Industrial Assessment Centers

Assessment #SD0270

Assessment Year	2001
SIC	3053
SIC Description	Gaskets, Packing And Sealing Devices
NAICS
NAICS Description
Principal Product	rubber o-rings
Sales	$ 35,000,000
# of Employees	650
Plant Area (Sq.Ft.)	200,000
Annual Production	1,500,000 Pounds
Production Hrs. Annual	7,200
Location (State)	CA
Yearly Energy Cost	$ 1,127,534

Current Energy Usage & Costs

Energy Sources	Yearly Usage	Yearly Cost	Unit Price
Electricity	15,392,861 kWh	$ 783,886	$ 0.051 /kWh
- Demand Charge	32,021 kW	$ 326,400	$ 10.19 /kW
- Electricity Fees	-	$ 4,308	-
Natural Gas	4,702 MMBtu	$ 12,940	$ 2.75 /MMBtu
TOTAL ENERGY	162,479 MMBtu	$ 1,127,534	$ 6.94 /MMBtu

Recommended Reduction in Usage & Costs

Recommended Implemented

Energy Sources	Yearly Savings	Yearly Cost	% Saved	Unit Price
Electricity	19,730,027 kWh 3,331,307 kWh	$ 1,006,131 $ 169,896	128.35 % 21.67 %	$ 0.051 /kWh
- Demand Charge	35,016 kW 6,648 kW	$ 355,902 $ 66,833	109.04 % 20.48 %	$ 10.19 /kW
- Electricity Fees	-	$ 0 $ 0	0.00 % 0.00 %	-
Natural Gas	-312,031 MMBtu 0 MMBtu	$ -749,639 $ 0	-5,793.19 % 0.00 %	$ 2.75 /MMBtu
TOTAL ENERGY	-109,800 MMBtu 34,145 MMBtu	$ 612,394 $ 236,729	54.31 % 21.00 %	$ 6.94 /MMBtu

Recommendations

AR #

Description

ARC Code

Status

Cost

Savings

Payback
(Years)

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details

REDESIGN PROCESS

2.5194

$ 35,000

$ 182,520

0.19

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	1,311,250 kWh	$ 66,874	$ 0.051 /kWh
- Demand Charge	2,870 kW	$ 29,246	$ 10.19 /kW
TOTAL ENERGY	13,440 MMBtu	$ 96,120	-
Personnel Changes	-	$ 129,600	-
Administrative Changes	-	$ -43,200	-
TOTAL PRODUCTON	-	$ 86,400	-

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details

USE COOLING TOWER OR ECONOMIZER TO REPLACE CHILLER COOLING

2.2614

$ 15,000

$ 21,642

0.69

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	364,007 kWh	$ 18,564	$ 0.051 /kWh
- Demand Charge	685 kW	$ 6,078	$ 10.19 /kW
TOTAL ENERGY	3,731 MMBtu	$ 24,642	-
Administrative Changes	-	$ -3,000	-
TOTAL PRODUCTON	-	$ -3,000	-

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details

ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES

2.4236

$ 800

$ 23,189

0.03

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	429,376 kWh	$ 21,898	$ 0.051 /kWh
- Demand Charge	716 kW	$ 7,291	$ 10.19 /kW
TOTAL ENERGY	4,401 MMBtu	$ 29,189	-
Personnel Changes	-	$ -6,000	-
TOTAL PRODUCTON	-	$ -6,000	-

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details

REPLACE ELECTRICALLY-OPERATED EQUIPMENT WITH FOSSIL FUEL EQUIPMENT

2.1311

$ 90,000

$ 63,100

1.43

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	933,120 kWh	$ 47,489	$ 0.051 /kWh
- Demand Charge	2,592 kW	$ 26,412	$ 10.19 /kW
Natural Gas	-39,799 MMBtu	$ -10,801	$ 2.75 /MMBtu
TOTAL ENERGY	-30,235 MMBtu	$ 63,100	-

