Energy Efficiency and Savings Tools

FIA and FIERF have partnered with the U.S. Department of Energy's (DOE) Industrial Technologies Program to help members increase their energy efficiency and decrease costs. See below for resources available through the program.

Discover your plant's Energy Savings Potential by taking this quick on-line test developed by the DOE.

Software Tools

The Quick Plant Energy Profiler, Version 2.0 is an online software tool that helps quickly diagnose how energy is being used in the plant and the largest opportunities to save energy and money. This tool is your first step in identifying areas for potential savings.


Process Heating Assessment and Survey Tool (PHAST), Version 2.0 introduces methods to improve thermal efficiency of heating equipment. This tool helps users survey process heating equipment that consumes fuel, steam or electricity and identifies the most energy-intensive equipment. Use the tool to compare performance of equipment under various operating conditions and test 'what-if' scenarios. See fact sheet for more information.


AIRMaster+ LogTool Version 2.0 is a companion tool to AIRMaster+ that helps userd determine the operating dynamics of a compresses system. Use the LogTool first to gather critical data in preparation for AIRMaster+. Then you can input that data into AIRMaster+to model existing and future compressed air system upgrades.


AIRMaster +, Version 1.2.3 provides comprehensive information on assessing compressed air systems, including modeling, existing and future system upgrades and evaluating savings and effectiveness of energy efficiency measures. See Fact Sheet (pdf) for more information.


Combined Heat and Power Application Tool (CHP) helps users evaluate the feasibility of using gas turbines to generate power and the turbine exhaust gases to supply heat to industrial heating systems. It allows analysis of three typical systems types: fluid heating, exhaust-gas heat recovery, and duct burner systems. Use the tool to estimate energy savings, system costs, and payback period, and to perform "what-if" analysis for various utility costs. See Fact Sheet (pdf) for more information.


Steam System Tool Suite - If you consider potential steam system improvements in your plant, the results could be worthwhile. Steam System improvements can save 10% to 20% in fuel costs in many facilities. DOE offers a suite of tools for evaluating and identifying steam system improvements.

  • Steam System Scoping Tool - is designed to help steam system energy manager and operations personnel to perform initial self-assessments of their steam systems. This tool will profile and grade steam system operations and management and help you evaluate your steam system operations against best practices. See Fact Sheet (pdf) for more information.
  • Steam System Assessment Tool (SSAT), Version 3 Allows steam analysts to develop approximate models of real steam systems. Using these models, you can apply SSAT to quantify the magnitude - energy, cost and emissions-savings of key potential steam improvement opportunities. SSAT contains the key features of typical steam systems.
  • 3E Plus®, Version 4.0 calculates the most economical thickness of industrial insulation for user input operation conditions. You can make calculations using the built-in thermal performance relationships of generic insulation materials or supply conductivity data for other materials.

MotorMaster+ Version 4.0.6 An energy-efficient motor selection and management tool, MotorMaster+ software includes a catalog of over 20,000 AC motor. This tool features motor inventory management tools, maintenance log tracking, efficiency analysis, savings evaluation, energy accounting, and environmental reporting capabilities. See Fact Sheet (pdf) for more information.


MotorMaster+ International 1.0.15 MotorMaster+ International includes many of the capabilities and features of MotorMaster+; however, now you can evaluate repair/replacement options on a broader range of motors, including those tested under the Institute of Electrical and Electronic Engineers (IEEE) standard, and those tested using international Electrical Commission (IEC) methodology. See Fact Sheet (pdf) for more information.

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Save Energy Now Webcasts

Free Save Energy Now Webcasts on software tools are now available.

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 Process Heating Resources

Improving Process Heating System Performance: A Sourcebook for Industry, Second Edition (pdf) provides information on activities, resources, applications, standard and guidelines for increasing industrial energy efficiency.

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 Best Practice Process Heating Tip Sheets

Quick and to the point, these two-page tip sheets give engineers, technicians, equipment operators and others technical advice to improve process heating systems:




 Best Practices Tip Sheets




 Natural Gas

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 Case Studies

The industrial Systems listed below can account for a large part of the energy used in manufacturing processes. System improvements and new technologies can help save energy and money. These case studies describe demonstrated energy improvement projects, process improvement projects, and/or assessments at the plant level. Many examine the bottom-line benefits that successful applications of energy-efficient practices and technologies can yield.

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Industrial Technologies Program State Activities

Through the Industrial Technologies Program (ITP), DOE is currently working in each state to help industry use energy more efficiently. Click here for information about activities in your state.

Industrial Assessment Centers (IACs) are aimed at small- to medium-sized manufactures and provide a comprehensive industrial assessment at no cost. Engineering faculty and students conduct industrial assessments to identify opportunities to improve productivity, reduce waste, and save energy. Recommendations from the IAC audits have saved manufacturers an average of $55,000 annually. Read the IAC fact sheet (pdf) to learn more. Contact the IAC school in your area to request an assessment today. See list of companies for information about completed plant assessments.

See the Save Energy Now website for additional information.

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 March 24th Workshop Presentations

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