01 May

EPA Now Considering Regulations for the Steam Electric Power Generating Industry

EPA Now Considering Regulations for the Steam Electric Power Generating Industry

The EPA is proposing new regulations for the steam electric power generating industry to control the amount of contaminates being released into America’s waterways, according to a Power Engineering article. The rule as it stands has not been updated since 1982 and, according to an EPA fact sheet, “does not adequately address the associated toxic metals discharged to surface waters from facilities in this industry.”

Toxins specifically addressed include arsenic, mercury, lead, boron, cadmium, selenium, chromium, nickel, thallium, vanadium, zinc, nitrogen, chlorides, bromides, iron, copper and aluminum. These elements increase the risk of cancer and may have other health consequences when humans consume them through eating fish or drinking the water.

Proposed requirements will affect the following processes/byproducts in the electric power generating industry:

  • Flue gas desulfurization
  • Fly ash
  • Bottom ash
  • Flue gas mercury control
  • Gasification of fuels

The fact sheet mentions four options the EPA is currently looking at to reduce toxins in waterways.  Also mentioned are studies showing that the new regulations will have little effect on the energy industry.  Numbers or stats related to the benefits of the plans were not given.  The EPA estimates fewer than half of coal-fired power plants will incur any cost due to the regulations. They are trying to work with existing equipment and most power plants already possess the technology needed to meet the proposed standards.

More information can be found on the EPA website.

24 Apr

What Savings Are You Missing?

We are all about optimizing the process and boiler room of a plant, saving funds, energy and time for our clients. When plant managers are looking for savings using cutting edge technology, we have what they need. Yet, many factories aren’t aware of the savings they could reap. They run in less-than-optimal conditions, venting steam, wasting money and adding unnecessary emission into the air. The elements of that plant may not be optimized, causing plant managers and engineers to miss crucial warning signs or  areas that need improvement.

 

How does a plant manager find a solution when so often they are unaware of the issues? The answer is simple: have the plant tested for overall efficiency. Boiler efficiency visits from combustion experts will pin-point all the issues that are draining money and productivity.

 

Specifically, an expert boiler efficiency visit will provide measurable numerical values for the following:

 

• the money that could be saved through optimization

• The plant’s carbon footprint

• How much steam (and therefore energy) is being vented and wasted

• Emissions and improvements to reduce them

• Where energy is being used and for what purposes.

 

Each of these elements is essential for the optimization of a plant. If energy is being used inefficiently or other elements of the plant are less than optimal, money is being wasted somewhere. Consider what you could do with the information from a boiler efficiency visit. Monetary gains are certainly high on the list of benefits, right next to increased plant safety and productivity.

 

If you are wondering where you are losing money in your plant, contact us today. One boiler efficiency visit from one of our combustion engineers is all it takes for you to reap the benefits.

 

 

17 Apr

10 Years Into Manufacturing’s Future

 

Manufacturing Executive has published an article highlighting the Manufacturing Leadership Council’s predictions for the next decade of manufacturing. The council, which is an invitation-only network of executives who work to design and shape a better future for manufacturers around the world, noted five different areas of change.

  •  Factory Network Models
  • Key Technologies
  •  Energy Sources
  • Design/Production Digitization
  • Workforce

While the changes in these five areas largely reflects how our world is changing in terms of education, energy production and technology.

Currently, the majority of manufacturing executives (39%) favor having a few large factories that produce for the global market rather than have a network of many small factories. This trend is expected to continue through the next decade, although the gap between those who favor large factories to those who favor small is expected to shrink. Only 31% of manufacturers are expected to follow the model of large factories.

The reason for favoring large factories may, in large part, be due to technological advances that make it easier to keep track of every important section and measurement in a factory. Intelligent technologies, which allow for simplified conversion of data into usable information, predictive alarming and the fine tuning of every factory compensate, are a key technology in the optimization of the plant. These technologies, when first installed, can result in large monetary savings since they can regulate energy consumption based on demand.

Energy itself is also expected to see a change in the future. More than 90% of factories currently use electricity from the electric grid. In a decade, that number is expected to drop to 84% as manufacturing executives continue to incorporate more and more renewable sources of energy into their factories. Wind energy, in particular, is expected to make a big impact. While only 7% use this source today, in 10 years, it is expected that 97% of manufacturers will be incorporating the renewable source into their energy usage.

The growth of renewable energy is especially exciting in terms of Synergy’s goal to work towards an energy independent America, an idea reflected in our Energy Patriot pilot program.

New technology also plays a part in the further digitization of the design and production process. While only 13% of manufacturers have completely digitized these processes, in a mere 10 years, 53% are expected to have completely digitized design and productions processes. Digital manufacturing allows the transfer of relevant product information between design and manufacturing groups in a plant. This kind of technology can be a huge asset in the optimization and profitability of a plant.