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details

USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MOTOR-GENERATOR SET

2.4142

$ 36,000

$ 27,077

1.33

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	398,260 kWh	$ 20,311	$ 0.051 /kWh
- Demand Charge	664 kW	$ 6,766	$ 10.19 /kW
TOTAL ENERGY	4,082 MMBtu	$ 27,077	-

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details

USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MOTOR-GENERATOR SET

2.4142

$ 103,000

$ 51,823

1.99

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	762,174 kWh	$ 38,871	$ 0.051 /kWh
- Demand Charge	1,271 kW	$ 12,952	$ 10.19 /kW
TOTAL ENERGY	7,812 MMBtu	$ 51,823	-

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details

INSTALL SKYLIGHTS

2.7145

$ 12,500

$ 7,878

1.59

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	66,240 kWh	$ 3,378	$ 0.051 /kWh
- Demand Charge	442 kW	$ 4,500	$ 10.19 /kW
TOTAL ENERGY	679 MMBtu	$ 7,878	-

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details

USE COMBINED CYCLE GAS TURBINE GENERATOR SETS WITH WASTE HEAT BOILERS CONNECTED TO TURBINE EXHAUST

2.3416

$ 3,037,200

$ 983,363

3.09

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	15,465,600 kWh	$ 788,746	$ 0.051 /kWh
- Demand Charge	25,776 kW	$ 262,657	$ 10.19 /kW
Natural Gas	-272,232 MMBtu	$ -738,838	$ 2.75 /MMBtu
TOTAL ENERGY	-113,710 MMBtu	$ 312,565	-
One-time Revenue or Avoided Cost	-	$ 670,798	-
TOTAL PRODUCTON	-	$ 670,798	-

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details

SALVAGE AND RE-USE PROCESS WASTE

3.5312

$ 5,000

$ 32,522

0.15

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Solid Waste (non-haz)	63,000 lbs	$ 10,764	$ 0 /lbs
TOTAL WASTE	-	$ 10,764	-
Personnel Changes	-	$ -28,800	-
Administrative Changes	-	$ 51,558	-
Water Consumption	-	$ -1,000	-
TOTAL PRODUCTON	-	$ 21,758	-

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details

MINIMIZE CONTAMINATION OF WATER BEFORE TREATMENT

3.4131

$ 1,500

$ 3,170

0.47

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Other Liquid (haz)	3,162 Gal	$ 3,170	$ 0 /Gal
TOTAL WASTE	-	$ 3,170	-

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details

USE LESS TOXIC AND VOLATILE SOLVENT SUBSTITUTES

3.8132

$ 0

$ 648

0.00

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Other Liquid (haz)	792 Gal	$ 648	$ 0 /Gal
TOTAL WASTE	-	$ 648	-

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details

INSTALL EQUIPMENT (eg COMPACTOR) TO REDUCE DISPOSAL COSTS

3.6193

$ 15,000

$ 25,910

0.58

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Administrative Changes	-	$ -500	-
One-time Revenue or Avoided Cost	-	$ 26,410	-
TOTAL PRODUCTON	-	$ 25,910	-

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details

REUSE / RECYCLE/ SELL RUBBER PRODUCTS

3.5218

$ 0

$ 35,880

0.00

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
One-time Revenue or Avoided Cost	-	$ 35,880	-
TOTAL PRODUCTON	-	$ 35,880	-

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details

PAY BILLS ON TIME TO AVOID LATE FEES

4.8210

$ 0

$ 1,393

0.00

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
One-time Revenue or Avoided Cost	-	$ 1,393	-
TOTAL PRODUCTON	-	$ 1,393	-

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details

IMPROVE SPACE COMFORT CONDITIONING

4.4240

$ 30,000

$ 65,375

0.46

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Administrative Changes	-	$ 65,375	-
TOTAL PRODUCTON	-	$ 65,375	-

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details

CONSIDER USE / PURCHASE OF BULK MATERIALS WHERE POSSIBLE

4.2110

$ 30,000

$ 21,296

1.41

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Personnel Changes	-	$ 8,352	-
Administrative Changes	-	$ 12,944	-
TOTAL PRODUCTON	-	$ 21,296	-