Reduce Idling & Increase Fuel Savings

Oilfield and Mining

applIcatIons

+providing cold Weather Engine

RelIabIlIty

> Heating Systems

for Mobile ApplicAtions

Automatic Altitude Adjustment

*EliminAtEs Cold StartS

OIl, GaS, MInInGOIl, GaS, MInInG

COntentS

INTRODUCTION

3 espar heaters: A winning technology

ApplICATION STORIeS

4 espar heaters: Hot news for cold climates

5 espar solutions

5 How they work

6 Where you save

6 look ma, no hands

7 A history of reliability

pRODUCT SpeCIfICATIONS

8 Airtronic D2/D4/D5

9 Hydronic l-11

10 Hydronic M-11

eCO eNvIRONmeNTAl INITIATIveS

11 saving money while saving the planet

TRANSpORTATION leADeR

11 espar in Arkansas

11 trucking counts on espar

12 idle money

espAr HeAters: A wInnInG tecHnology

In recent years there has been growing concern about our environment and, in particular, the contribution of heavy equipment in industries such as mining and oil & gas to harmful greenhouse gas emissions.

Idling engines, whether they’re installed in trucks, fracking equipment, deck engines or earth-moving machines, affect our environment and our energy supply in several ways. a large gas-fueled engine, for example, consumes as many as eight gallons of fuel for every hour that it idles. In a single year, such an engine consumes 2,400 gallons of fuel. an idling engine also generates as much as 21 tons of carbon dioxide and 0.3 tons of nitrogen oxides in a year.

Governments in North america and throughout the world are trying to reduce these emissions and alleviate our dependency on non-renewable resources with regulations directed at idling engines. at the same time, they’re working with industry to foster awareness of the harmful effects of idling and the solutions available from suppliers to combat these effects.

as a manufacturer of idle-reduction products, Espar has formed partnerships with several government agencies in Canada and the U.S. When it’s available, Espar also tries to secure government funding for demonstration programs so that it can present to its customers in the mining, oil & gas and other industries the positive effects of independent heating systems in reducing idling and lowering fuel consumption.

Espar has played an integral role in devel-oping many of these programs. With our insights and expertise, acquired from more than 35 years of working with North american industry, we have contributed to a variety of government programs to reduce and eliminate idling. For example: Espar was the first anti-idling manufacturer to receive approval

for its products from the California air resources Board (CarB), one of the world’s most demanding environmental regulators. We took the initiative, working with the state agency in advance of new regulations to help create protocols for testing and setting the standards that followed.

the U.S. Environmental Protection agency’s SmartWay transport Partnership has verified all of Espar’s products, and we maintain a solid and beneficial working relationship with the group.

Espar works with other government agencies such as the U.S. department of Energy and Environment Canada to help send the message to participants in the mining and oil & gas industries that they can find cost-saving alternatives to idling engines, even in the harshest climates.

Using idle-reduction technologies, our customers not only comply with stricter emissions and anti-idling regulations, they also reduce their fuel and engine maintenance costs. By contributing to the comfort and safety of employees, these technologies also increase productivity and reduce staff turnover.

By reducing engine idling, the mining and oil & gas industries can seize a rare opportunity to create a win-win-win situation: a win for their bottom line; a win from increased energy efficiency, and a win for the environment. that means, in the long run, that everyone wins.

John dennehyVice PresidentMarketing & CommunicationsEspar Heating Systems

oil, gAs, Mining 3

espAr SOlutIOnSEspar provides two basic types of heater for vehicles used in mining and oil and gas operations: air heaters and water heaters. Both systems satisfy the highest demands for sturdiness and cost-effectiveness.

“lots of our customers are using them,” says darcy Hoffman, oil & gas sales manager for Cummins Western Canada (CWC) in Calgary.

Espar’s air heaters improve engine startability in cold weather, while supplementing cabin heat independently of the engine. Models are available for one-person and larger cab units and require no electrical plug-ins. they range from 2 kW/7,500 BtUs to 5 kW/ 18,800 BtUs and are available with Espar’s digi-controller, which incorporates an internal ambient-air temperature sensor for precise compartment heating.

Espar’s coolant heaters provide automatic heat regulation on two levels. they run on low amounts of fuel and power, require no electrical plug-ins, are easy to start and include self-diagnostics.

