721,531 $ 5.56 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 4,596,674 kWh
163,374 kWh		 $ 284,498
$ 10,110		 23.73 %
0.84 %		 $ 0.062 /kWh

- Demand Charge

 6,926 kW
221 kW		 $ 39,836
$ 1,286		 18.04 %
0.58 %		 $ 5.75 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 5.80 /MMBtu

Coal

 3,608 MMBtu
646 MMBtu		 $ 17,056
$ 3,052		 0.91 %
0.16 %		 $ 4.73 /MMBtu

TOTAL ENERGY

 50,724 MMBtu
2,321 MMBtu		 $ 341,390
$ 14,448		 9.17 %
0.39 %		 $ 5.56 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 BURN FOSSIL FUEL TO PRODUCE STEAM TO DRIVE A STEAM TURBINE-GENERATOR AND USE STEAM EXHAUST FOR HEAT 2.3413 N $ 260,000 $ 146,006 1.78
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,364,960 kWh $ 146,391 $ 0.062 /kWh

- Demand Charge

 4,548 kW $ 26,151 $ 5.75 /kW

Coal

 -5,618 MMBtu $ -26,536 $ 4.73 /MMBtu

TOTAL ENERGY

 18,623 MMBtu $ 146,006 -
02 view
details		 REPAIR OR REPLACE STEAM TRAPS 2.2113 N $ 9,100 $ 29,233 0.31
Energy Sources Yearly Reduction Yearly Savings Unit Price

Coal

 8,390 MMBtu $ 39,643 $ 4.73 /MMBtu

TOTAL ENERGY

 8,390 MMBtu $ 39,643 -

Personnel Changes

 - $ -1,660 -

Ancillary Material Cost

 - $ -8,750 -

TOTAL PRODUCTON

 - $ -10,410 -
03 view
details		 REPAIR LEAKS IN LINES AND VALVES 2.2133 I $ 2,100 $ 3,142 0.67
Energy Sources Yearly Reduction Yearly Savings Unit Price

Coal

 646 MMBtu $ 3,052 $ 4.73 /MMBtu

TOTAL ENERGY

 646 MMBtu $ 3,052 -

Water Disposal

 54,619 Gal $ 90 $ 0 /Gal

TOTAL WASTE

 - $ 90 -
04 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 98,248 $ 43,177 2.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 584,776 kWh $ 36,187 $ 0.062 /kWh

- Demand Charge

 1,125 kW $ 6,466 $ 5.75 /kW

TOTAL ENERGY

 5,994 MMBtu $ 42,653 -

Ancillary Material Cost

 - $ 524 -

TOTAL PRODUCTON

 - $ 524 -
05 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 80,231 $ 24,871 3.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 340,646 kWh $ 21,080 $ 0.062 /kWh

- Demand Charge

 660 kW $ 3,791 $ 5.75 /kW

TOTAL ENERGY

 3,492 MMBtu $ 24,871 -
06 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 6,902 $ 5,787 1.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 69,264 kWh $ 4,286 $ 0.062 /kWh

- Demand Charge

 133 kW $ 766 $ 5.75 /kW

TOTAL ENERGY

 710 MMBtu $ 5,052 -

Ancillary Material Cost

 - $ 735 -

TOTAL PRODUCTON

 - $ 735 -
07 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 4,405 $ 42,119 0.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 680,639 kWh $ 42,119 $ 0.062 /kWh

TOTAL ENERGY

 6,977 MMBtu $ 42,119 -
08 view
details		 USE / PURCHASE OPTIMUM SIZED COMPRESSOR 2.4226 N $ 0 $ 16,624 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 268,560 kWh $ 16,624 $ 0.062 /kWh

TOTAL ENERGY

 2,753 MMBtu $ 16,624 -
09 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 500 $ 8,756 0.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 163,374 kWh $ 10,110 $ 0.062 /kWh

- Demand Charge

 221 kW $ 1,286 $ 5.75 /kW

TOTAL ENERGY

 1,675 MMBtu $ 11,396 -

Personnel Changes

 - $ -2,400 -

Ancillary Material Cost

 - $ -240 -

TOTAL PRODUCTON

 - $ -2,640 -
10 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 3,200 $ 2,532 1.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 34,719 kWh $ 2,148 $ 0.062 /kWh

- Demand Charge

 67 kW $ 384 $ 5.75 /kW

TOTAL ENERGY

 356 MMBtu $ 2,532 -
11 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 N $ 7,515 $ 6,426 1.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 88,106 kWh $ 5,452 $ 0.062 /kWh

- Demand Charge

 169 kW $ 974 $ 5.75 /kW

TOTAL ENERGY

 903 MMBtu $ 6,426 -
12 view
details		 INSULATE STEAM / HOT WATER LINES 2.2131 N $ 1,290 $ 897 1.44
Energy Sources Yearly Reduction Yearly Savings Unit Price

Coal

 190 MMBtu $ 897 $ 4.73 /MMBtu

TOTAL ENERGY

 190 MMBtu $ 897 -
13 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 N $ 11 $ 119 0.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,630 kWh $ 101 $ 0.062 /kWh

- Demand Charge

 3 kW $ 18 $ 5.75 /kW

TOTAL ENERGY

 17 MMBtu $ 119 -