The Results (Lessons Learned) of More than 110 Energy Audits for Manufacturers by the Louisiana Industrial Assessment Center

Abstract

This paper and discussion presents the summary and results of energy audits or assessments conducted by the University of Louisiana Lafayette Industrial Assessment Center, which is sponsored by the US Department of Energy, for the first four years of operation. To insure the confidentiality of our clients, the results are generalized and summarized by industry type and recommendation type. Where the assessment finding and recommendations have been implemented, the implementation rate is shown. For recommendations that have the most significant savings and a high implementation rate, we will show the summarized implementation cost and payback period. The Industrial Assessment Center of the University of Louisiana Lafayette began operation in FY01 and conducted its first industrial energy assessment in December 2000. In this paper we present the results of this energy assessment and those of 112 more through August 2004. By industrial type, these assessments were for: Oilfield Equipment Manufacturing (23%), Food and Food Processing (18%), Petrochemical Manufacturing and Refineries (13%), Other (non-Oilfield) Equipment Manufacturing (12%), Ship Building and Repair (8%), Woodworking, Clothing and Wire Manufacturing (6%), Paper, Cardboard, Boxes and Bag Manufacturing (5%), Machining (4%), Building and Building Materials (4%), Printing (4%), and Glass and Ceramics Manufacturing (3%). The distribution of manufacturers for the State of Louisiana is weighted much higher in the Petrochemical Manufacturing and Refineries, however because of limitations on the amount of energy consumed (restrictions for the Industrial Assessment Centers), many of these are beyond the scope for Industrial Assessment Centers. For most of the recommendations we make, we try to keep the installation cost (parts and labor) within a one-year payback period. However, we have occasionally looked at longer payback periods when suggested by the client. The recommendations for each industry type are summarized in the following ten categories: air leaks and operating compressed air pressure (includes methods to lower cost by lowering the operating air pressure), replace air tools with electric tools (includes grinders, chippers, wrenches, and fans or blowers to replace air horns), installation of insulation (on hot or cold equipment, pipes and buildings), lighting (photo sensors, reductions, occupancy sensors, and LED exit signs), recycling, combustion efficiency and CHP, steam leaks and traps, heating and cooling (people and space), alternative fuels and operations, and productivity improvements (including preventive maintenance and group lighting replacement).