Heat output from Espar’s coolant heaters ranges from 5,500 BtUs to 120,000 BtUs. the HYdroNIC 5, for example, suits engines

of 2,000 pounds or less and a displacement smaller than 700 cubic inches. For larger engines up to 15,000 pounds and a displacement of up to 3,000 cubic inches, the HYdroNIC 35 works best.

For oilfield and mining applications in particular, Espar’s M-Series units come with automatic altitude adjustment and six operating speeds for lower amp draw.

Espar’s heaters come with a two-year parts and labour warranty. they’re approved by the California air resources Board, one of the most demanding clean-air agencies in North america, and verified by the U.S. Environmental Protection agency.

“our customers operate everywhere in the world,” says CWC’s Hoffman, “so if it works in Canada, it will work in any country where cold-weather starts are a concern.”

Tailor-made for mines and well siTesManufactured specifically for the oil & gas and mining industries, Espar’s HYDRONIC L-II heaters come in a boxed enclosure. The kit includes the HYDRONIC 16 – 35Kw heater in either 12V or 24V, 5000L coolant pump, fuel filter, silicone hose and extra constant torque clamps for installation.

Meanwhile, Espar has just introduced its Hydronic II D5 E to North America. The unit is used in oilfield and forestry vehicles as well as some mining applications.

HoW tHey

wORkEspar’s coolant heating units raise the temperature of the coolant, then circulate it to warm the engine and heat exchangers to near operating temperatures. the units can also be configured to provide auxiliary heat for other critical fluids.

depending on the model, Espar heaters come with as many as six operating speeds, brushless blower motors and automatic altitude adjustment.

Espar heaters reduce fuel costs by minimizing engine idling. they consume as little as 0.08 gallons of fuel an hour, and not more than 0.16 gallons an hour.

Using timer controls incorporated into Espar heaters, operators can program the units to start pre-heating an engine at scheduled

intervals. alternatively, operators can activate an Espar heater using a SmartPhone or other remote device. In projects involving more than one engine, operators can turn on all their engine heaters at once, to a maximum of 50 vehicles, using Espar’s multi-max option. No matter how an Espar heater is activated, it warms up an engine, in advance, so equipment is ready to go from the beginning of the work shift.

espAr HeAters: HOt newS for

COld ClIMateSFor mining and oil and gas companies that operate in winter conditions throughout the world, a small investment in an Espar heater pays off in more ways than one.

that’s why mining and oil and gas companies such as Syncrude, Suncor, teck Cominco and Cardinal river Coals have installed Espar heaters on a wide variety of their equipment, from deck engines to fracking units to portable units for pre-heating helicopter engine bays and cabs

Espar heaters operate as miniature furnaces independent of the engine. they tap directly into a vehicle’s fuel and power supply, which avoids the need for external hook-ups. timers and remote key-chain starters make it possible to program pre-heating for as long as a week in advance or to activate pre-heating from inside a building or shelter, so that engines are ready to go from the beginning of a shift.

“Savings in fuel and maintenance costs justify the expenditure for a heater,” says Ian duivan, General Sales Manager for Polar Mobility research ltd. in Calgary, an Espar distributor for more than 35 years.

By heating diesel and gas-fueled engines up to 3,000 horsepower, Espar’s coolant heaters ensure that equipment starts reliably and on schedule, even in the coldest temperatures.

at the same time, Espar’s heaters also raise the temperature of other drivetrain and engine fluids, hydraulic oils and fuel, eliminating delays and ensuring system readiness.

and by extending its warmth to a vehicle’s cab and compartment, an Espar heater enables operators and technicians to work safely and productively in winter conditions, no matter how remote the location.

Engines pre-heated by an Espar heater not only start more easily, they also suffer less stress on their cranking systems and less wear on major powertrain parts. By eliminating idling time, mining and oilfield companies reduce their winter operating costs and lower their fuel consumption. they also reduce jobsite emissions and maximize the productivity of their personnel and equipment.

“large vehicle engines consume up to one gallon of diesel fuel for each hour of idling,” says John dennehy, Vice President of Marketing and Communications for Espar Heating Systems. “So an idling engine burns as much as 2,400 gallons of fuel in a year and emits more than 13 tons of carbon dioxide.”

By comparison, an Espar coolant pre-heater eliminates engine idling and can raise the temperature of an engine in one hour by 100 degrees Fahrenheit while consuming only 0.16 U.S. gallons of fuel.

“For applications on well sites, heaters may require modifications such as positive air shut-off or spark arresters,” says duivan. “But even when modifications are necessary, the fuel and maintenance savings and the reduced environmental impact outweigh the cost.”

