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

Industrial Assessment Centers

Assessment #WV0428


Assessment Year 2011
SIC 3431
SIC Description Metal Sanitary Ware
NAICS 332312
NAICS Description Fabricated Structural Metal Manufacturing
Principal Product Nickel products and Extruded tubes
Sales $ 30,000,000
# of Employees 100
Plant Area (Sq.Ft.) 200,000
Annual Production 44,100,000 Pounds
Production Hrs. Annual 7,200
Location (State) KY
Yearly Energy Cost $ 4,316,761

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 52,368,000 kWh $ 1,521,814 $ 0.029 /kWh

- Demand Charge

 128,616 kW $ 1,707,695 $ 13.28 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 180,477 MMBtu $ 1,087,252 $ 6.02 /MMBtu

TOTAL ENERGY

 717,254 MMBtu $ 4,316,761 $ 6.02 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 2,971,598 kWh
1,366,815 kWh		 $ 84,780
$ 38,996		 5.57 %
2.56 %		 $ 0.029 /kWh

- Demand Charge

 4,877 kW
2,277 kW		 $ 65,144
$ 29,984		 3.81 %
1.76 %		 $ 13.28 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 17,042 MMBtu
2,303 MMBtu		 $ 102,540
$ 13,865		 9.43 %
1.28 %		 $ 6.02 /MMBtu

TOTAL ENERGY

 47,501 MMBtu
16,313 MMBtu		 $ 252,464
$ 82,845		 5.85 %
1.92 %		 $ 6.02 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 N $ 209,000 $ 74,991 2.79
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 12,457 MMBtu $ 74,991 $ 6.02 /MMBtu

TOTAL ENERGY

 12,457 MMBtu $ 74,991 -
02 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 80,800 $ 45,746 1.77
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 894,218 kWh $ 25,512 $ 0.029 /kWh

- Demand Charge

 1,490 kW $ 20,234 $ 13.28 /kW

TOTAL ENERGY

 9,166 MMBtu $ 45,746 -
03 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 60,550 $ 40,236 1.50
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 804,894 kWh $ 22,964 $ 0.029 /kWh

- Demand Charge

 1,341 kW $ 17,272 $ 13.28 /kW

TOTAL ENERGY

 8,250 MMBtu $ 40,236 -
04 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 N $ 24,000 $ 12,157 1.97
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 237,600 kWh $ 6,779 $ 0.029 /kWh

- Demand Charge

 396 kW $ 5,378 $ 13.28 /kW

TOTAL ENERGY

 2,435 MMBtu $ 12,157 -
05 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 I $ 815 $ 11,317 0.07
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 230,695 kWh $ 6,582 $ 0.029 /kWh

- Demand Charge

 384 kW $ 5,215 $ 13.28 /kW

TOTAL ENERGY

 2,365 MMBtu $ 11,797 -

Personnel Changes

 - $ -480 -

TOTAL PRODUCTON

 - $ -480 -
06 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 1,000 $ 9,763 0.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,625 MMBtu $ 9,783 $ 6.02 /MMBtu

TOTAL ENERGY

 1,625 MMBtu $ 9,783 -

Personnel Changes

 - $ -20 -

TOTAL PRODUCTON

 - $ -20 -
07 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 9,060 $ 8,107 1.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 158,515 kWh $ 4,522 $ 0.029 /kWh

- Demand Charge

 264 kW $ 3,585 $ 13.28 /kW

TOTAL ENERGY

 1,625 MMBtu $ 8,107 -
08 view
details		 USE FLUE GAS HEAT TO PREHEAT BOILER FEEDWATER 2.2412 N $ 8,550 $ 8,061 1.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,339 MMBtu $ 8,061 $ 6.02 /MMBtu

TOTAL ENERGY

 1,339 MMBtu $ 8,061 -
09 view
details		 ESTABLISH A PREDICTIVE MAINTENANCE PROGRAM 2.4157 I $ 2,000 $ 7,253 0.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 149,951 kWh $ 4,278 $ 0.029 /kWh

- Demand Charge

 250 kW $ 3,395 $ 13.28 /kW

TOTAL ENERGY

 1,537 MMBtu $ 7,673 -

Personnel Changes

 - $ -420 -

TOTAL PRODUCTON

 - $ -420 -
10 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 700 $ 7,120 0.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 139,114 kWh $ 3,969 $ 0.029 /kWh

- Demand Charge

 232 kW $ 3,151 $ 13.28 /kW

TOTAL ENERGY

 1,426 MMBtu $ 7,120 -
11 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 1,890 $ 5,623 0.34
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 943 MMBtu $ 5,623 $ 6.02 /MMBtu

TOTAL ENERGY

 943 MMBtu $ 5,623 -
12 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 3,010 $ 5,254 0.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 102,781 kWh $ 2,932 $ 0.029 /kWh

- Demand Charge

 171 kW $ 2,322 $ 13.28 /kW

TOTAL ENERGY

 1,054 MMBtu $ 5,254 -
13 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 0 $ 4,404 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 126,187 kWh $ 3,600 $ 0.029 /kWh

- Demand Charge

 210 kW $ 2,704 $ 13.28 /kW

TOTAL ENERGY

 1,293 MMBtu $ 6,304 -

Ancillary Material Cost

 - $ -1,900 -

TOTAL PRODUCTON

 - $ -1,900 -
14 view
details		 REDUCE SPACE CONDITIONING DURING NON-WORKING HOURS 2.7224 I $ 600 $ 4,082 0.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 678 MMBtu $ 4,082 $ 6.02 /MMBtu

TOTAL ENERGY

 678 MMBtu $ 4,082 -
15 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 25 $ 2,154 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 42,161 kWh $ 1,203 $ 0.029 /kWh

- Demand Charge

 70 kW $ 951 $ 13.28 /kW

TOTAL ENERGY

 432 MMBtu $ 2,154 -
16 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 N $ 3,000 $ 2,125 1.41
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 41,628 kWh $ 1,188 $ 0.029 /kWh

- Demand Charge

 69 kW $ 937 $ 13.28 /kW

TOTAL ENERGY

 427 MMBtu $ 2,125 -
17 view
details		 REMOVE OR CLOSE OFF UNNEEDED COMPRESSED AIR LINES 2.4235 N $ 0 $ 860 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 30,141 kWh $ 860 $ 0.029 /kWh

TOTAL ENERGY

 309 MMBtu $ 860 -
18 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 770 $ 391 1.97
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 13,713 kWh $ 391 $ 0.029 /kWh

TOTAL ENERGY

 141 MMBtu $ 391 -