This 125,000 square foot facility is a metal fabrication plant that supplies the automotive industry. With a peak electrical demand of 2,500 kW, the plant consumes approximately 9.3 million kWh annually. At the request of the local electric supplier, a survey was conducted to assist plant personnel in determining potential opportunities for reducing energy expenditures.

Areas of Investigation:

The specific areas of focus for the survey included the plant electrical system (rate structure, power factor correction, controlling peak demand, etc.), AC induction motors, lighting systems, compressed air system, and HVAC systems.

Survey Results/Savings Potential:

As a result of this survey, recommendations were provided for potential annual saving of $87,400, with a collective average simple payback of less than one year. This equated to an annual electrical expenditure reduction of approximately 19.7%.

Recommendations were also provided regarding maintenance and establishment of policies that would ensure continued efficient operation, with emphasis on safety and the environment.

Environmental Impact:

The recommended measures in this survey have the potential of reducing the amount of CO₂ discharged into the atmosphere by 20.3 million pounds annually. In addition, these measures can reduce the emission levels of SO₂ by 160,770 lbs. and NOx by 62,625 lbs. each year.

A summary of the recommendations and their estimated annual savings is presented in the following table.

Table – Recommended Measures Case Study No. 1