Espar’s coolant heaters are compact, with all heat creation, fan distribution and plumbing neatly packaged within the unit. they operate on as many as six heat levels and cycle between these levels to maintain the constant coolant temperature prescribed by the control unit. they come in sizes to fit almost any application and are backed by an extensive worldwide dealer network.

oil, gAs, Mining 54 oil, gAs, Mining

ApplicAtion StorieS

Look ma, nO HandSas an alternative to a manually adjusted fuel setting, Espar heaters can be equipped with an optional high-altitude kit with preset fuel pump or a plug-and-play module that automatically adjusts fuel settings as required.

Espar heaters also incorporate a Zero obstacle option Management (ZooM) switch, which increases a unit’s functionality while minimizing demands on the operator.

an Espar heater’s ZooM switch includes several programmable functions, such as: timer: allows operators to turn on a heater and leave it running with full confidence that the unit will automatically shut off. Particu-larly useful in remote locations, this protects against no-start situations if the heater is accidentally left on.

low-voltage disconnect: automatically turns off the heater if battery voltage levels drop below programmed limits, avoiding no-start situations from drained batteries.

Ambient temperature sensor: Prevents heater operation on warmer days. this further reduces operating power requirements and eliminates unnecessary run-time hours.

Dual output capability: Enables remote or local mounting of start button.

a history of

RelIabIlItyGlobal mining and oil & gas operations can rely on Espar’s worldwide network for service and maintenance under any conditions. a subsidiary of J. Eberspäecher, based in Esslingen, Germany, Espar is backed by a network of factory-trained personnel as well as distributors and dealers in 26 countries, who can attend to the company’s equipment at short notice. In addition, Espar customers can rely on the company’s toll-free technical support lines and an interactive website.

Founded in 1865, Espar’s parent company, J. Eberspäecher, is a leader in design and manufacturing of exhaust and heater systems. More than 5,000 employees work for the global organization, which remains a family-owned business under the fifth generation of descendants. With 60 locations throughout the world and assembly plants on four continents, J. Eberspäecher generates annual sales of more than $3 billion.

Espar’s parent company has been involved in the growth of the industrialized world since 1865, initially as a producer of sheet metal products and metal–framed roof-glazing panels designed for large public projects such as Milan’s railway station.

In post-war years, J. Eberspäecher began producing pre-heaters for the Volkswagen Beetle as well as a range of heating and exhaust equipment for the automotive industry. It was the first company in the world to market a fuel-burning auxiliary heater to compensate for heat loss in low-fuel consumption diesel cars.

Expanding into North america in 1973, the company operates manufacturing and service facilities throughout the continent, including a $60-million technical Center in detroit.

In North america, Espar imports heater units themselves from Germany, but all installation kits and mounting hardware are designed, manufactured and assembled at Espar’s head office and factory in Mississauga, just outside of toronto. “Having our own factory allows Espar to address the specific needs of our North american customers,” says John dennehy, Espar’s Vice President of Marketing and Communications in Mississauga.

In addition to heaters designed especially for operators in the mining and oil & gas industries, Espar also sells and services fuel-operated heater systems for applications in trucks, school buses, recreational vehicles, vans, marine, military, and off-highway equipment.

“We build specific kits for specific clients,” says Ed Hart, Vice President of oEM Sales, “to make it easier to install by anyone in North america.”

a presence in North america for more than 35 years, Espar is ISo/tS 16949:2009 certified and has now received certification for ISo 14001:2004.

For more information on Espar, visit

www.espar.com

“ ”

Where you

SaveEspar heating systems pay for themselves primarily by reducing fuel costs. Payback time depends on idling time and fuel prices, but in general, the less time an engine idles and the less fuel it consumes as it warms up to its operating temperature, the faster the payback time for an Espar heater.

Espar heaters save money in other ways, as well. By eliminating excessive idling time, the units extend the life of an engine and reduce maintenance costs. a low idling history should also increase a vehicle’s resale value, while vehicles equipped with Espar heaters should attract a higher resale price.

Meanwhile, Espar heaters help to increase productivity in the field. By heating their engines in advance, operators can go directly to work upon arrival instead of waiting for an hour or more for a vehicle’s engine to heat.

