Industrial Assessment Center—UL LafayetteTheodore Kozman Jim Lee

Funding provided by US DOE

Types of Manufacturers

Results of Assessments• ~$173M/year in Energy Saving

Recommendations Made (more than 1650 individual recommendations)– More than $90M/year have a payback period of

less than one year– Longer payback periods include CHP and/or

major operational changes

• ~$35M/year Energy Saving Recommendations implemented within 9 months of the assessment more than 250 plants ($140k/plant/yr.)– ~41% of the total number of recommendations– ~26% of the dollar value of recommendations

Recommended Savings

Implementation rate by recommendation type

Implementation by Industry type

Overall Implementation savings

Lessons Learned• Short payback periods are

implemented more frequently than longer payback periods.

• Companies with on-going preventive maintenance without plant-wide shutdown implement a higher percentage of recommendations.

• In general, recommendations are proportional to energy utility use (not so with implementation).

Lessons Learned (2)• Steam system (including leaks and

faulty traps) yield the highest dollar savings recommendations and implementations.

• Repair air leaks and lowering the operating pressure of the compressed air system findings are implemented more than any other findings (on percentage basis).

• Recycling can be implemented frequently to save waste/disposal costs.

Box and Whisker Plot

Lessons Learned (3)• Insulation of hot or cold surfaces

will generally have a payback period of less than one year.

• Steam system efficiency improvement can yield good cost savings—however may require a major shutdown for a period of time.

• Lighting and lighting controller improvements can save significant energy with pay back periods of less than one-year.– Used at home—not at work

Lessons Learned (4)• Using a different energy source or moving

some operations to the second shift can save energy dollars, sometimes (depends mostly on time of day charges).

• Electrically driven tools can consume less than one-sixth the amount of electricity as compressed air-driven tools.

• The amount of energy used by heating and cooling systems can be improved with set-back devices or timers. For some, these may have to be locked.

Lessons Learned [5]• Productivity improvements can save a

great deal of money, the payback period maybe substantial.

• CHP and Combustion changes can have significant savings. However, with current gas and electric prices, the payback period maybe significant. (several years-with different combustion components).

• Use your local IAC if you are a manufacturer desiring to reduce your annual energy cost.

Date

Location

Component

SPOT 1 147 FSPOT 2 135 FSPOT 3 99.9 FLOAD Loaded

Temperature Rise

1 -18 F

19 -63 F

64 -128F

Monitor circuit and component

Monitor & Repair next scheduled maintenance

Schedule Repair ASAP

REPAIR IMMEDIATELYCRITICAL

Possible Solution

Monitor circuit. Clean and tighten connection during next regular maintenance cycle.

Reference

Level of Severity

Minor

Intermediate

Severe

>129 F

Preventative Action

Possible Cause

Conclusion

Component 1 shows a 47.1° and component 2 shows a 35.1º Temperature Rise. These temperatures rise is not within normal operating parameters. The lighting was on at the time and the circuit should be repaired ASAP to avoid any accidents and/or shut downs.

SPOT 2-3 35.1 F

Analysis

Identification3/7/2005

Circuit Room Gueydan

Lighting

TEMP DIFFERENCESPOT 1-3 47.1 F

Centers Close:• Oklahoma/Arkansas/Texas

– Dr. William Kolorik (Oklahoma State)– 405/744-5042

• Texas– Dr. Warren Heffington (Texas A&M)– 979/845-5019

• Mississippi/Arkansas– Dr. B. K. Hodge (Mississippi State)– 662/325-7315

• Louisiana/Arkansas/Texas/Mississippi– Dr. Theodore Kozman (University of Louisiana

Lafayette) 337/482-5717