Enercon Performance – Customer Anecdotal Evidence and Related Notes and Data

 

1.       A small petroleum refinery with a completely closed-loop condensate system, converted in 1994 and was completely reviewed in 2007.

a.       Upon initial conversion

1)      Condensate return tank pressure dropped 80% - from 100 psig to 20 psig.

2)      Steam load dropped approximately 12% - 4,000 lbs/hr.

3)      Entirely eliminated steam trap maintenance – entity claims to having had no maintenance issues, nor spent any time on maintenance, with the Enercon units since their install.

b.      In  the 2007 retest of individual units, orifice size and line pressure/BTU count

1)      Distribution lines were tested from boiler to end of the lines and found to have a consistent pressure, temperature, and BTU count throughout the lines.

2)      Condensate return tank pressure was 20 psig – exactly the same as thirteen years earlier.

3)      Steam load was exactly the same as thirteen years earlier.

 

2.       A major northern oil and gas refinery performed a 425 unit test, (of a 30,000 unit trap population) along with repairing of mechanical steam trap related water damage to pipes.

a.       Calculated water savings of 66,000,000 million gallons per year.

b.      Total calculated savings when combining reduced fuel, water conservation, reduced maintenance, and improved operational issues of over $8,500,000 annually (in excess of $20,000 per unit annually).

 

3.       One company replaced mechanical traps in 8 mills over an 18 month period starting in 2003.  Operations are constant variable load situations with “zone control”

a.       Experienced increased heat release in coils resulting in average Kiln time dropping 25%, from 67 hours to 50 hours

b.      Increased uniformity of drying throughout the kiln resulting in a better and more consistent product.

c.       One mill, approximately 100 Enercon units, saved 1,916,640 gallons per year.

d.      Steam venting from the condensate return tank reduced significantly

 

4.       One company tested Enercon units against new inverted bucket traps using the identical kiln, wood species, and drying schedule

a.       Initial setpoint temperature dropped 56.19% - from 14 hour 0 minutes to 6 hours,8 minutes

b.      Charge time was reduced 30% - from 10 days to 7 days.

c.       Kiln temperatures responded more quickly to setpoint changes.

 

5.       One surface finishing company replaced 500 conventional traps in 1996. President & CEO Periodical – Sept/Oct 2001 issue; Finishers’ Management – Nov/Dec 2001 issue

a.       Gas bill was cut 18%

b.      Boiler pressure was reduced 30%

c.       Maintenance expense eliminated

 

6.       A Cogeneration facility, where winter temperatures reached 35 to 40 below zero, experienced large problems from the freezing of condensate in the mechanical traps. Upon converting the entire facility to the EVCR Units;

a.       Trap related freezing issues completely disappeared.

b.      Has experienced zero maintenance requirements with EVCR Units installed on pressures ranging from 50 psig to 790 psig, on the four years to date since conversion.

c.       Has experienced savings on repairing turbine damage from ice estimated at a minimum of $150,000 per year.

 

7.       One food processing company, after EVCR Unit installation;

a.       Reduced plant steam pressure setting 13.6% - from 110 psig to 95 psig

b.      Experienced better heating in cooking vessels resulting in average steam load reduction of 5,000 lbs/hr to 7,000 lbs/hr.

c.       Improved cooking processes with better temperature control and quicker cooking time resulting in improved throughput and product quality.

d.      Eliminated the service of mechanical traps, an elimination of a constant maintenance problem.

 

8.       In Canada, one company had a job shop anodizing 2 million parts per year;

a.       Eliminated the constant downtime repairing and changing conventional mechanical traps.

b.      Eliminated the problem of not being able to maintain adequate steam pressure during the cold Quebec winters.

c.       Significantly increased the amount of steam even when incoming water temperature dropped to 40 degrees F.

 

9.        A Wisconsin company, after EVCR Unit installation;

a.       Reduced overall system pressure 33.33% - from 12 psig to 8 psig.

b.      Reduced start up time 37.50% - from 8 hours to 5 hours.

c.       Increased the reliability of the steam system, reduced downtime and eliminated all trap maintenance.

d.      Retesting of entire system six years after install found all units operating exactly as the day installed with no appreciable wear.