You can estimate more precisely the amount of money that you’ll save with an Espar heater using the online savings calculator at www.espar.com.

oil, gAs, Mining 76 oil, gAs, Mining

Process air

Hot air outlet

air inlet

Control unit with diagnostic

Heat exchanger

Combustion air inletFuel metering pump

Exhaust outlet

Fuel connection

Combustion air blower

Flame overheat sensor

Ceramic glow pin

Air HEAtErs

AIRTRONIC D2 AIRTRONIC D4 AIRTRONIC D5

Heat output

BtU/hr (kW)

Boost

High

Med

low

7,500 (2.2)

6,500 (1.8)

4,100 (1.2)

2,900 (0.85)

13,650 (4)

10,200 (3)

6,800 (2)

3,400 (0.9)

18,800 (5.5)

16,400 (4.8)

9,200 (2.7)

4,100 (1.2)

Fuel Consumption

U.S. gal/hr (l/hr)

diesel 1/2

Boost

High

Med

low

0.07 (0.28)

0.06 (0.23)

0.04 (0.15)

0.02 (0.10)

0.13 (0.51)

0.10 (0.38)

0.07 (0.25)

0.03 (0.11)

0.17 (0.66)

0.15 (0.58)

0.09 (0.34)

0.04 (0.15)

Electrical

Consumption

12V model shown

12V or 24V available

Boost

High

Med

low

2.8 amps

1.8 amps

1.0 amps

0.67 amps

3.3 amps

2.0 amps

1.1 amps

0.6 amps

7.1 amps

6.7 amps

2.5 amps

1.3 amps

Weight 5.9 lbs. (2.7 kg) 9.9 lbs. (4.5 kg) 20 lbs. (9.3 kg)

HYDrOniC l-ii COOlAnt HEAtEr

HYDRONIC 16 HYDRONIC 24 HYDRONIC 30 HYDRONIC 35

Heat output BtU/hr

(watts)

54,630

(16,000)

87,950

(24,000)

102,430

(30,000)

120,000

(35,000)

Fuel Consumption U.S.

gal/hr (l/hr)0.53 (2.0) 0.77 (2.9) 0.98 (3.7) 1.11 (4.2)

Electrical Consumption

24V heater only

(without coolant pump)

12V converter available

2.5 amps

2.8 amps

1.8 amps

1.0 amps

0.67 amps

3.3 amps

2.0 amps

1.1 amps

0.6 amps

7.1 amps

6.7 amps

2.5 amps

1.3 amps

Weight40 lbs.

(18.14 kg)

40 lbs.

(18.14 kg)

40 lbs.

(18.14 kg)

40 lbs.

(18.14 kg)

Water throughput1,374 U.S. gal/hr against 3 psi

(5200 l/hr against 0.2 bar)

AirtrOniC D2/D4/D5 Air HEAtEr

the aIrtroNIC heaters are designed for many types of applications. they are especially suited for cab and sleeper heat in trucks, workshop vehicles, freight compartments and interior heat in general. these air heaters cycle quietly through four heat levels to maintain a desired temperature range, without idling your engine.

HYDrOniC l-iiCOOlAnt HEAtEr

Espar’s HYdroNIC l-II series are for the largest coaches, boats and off-road engines. these heaters provide engine, fuel and hydraulic preheat and can be incorporated into a coaches heating system to provide supplemental heat. the first choice for those who require rapid heating when operating in “arcticlike” climates. the 24V heaters can now be adapted to 12 V with Espar’s conversion kit.

Combustionair blower

Electric motor

Combustionair inlet

Heat exchanger

Fuel nozzleExhaust outlet

Combustion chamber

Fuel connection

Control unit with diagnostic and integrated optical flame monitor

Service-optimizedburner head

temperature sensorCoolant inlet

Integrated fuelpump withsolenoid valve

overheat sensor

Coolant outlet

Ignition sparkgenerator withelectrodes

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ECO EnvirOnmEntal initiativEs

TRANSpORTATION leADeR

tRuCkInG counts on espArEspar heaters have addressed growing demand in a number of industries for technology that reduces fuel consumption while minimizing exhaust emissions. But they’ve had their biggest impact to date on the North american trucking industry.

there are more than 2.2 million long-haul trucks operating in North america, and each one typically idles for about 2,000 hours a year. Each idling vehicle consumes 1,600 to 2,400 gallons of fuel worth as much as $8,500 a year.

