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

Industrial Assessment Centers

Assessment #TN0672


Assessment Year 2000
SIC 3621
SIC Description Motors And Generators
NAICS
NAICS Description
Principal Product Hermetic motors
Sales $ 80,000,000
# of Employees 400
Plant Area (Sq.Ft.) 200,000
Annual Production 5,000,000 Pieces
Production Hrs. Annual 8,400
Location (State) TN
Yearly Energy Cost $ 1,556,031

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 19,556,565 kWh $ 796,768 $ 0.041 /kWh

- Demand Charge

 36,492 kW $ 205,980 $ 5.64 /kW

- Electricity Fees

 - $ 102,299 -

LPG

 52,149 MMBtu $ 450,984 $ 8.65 /MMBtu

TOTAL ENERGY

 252,604 MMBtu $ 1,556,031 $ 6.16 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 1,392,438 kWh
0 kWh		 $ 62,797
$ 0		 7.88 %
0.00 %		 $ 0.041 /kWh

- Demand Charge

 2,006 kW
0 kW		 $ 14,199
$ 0		 6.89 %
0.00 %		 $ 5.64 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

LPG

 683 MMBtu
0 MMBtu		 $ 7,385
$ 0		 1.64 %
0.00 %		 $ 8.65 /MMBtu

TOTAL ENERGY

 14,956 MMBtu
0 MMBtu		 $ 84,381
$ 0		 5.42 %
0.00 %		 $ 6.16 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 MOVE PRODUCT USING MECHANICAL MEANS 4.4230 N $ 167,200 $ 65,150 2.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 58,750 -

Increase in Production

 - $ 6,400 -

TOTAL PRODUCTON

 - $ 65,150 -
02 view
details		 MINIMIZE USE OF RAGS THROUGH WORKER TRAINING 3.7135 N $ 0 $ 30,000 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 1,500 lbs $ 30,000 $ 0 /lbs

TOTAL WASTE

 - $ 30,000 -
03 view
details		 USE DEMAND CONTROLLER OR LOAD SHEDDER 2.3191 N $ 27,000 $ 18,266 1.48
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 195,487 kWh $ 7,967 $ 0.041 /kWh

- Demand Charge

 1,646 kW $ 10,299 $ 5.64 /kW

TOTAL ENERGY

 2,004 MMBtu $ 18,266 -
04 view
details		 UTILIZE A LESS EXPENSIVE COOLING METHOD 2.2628 N $ 17,800 $ 14,770 1.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 293,083 kWh $ 14,770 $ 0.041 /kWh

TOTAL ENERGY

 3,004 MMBtu $ 14,770 -
05 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 1,650 $ 13,010 0.13
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 241,794 kWh $ 13,010 $ 0.041 /kWh

TOTAL ENERGY

 2,478 MMBtu $ 13,010 -
06 view
details		 USE DIRECT AIR SUPPLY TO EXHAUST HOODS 2.7245 N $ 19,000 $ 8,990 2.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 167,057 kWh $ 8,990 $ 0.041 /kWh

TOTAL ENERGY

 1,712 MMBtu $ 8,990 -
07 view
details		 REDUCE OR ELIMINATE WASTE 3.7214 N $ 3,650 $ 8,100 0.45
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 4,050 lbs $ 8,100 $ 0 /lbs

TOTAL WASTE

 - $ 8,100 -
08 view
details		 RECOVER HEAT FROM OVEN EXHAUST / KILNS 2.2432 N $ 13,750 $ 7,385 1.86
Energy Sources Yearly Reduction Yearly Savings Unit Price

LPG

 683 MMBtu $ 7,385 $ 8.65 /MMBtu

TOTAL ENERGY

 683 MMBtu $ 7,385 -
09 view
details		 COVER OPEN TANKS 2.2514 N $ 1,500 $ 7,260 0.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 134,818 kWh $ 7,260 $ 0.041 /kWh

TOTAL ENERGY

 1,382 MMBtu $ 7,260 -
10 view
details		 REDUCE COMBUSTION AIR FLOW TO OPTIMUM 2.1113 N $ 13,800 $ 6,380 2.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 216,002 kWh $ 6,380 $ 0.041 /kWh

TOTAL ENERGY

 2,214 MMBtu $ 6,380 -
11 view
details		 USE SYNTHETIC LUBRICANT 2.4314 N $ 0 $ 3,630 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 61,547 kWh $ 1,420 $ 0.041 /kWh

- Demand Charge

 204 kW $ 2,210 $ 5.64 /kW

TOTAL ENERGY

 631 MMBtu $ 3,630 -
12 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 1,440 $ 2,770 0.52
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 38,101 kWh $ 1,080 $ 0.041 /kWh

- Demand Charge

 156 kW $ 1,690 $ 5.64 /kW

TOTAL ENERGY

 391 MMBtu $ 2,770 -
13 view
details		 CHANGE PRODUCT DESIGN TO REDUCE ENERGY REQUIREMENTS 2.5195 N $ 5,000 $ 1,920 2.60
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 44,549 kWh $ 1,920 $ 0.041 /kWh

TOTAL ENERGY

 457 MMBtu $ 1,920 -