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

Industrial Assessment Centers

Assessment #WV0415


Assessment Year 2010
SIC 3465
SIC Description Automotive Stampings
NAICS 336370
NAICS Description Motor Vehicle Metal Stamping
Principal Product Automotive Stampings
Sales $ 25,000,000
# of Employees 160
Plant Area (Sq.Ft.) 250,000
Annual Production 64,000,000 Pounds
Production Hrs. Annual 6,000
Location (State) OH
Yearly Energy Cost $ 963,157

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 8,652,000 kWh $ 586,322 $ 0.068 /kWh

- Demand Charge

 23,021 kW $ 184,170 $ 8.00 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 18,667 MMBtu $ 192,665 $ 10.32 /MMBtu

TOTAL ENERGY

 107,350 MMBtu $ 963,157 $ 8.97 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 2,872,976 kWh
324,327 kWh		 $ 194,788
$ 21,990		 33.22 %
3.75 %		 $ 0.068 /kWh

- Demand Charge

 8,685 kW
2,475 kW		 $ 69,480
$ 19,800		 37.73 %
10.75 %		 $ 8.00 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 -7,562 MMBtu
100 MMBtu		 $ -78,039
$ 1,032		 -40.51 %
0.54 %		 $ 10.32 /MMBtu

TOTAL ENERGY

 21,886 MMBtu
3,424 MMBtu		 $ 186,229
$ 42,822		 19.34 %
4.45 %		 $ 8.97 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REPLACE ELECTRICALLY-OPERATED EQUIPMENT WITH FOSSIL FUEL EQUIPMENT 2.1311 N $ 15,000 $ 86,422 0.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,276,255 kWh $ 154,330 $ 0.068 /kWh

- Demand Charge

 5,784 kW $ 46,272 $ 8.00 /kW

Natural Gas

 -11,064 MMBtu $ -114,180 $ 10.32 /MMBtu

TOTAL ENERGY

 12,268 MMBtu $ 86,422 -
02 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 N $ 30,800 $ 21,876 1.41
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 272,394 kWh $ 18,468 $ 0.068 /kWh

- Demand Charge

 426 kW $ 3,408 $ 8.00 /kW

TOTAL ENERGY

 2,792 MMBtu $ 21,876 -
03 view
details		 REDUCE BUILDING VENTILATION AIR TO MINIMUM SAFE LEVELS 2.7315 N $ 5,000 $ 18,153 0.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,759 MMBtu $ 18,153 $ 10.32 /MMBtu

TOTAL ENERGY

 1,759 MMBtu $ 18,153 -
04 view
details		 USE DEMAND CONTROLLER OR LOAD SHEDDER 2.3191 I $ 7,820 $ 14,296 0.55
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 1,787 kW $ 14,296 $ 8.00 /kW

TOTAL ENERGY

 0 MMBtu $ 14,296 -
05 view
details		 USE RADIANT HEATER FOR SPOT HEATING 2.7231 N $ 34,050 $ 12,353 2.76
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,197 MMBtu $ 12,353 $ 10.32 /MMBtu

TOTAL ENERGY

 1,197 MMBtu $ 12,353 -
06 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,503 $ 8,767 0.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 104,649 kWh $ 7,095 $ 0.068 /kWh

- Demand Charge

 209 kW $ 1,672 $ 8.00 /kW

TOTAL ENERGY

 1,073 MMBtu $ 8,767 -
07 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 2,000 $ 7,621 0.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 91,045 kWh $ 6,173 $ 0.068 /kWh

- Demand Charge

 181 kW $ 1,448 $ 8.00 /kW

TOTAL ENERGY

 933 MMBtu $ 7,621 -
08 view
details		 ESTABLISH A PREDICTIVE MAINTENANCE PROGRAM 2.4157 I $ 700 $ 5,733 0.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 69,850 kWh $ 4,736 $ 0.068 /kWh

- Demand Charge

 140 kW $ 1,120 $ 8.00 /kW

TOTAL ENERGY

 716 MMBtu $ 5,856 -

Administrative Changes

 - $ -123 -

TOTAL PRODUCTON

 - $ -123 -
09 view
details		 CENTRALIZE CONTROL OF EXHAUST FANS TO ENSURE THEIR SHUTDOWN, OR ESTABLISH PROGRAM TO ENSURE MANUAL SHUTDOWN 2.7316 N $ 5,265 $ 4,603 1.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 446 MMBtu $ 4,603 $ 10.32 /MMBtu

TOTAL ENERGY

 446 MMBtu $ 4,603 -
10 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 884 $ 3,852 0.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 45,958 kWh $ 3,116 $ 0.068 /kWh

- Demand Charge

 92 kW $ 736 $ 8.00 /kW

TOTAL ENERGY

 471 MMBtu $ 3,852 -
11 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 4,490 $ 1,398 3.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 12,825 kWh $ 870 $ 0.068 /kWh

- Demand Charge

 66 kW $ 528 $ 8.00 /kW

TOTAL ENERGY

 131 MMBtu $ 1,398 -
12 view
details		 UTILIZE CONTROLS TO OPERATE EQUIPMENT ONLY WHEN NEEDED 2.6231 I $ 1,312 $ 1,032 1.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 100 MMBtu $ 1,032 $ 10.32 /MMBtu

TOTAL ENERGY

 100 MMBtu $ 1,032 -