Continued on page 12

HYDrOniC COOlAnt HEAtErs

HYDRONIC m8

(Biodiesel)HYDRONIC m10 HYDRONIC m12

Heat output 12V

BtU/hr (kW) 24V

5,120 (1.5)

27,300 (8.0)

5,120 (1.5)

32,437 (9.5)

4,100 (1.2)

41,000 (12)

Fuel Consumption 12V

U.S. gal/hr (l/hr) 24V

0.24 (0.90)

0.05 (0.18)

0.32 (1.2)

0.05 (0.18)

0.40 (1.5)

0.04 (0.15)

Electrical Consumption 12V 2.9 – 4.6 amps 2.9 – 7.2 amps 2.8 – 11 amps

Weight 13.7 lbs. (6.2 kg) 13.7 lbs. (6.2 kg) 13.7 lbs. (6.2 kg)

HYDrOniC m-iiCOOlAnt HEAtEr

this series of heaters is powerful, compact and light weight but rugged in design making it ideal for providing engine, fuel and hydraulic pre-heat for off-road equipment. It is also ideal for providing both engine and supplemental cabin heat for buses and boats.

Saving money while Saving the planet

esPar in arkansas“Saving money was the real driving force behind the decision to spec Espar’s coolant heater,” says Kevin Hurtt, Vice President of Maintenance at Calark trucking in Mabelvale, ark. Calark operates a fleet of 800 tractors, 2,200 dry vans and 200 refrigerated trailers that serve the U.S., Canada and Mexico. the majority of Calark’s fleet are International ProStar, loneStar and 9400 models along with a mix of Volvo, Freightliner, Kenworth and Peterbilt units. to date, the company has installed 200 Espar heater systems in its vehicles.

“We realized we needed a product that delivered driver comfort at the same time as it helped us to meet anti-idling laws and mitigated concerns about starting the engine when cold,” says Hurtt. “Espar’s system has the ability to minimize idling, keep the driver warm, and save fuel and wear and tear on our equipment.”

“We see idle time percentages in the low single digits with vehicles that have an Espar heater,” says Hurtt, “and our drivers like not having to run the truck engine.

“I recommend to anyone who’s looking to save fuel and maintain driver comfort to take a look at Espar’s products.”

Combustionair blower

Electric motor

Ceramic Glow pin Fuel

Water outlet

Water inlet

Exhaust outletCombustion

air inlet

overheat sensor

Heat exchanger

Water pump

Combustion chamber

Flame sensor

Control unit

oil, gAs, Mining 1110 oil, gAs, Mining

eCO eNvIRONmeNTAl INITIATIveS

Continued from page 11

an investment in an Espar heater to reduce idling can pay for itself in less than 24 months and often much more quickly.

recognizing the value of Espar’s heaters, the company’s customers now include such major fleets as WalMart and Schneider. the company’s heaters are an oEM option on many new truck models and an aftermarket option through many extensive

networks, such as Freightliner, International, Kenworth, Western Star, Sterling and Volvo dealerships.

Espar’s impact on the trucking industry has become even more pronounced as North american jurisdictions apply more stringent regulations to protect the environment. Equipment such as Espar heaters, which eliminate extended periods of engine idling, have become mandatory for the new generation of cleaner, more fuel-efficient vehicles. at the same time, idle-reduction equipment reduces fuel costs by as much as 8%.

“Idle-reduction technologies do much more than help fleets comply with stricter emissions and anti-idling regulations,” Espar’s Vice President of regional Sales, dale Peay. “they also reduce costs for fuel by as much as 8%, lower the cost of vehicle maintenance and can help retain operators by providing a more comfortable work environment.”

While Espar has captured an enthusiastic market for its products in the trucking industry, it also provides independent heating systems for a multitude of other vehicles, including recreational vehicles and school buses, where warm starts, defrosted windows and a safe and comfortable environment, all without engine idling, can have a critical social impact.

idle moneyaccording to the U.S. department of Energy, idling trucks consume about 3 billion gallons of fuel a year. at an average of $3 a gallon, the trucking industry spends $9 billion a year just to keep its trucks idling.

the cost doesn’t stop there. a reduction in idling can cut maintenance and repair expenses by extending oil change intervals and increasing the lifespan of components such as air compressors, alternators, belts and hoses. By some estimates, idling adds about 15 cents an hour to vehicle maintenance costs. the less a truck idles, the more its operator saves.

Espar Products, Inc. (800) 387-4800 (905) 670-0960 (905) 670-0728 Fax inquiries@espar.com www.espar.com