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

Industrial Assessment Centers

Assessment #WV0356


Assessment Year 2007
SIC 3549
SIC Description Metalworking Machinery, Nec
NAICS 333513
NAICS Description Machine Tool (Metal Forming Types) Manufacturing
Principal Product Metal forming presses
Sales $ 13,000,000
# of Employees 60
Plant Area (Sq.Ft.) 161,851
Annual Production 100 Pieces
Production Hrs. Annual 2,574
Location (State) PA
Yearly Energy Cost $ 243,065

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 1,395,366 kWh $ 55,276 $ 0.040 /kWh

- Demand Charge

 5,019 kW $ 48,885 $ 9.74 /kW

- Electricity Fees

 - $ 1,860 -

Natural Gas

 11,141 MMBtu $ 137,044 $ 12.30 /MMBtu

TOTAL ENERGY

 25,444 MMBtu $ 243,065 $ 9.55 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 266,741 kWh
93,474 kWh		 $ 10,568
$ 3,706		 19.12 %
6.70 %		 $ 0.040 /kWh

- Demand Charge

 1,234 kW
298 kW		 $ 12,015
$ 2,902		 24.58 %
5.94 %		 $ 9.74 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 1,457 MMBtu
433 MMBtu		 $ 17,931
$ 5,326		 13.08 %
3.89 %		 $ 12.30 /MMBtu

TOTAL ENERGY

 4,191 MMBtu
1,391 MMBtu		 $ 40,514
$ 11,934		 16.67 %
4.91 %		 $ 9.55 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 33,400 $ 9,825 3.40
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 143,344 kWh $ 5,679 $ 0.040 /kWh

- Demand Charge

 426 kW $ 4,146 $ 9.74 /kW

TOTAL ENERGY

 1,469 MMBtu $ 9,825 -
02 view
details		 CLOSE HOLES AND OPENINGS IN BUILDING SUCH AS BROKEN WINDOWS 2.7444 N $ 16,300 $ 6,101 2.67
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 496 MMBtu $ 6,101 $ 12.30 /MMBtu

TOTAL ENERGY

 496 MMBtu $ 6,101 -
03 view
details		 USE HEAT PUMP FOR SPACE CONDITIONING 2.7234 I $ 9,600 $ 5,326 1.80
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 433 MMBtu $ 5,326 $ 12.30 /MMBtu

TOTAL ENERGY

 433 MMBtu $ 5,326 -
04 view
details		 BURN WASTE OIL FOR HEAT 3.6124 N $ 3,400 $ 4,096 0.83
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 333 MMBtu $ 4,096 $ 12.30 /MMBtu

TOTAL ENERGY

 333 MMBtu $ 4,096 -
05 view
details		 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS 2.3131 N $ 0 $ 2,275 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 480 kW $ 4,675 $ 9.74 /kW

TOTAL ENERGY

 0 MMBtu $ 4,675 -

Personnel Changes

 - $ -2,400 -

TOTAL PRODUCTON

 - $ -2,400 -
06 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 0 $ 1,880 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 22,142 kWh $ 877 $ 0.040 /kWh

- Demand Charge

 103 kW $ 1,003 $ 9.74 /kW

TOTAL ENERGY

 227 MMBtu $ 1,880 -
07 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 I $ 1,000 $ 1,349 0.74
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 19,305 kWh $ 765 $ 0.040 /kWh

- Demand Charge

 60 kW $ 584 $ 9.74 /kW

TOTAL ENERGY

 198 MMBtu $ 1,349 -
08 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 N $ 1,000 $ 1,061 0.94
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 96 MMBtu $ 1,181 $ 12.30 /MMBtu

TOTAL ENERGY

 96 MMBtu $ 1,181 -

Personnel Changes

 - $ -120 -

TOTAL PRODUCTON

 - $ -120 -
09 view
details		 LOWER TEMPERATURE DURING THE WINTER SEASON AND VICE-VERSA 2.7221 N $ 1,100 $ 942 1.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,681 kWh $ 302 $ 0.040 /kWh

Natural Gas

 52 MMBtu $ 640 $ 12.30 /MMBtu

TOTAL ENERGY

 131 MMBtu $ 942 -
10 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 1,900 $ 855 2.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 10,027 kWh $ 397 $ 0.040 /kWh

- Demand Charge

 47 kW $ 458 $ 9.74 /kW

TOTAL ENERGY

 103 MMBtu $ 855 -
11 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 350 $ 715 0.49
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 10,177 kWh $ 403 $ 0.040 /kWh

- Demand Charge

 32 kW $ 312 $ 9.74 /kW

TOTAL ENERGY

 104 MMBtu $ 715 -
12 view
details		 INSTALL OUTSIDE AIR DAMPER / ECONOMIZER ON HVAC UNIT 2.7241 I $ 1,080 $ 697 1.55
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 17,580 kWh $ 697 $ 0.040 /kWh

TOTAL ENERGY

 180 MMBtu $ 697 -
13 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 155 $ 674 0.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 9,678 kWh $ 382 $ 0.040 /kWh

- Demand Charge

 30 kW $ 292 $ 9.74 /kW

TOTAL ENERGY

 99 MMBtu $ 674 -
14 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 500 $ 587 0.85
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 47 MMBtu $ 587 $ 12.30 /MMBtu

TOTAL ENERGY

 47 MMBtu $ 587 -
15 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 I $ 270 $ 504 0.54
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,325 kWh $ 293 $ 0.040 /kWh

- Demand Charge

 34 kW $ 331 $ 9.74 /kW

TOTAL ENERGY

 75 MMBtu $ 624 -

Personnel Changes

 - $ -120 -

TOTAL PRODUCTON

 - $ -120 -
16 view
details		 REMOVE OR CLOSE OFF UNNEEDED COMPRESSED AIR LINES 2.4235 N $ 280 $ 499 0.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 12,564 kWh $ 499 $ 0.040 /kWh

TOTAL ENERGY

 129 MMBtu $ 499 -
17 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 40 $ 488 0.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,918 kWh $ 274 $ 0.040 /kWh

- Demand Charge

 22 kW $ 214 $ 9.74 /kW

TOTAL ENERGY

 71 MMBtu $ 488 -