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

Industrial Assessment Centers

Assessment #WV0421


Assessment Year 2011
SIC 3483
SIC Description Ammunition, Exc. For Small Arms, Nec
NAICS 332993
NAICS Description Ammunition (except Small Arms) Manufacturing
Principal Product Projectiles
Sales $ 20,000,000
# of Employees 125
Plant Area (Sq.Ft.) 100,000
Annual Production 3,500,000 Pounds
Production Hrs. Annual 7,488
Location (State) OH
Yearly Energy Cost $ 487,046

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 3,426,800 kWh $ 329,076 $ 0.096 /kWh

- Demand Charge

 9,568 kW $ 62,001 $ 6.48 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 10,274 MMBtu $ 95,969 $ 9.34 /MMBtu

TOTAL ENERGY

 45,399 MMBtu $ 487,046 $ 10.73 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 798,406 kWh
389,347 kWh		 $ 76,670
$ 37,388		 23.30 %
11.36 %		 $ 0.096 /kWh

- Demand Charge

 1,248 kW
615 kW		 $ 8,087
$ 3,985		 13.04 %
6.43 %		 $ 6.48 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 3,676 MMBtu
1,149 MMBtu		 $ 34,334
$ 10,732		 35.78 %
11.18 %		 $ 9.34 /MMBtu

TOTAL ENERGY

 11,860 MMBtu
5,140 MMBtu		 $ 119,091
$ 52,105		 24.45 %
10.70 %		 $ 10.73 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 33,993 $ 32,602 1.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 306,366 kWh $ 29,420 $ 0.096 /kWh

- Demand Charge

 491 kW $ 3,182 $ 6.48 /kW

TOTAL ENERGY

 3,140 MMBtu $ 32,602 -
02 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 28,554 $ 28,118 1.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 264,262 kWh $ 25,377 $ 0.096 /kWh

- Demand Charge

 423 kW $ 2,741 $ 6.48 /kW

TOTAL ENERGY

 2,709 MMBtu $ 28,118 -
03 view
details		 COVER OPEN TANKS WITH FLOATING INSULATION 2.2513 N $ 3,659 $ 15,551 0.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,665 MMBtu $ 15,551 $ 9.34 /MMBtu

TOTAL ENERGY

 1,665 MMBtu $ 15,551 -
04 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 I $ 2,469 $ 6,529 0.38
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 699 MMBtu $ 6,529 $ 9.34 /MMBtu

TOTAL ENERGY

 699 MMBtu $ 6,529 -
05 view
details		 USE FLUE GAS HEAT TO PREHEAT BOILER FEEDWATER 2.2412 N $ 10,314 $ 5,567 1.85
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 596 MMBtu $ 5,567 $ 9.34 /MMBtu

TOTAL ENERGY

 596 MMBtu $ 5,567 -
06 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 N $ 3,000 $ 5,339 0.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 50,204 kWh $ 4,821 $ 0.096 /kWh

- Demand Charge

 80 kW $ 518 $ 6.48 /kW

TOTAL ENERGY

 515 MMBtu $ 5,339 -
07 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 I $ 841 $ 4,203 0.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 44,056 kWh $ 4,231 $ 0.096 /kWh

- Demand Charge

 71 kW $ 460 $ 6.48 /kW

TOTAL ENERGY

 452 MMBtu $ 4,691 -

Personnel Changes

 - $ -488 -

TOTAL PRODUCTON

 - $ -488 -
08 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 1,910 $ 4,166 0.46
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 446 MMBtu $ 4,166 $ 9.34 /MMBtu

TOTAL ENERGY

 446 MMBtu $ 4,166 -
09 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 1,163 $ 4,091 0.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 38,410 kWh $ 3,689 $ 0.096 /kWh

- Demand Charge

 62 kW $ 402 $ 6.48 /kW

TOTAL ENERGY

 394 MMBtu $ 4,091 -
10 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 21 $ 3,731 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 35,077 kWh $ 3,368 $ 0.096 /kWh

- Demand Charge

 56 kW $ 363 $ 6.48 /kW

TOTAL ENERGY

 360 MMBtu $ 3,731 -
11 view
details		 USE WASTE HEAT FROM FLUE GASES TO HEAT SPACE CONDITIONING AIR 2.2426 N $ 8,964 $ 2,484 3.61
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 266 MMBtu $ 2,484 $ 9.34 /MMBtu

TOTAL ENERGY

 266 MMBtu $ 2,484 -
12 view
details		 ESTABLISH A PREDICTIVE MAINTENANCE PROGRAM 2.4157 I $ 3,000 $ 2,007 1.49
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 23,130 kWh $ 2,221 $ 0.096 /kWh

- Demand Charge

 37 kW $ 240 $ 6.48 /kW

TOTAL ENERGY

 237 MMBtu $ 2,461 -

Personnel Changes

 - $ -454 -

TOTAL PRODUCTON

 - $ -454 -
13 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 386 $ 1,849 0.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 17,373 kWh $ 1,668 $ 0.096 /kWh

- Demand Charge

 28 kW $ 181 $ 6.48 /kW

TOTAL ENERGY

 178 MMBtu $ 1,849 -
14 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 1,551 $ 1,352 1.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 14,079 kWh $ 1,352 $ 0.096 /kWh

TOTAL ENERGY

 144 MMBtu $ 1,352 -
15 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 241 $ 294 0.82
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,190 kWh $ 210 $ 0.096 /kWh

Natural Gas

 9 MMBtu $ 84 $ 9.34 /MMBtu

TOTAL ENERGY

 31 MMBtu $ 294 -
16 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 191 $ 266 0.72
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,259 kWh $ 313 $ 0.096 /kWh

Natural Gas

 -5 MMBtu $ -47 $ 9.34 /MMBtu

TOTAL ENERGY

 28 MMBtu $ 266 -