Enercon Systems Co. Services

Starting at the boiler, we survey the entire steam system and compile a report based on data collected. The report divides the system into plant areas for easy customer reference and includes: (1) Survey Notes Indicating System Problems and Remedies; (2) General and Specific Location of Required Venturi; (3) Inlet and Return Pressure; (4) Heat Transfer Data; (5) Venturi Size Per Location and (6) Assembly Required. Documentation is such that sizing (for later additions and modifications) can usually be handled by phone.

(1) BOILER ROOM

Record Steam Pressure, Header Traps and Return Pressure.

(2) OVERALL SYSTEM

Record Individual Steam Trap Location, Condensate and Piping.

(3) TRACING

For plants with outside tracing lines, we review inlets & outlets, eliminate unnecessary traps and inefficient parts.

(4) FUEL SAVINGS ESTIMATES

In estimating fuel savings (cost per 1000 lbs of steam), we utilize existing system information: (1) Pressure drops from Main Header to E.O.L; (2) Return Line Temperatures; (3) Type of System; (4) Steam Pressure; (5) Average Condensate Load Per Trap; (6) Customer Maintenance Schedule.

We then compare the resulting steam loss calculations (lb/hr) to the system’s projected performance using Enercon units. These estimates consistently prove to be accurate. They do not include savings from the elimination of trap repair and replacement.

FUEL SAVINGS OF 10%-25%
STEAM TEMPERATURE FLUCTUATIONS MINIMIZED
BLOWING TRAPS ELIMINATED
WATER HAMMER ELIMINATED
NO INVENTORY, UNITS PERMANENT
VIRTUALLY MAINTENANCE-FREE
STAINLESS STEEL CONDENSATE REMOVAL UNITS
LIFETIME WARRANTY
LIFETIME EXCHANGE POLICY ON TOTAL CONVERSIONS

NAVY’S 30-YEAR COMMITMENT TO FIXED ORIFICE TRAPS

Fixed orifice technology gained credibility in the early 60’s, when the U.S. Navy began looking for ways to keep ships at sea longer. The Navy studied steam trapping techniques, steam trap operation and maintenance.

The Steam Trap Handbook (James F. McCauley pub. 1995), says “researchers reasoned if a fixed size orifice was used to pass only the

The fixed orifice has been the steam trap of choice for the U.S. Navy's fossil-fueled fleet for 30 years.

quantity of condensate produced, then steam emitted from the orifice, under conditions when no condensate was present, would be minimal.

“This steam loss, although minute, is greater than that encountered if a properly functioning conventional steam trap were in its place. However, Navy experience with conventional steam traps has been poor; even though maintenance was stressed and preventive maintenance systems and procedures rigidly employed.”

Mr. McCauley points out that the Navy is concerned with reliability and energy efficiency; that a ship cannot depend on manufacturer's services at sea. “Optimally,’ he says, “they want equipment that will function reliably... Reliability, however, is not the only consideration in operating a vessel underweigh. The distance the ship can travel without replenishing its fuel is probably the second most important factor, since steam utilization is directly proportional to fuel consumption.

“The Navy was impressed with the researchers’ work with the orifice steam trap. After a pilot program on a major combatant ship, the decision was made to outfit the entire fossil-fueled fleet of over 300 ships with this unique device. After more than thirty years of use the orifice steam trap is still used exclusively in the fleet. Results have been more than satisfactory.”

One of Enercon’s Independent Distributors, a decorated 30-year U.S. Naval Officer holding an M.S. in Mechanical Engineering and a B.S. in Electrical Engineering, was closely involved with the fixed orifice during the time the Navy was converting its fleet to this technology.

FINISHER'S MANAGEMENT MAGAZINE
‘Ensuring Energy Efficiency: A Look at
Energy Conservation in Finishing Shops’
Nov./Dec. 2001 Issue, Page 24

Enercon Systems Company unconditionally guarantees its condensate removal unit against defects in material and workmanship, venturi wear, and wire draw while it is the property of the original owner. It does not cover the labor, material or other costs related to cleaning or installing them. If such defects or damages occur, Enercon will replace said unit(s) free of charge. This warranty covers the Condensate Removal Unit only; not the Y-strainer, blowdown valve or other parts of the Enercon assembly.

This warranty applies to normal use and not to intentional damage, improper piping or unreasonable use. In honoring this warranty, Enercon’s responsibility covers replacing defective condensate removal units only, not for labor, material or other costs related to installing them.

Exchange Policy

On full conversions (all qualifying mechanical traps replaced) Enercon will exchange and resize for a nominal fee (currently $30.00 U.S. per unit plus shipping) standard venturis (1/2", 3/4" & 1") that must be replaced due to steam system modification, expansion or process changes while they are the property of the original owner. This exchange policy covers the venturi only. Any other part of the assembly that needs to be replaced will be billed at current prices.

While cutting fuel consumption 10%-25%, Enercon projects have had a positive and lasting environmental impact.
	Replacing 600 conventional traps for the country’s largest, privately owned job shop plater cut fuel usage 18%, allowed a 30% steam pressure reduction (50 psi to 35 psi) and eliminated $20,000 in annual trap maintenance. By significantly cutting steam loss through traps, the company’s natural gas needs dropped about 250,000 therms annually. Boiler make-up water needs were also reduced some 18%.
President & CEO, Nov/Dec 2001 @Hughes Communications, Inc.
A leading lumber producer, which converted six plants to the Enercon System in 2003, points out in a trade magazine article that at one mill "Enercon made suggestions for improvement that saved us 5,324 gallons of water a day, 1.9 million gallons annually" In addition to using considerably less fuel, the company didn’t have to reheat and chemically treat many thousands of gallons of fresh water that would otherwise end up in a wastewater treatment facility.