With all the new technology swirling around, a future of growth and development can be seen for manufacturing. The one wrench in the machine is related to the skilled workforce, or the lack thereof. Manufacturing executives cited finding skilled workers as their biggest challenge to success in the future. It is a bit ironic, considering there is plenty of news about how difficult it is to find a job. The Manufacturing Leadership Council has created a group dedicated to this issue. Just like other industries, attaining a skilled workforce means getting involved with high school and college students, making sure they know the opportunities that await them in manufacturing.

Synergy offers opportunities for college students interested in part-time or internship work in the automation industry. Interested applicants can apply through our career page

Regardless of the challenges that await the manufacturing industry, most numbers point towards a growing, high-tech and energy conscious future, with the continued growth of technology at the forefront of change.

10 Apr

Rockwell Celebrates 110 Years of Allen-Bradley With a Contest

Source: https://www.facebook.com/ROKAutomation
Source: https://www.facebook.com/ROKAutomation

Synergy ally Rockwell Automation is celebrating 110 years of their Allen-Bradley brand. We prefer this highly dependable bran in our Program Logic Control (PLC) and Programmable Automation Controller (PAC) solutions.

To celebrate, Rockwell is having a photo contest on their Facebook page. They ask their fans and customer’s to post any photos related to the Allen-Bradley brand and stress the older the photo, the better. Rockwell will choose their favorite picture to feature each week and also promise some fantastic prizes. They’re not announcing all of them yet, but their website mentions a Jambox JAMBOX wireless speaker is up for grabs.

The Facebook page is currently taking submissions and will be doing so through April 26th. A grand prize winner will be chosen on May 3rd.

Here at Synergy, we are currently going through our stock of Allen-Bradley to find our winner. We would like to extend our congratulations to Rockwell Automation for 110 years of fantastic PLCs, PACs and all other Allen-Bradley hardware.

 

 

 

03 Apr

Safety and the Value of Risk Assessments

The control of combustion elements in a boiler system is similar to controlling an explosion. Within any process system, where specific elements need to maintain their prescribed balance, small miscalculations can be devastating. This is why safety is one of Synergy’s top priorities. While optimization and efficiency are of great importance, none of it matters if a system isn’t safe.

Regular risk assessments and timely inspections are essential in order to maintain plant safety. The illusion of a safe environment is often created by the fact that no harmful incident has happened. The time to consider a risk assessment is not after an employee or system has been severely injured, but before.

Like every other area of a plant, safety can be optimized for the greatest efficiency. Synergy’s safety measures, including our PLC systems and valve trains, have redundant controls to make sure that processes in a plant continue to operate optimally, even in the event that one small part malfunctions. In addition, we have perfected safety optimization to dramatically reduce nuisance trips.

The highest standard of safety is essential in a workplace to ensure the well-being of employees and equipment. That doesn’t mean you have to pay the highest price. Our combustion and engineering experts would be happy to perform an assessment of your plant and provide you with custom, optimized solutions for your safety, budget and goals.

27 Mar

Changes to Clean Air Act Coal-Fired Plant Regulations a Possibility

The Clean Air Act continues to be debated as the EPA comes closer to the April 13th deadline to finalize new source performances standard (NSPS) regulations. According to a Power Engineering Article from March 15, the Obama administration is considering more changes to the rule regulating greenhouse gasses.

The rule established in March of last year would require all new coal-fired power plants to emit no more than 1,000 pounds of carbon dioxide per MW/h of electricity produced. Existing coal-fired power plants had no such restrictions.

Concerns about the probability that new plants would be able to meet that rule were raised by four Democratic senators, who sent a letter to Obama urging him to amend the standard.

According to the letter, the senators worry that having the same emission standard for both gas-fired and coal-fired will actually hinder goals to reduce emissions in the United States. Not only are they concerned that new plants won’t be built, they also state that current coal-fired plants may choose not to upgrade their plant with cleaner systems because they will not be able to meet the regulations.

The letter then states that it is possible to continue to build new coal-fired plants – with state of the art technologies – and reduce admissions. Continued advancement of technology will help the industry grow cleaner throughout the years.

The concerns of the senators are clear in their letter. If those who are currently planning to build coal-firing plants are prevented due to inability to comply with the law, the jobs that may have been created will be lost and the cost of electricity has the potential to grow. In addition, these four senators are worried that such restrictions will prevent the further creation of technologies that will reduce emissions even farther.

Synergy Systems celebrates the creation of new technologies that further reduce emissions as they also tend to save businesses money and create a more efficient plant. The aim of our Energy Patriot program is to recognize the achievements of those plants and businesses that make great strides in working towards American energy independence.

Goals such as energy independence and dramatic reductions in emissions cannot be met overnight. Fine tuning of current technologies and the freedom to invent new state-of-the-art systems is an absolute necessity to achieving those goals. Synergy is proud to be a part of a movement toward a cleaner society, with systems that are optimized to create the greatest amount of product or energy while at the same time reducing the amount of fuel and emissions used.

If you are curious about what our engineers can do to save you money through optimized systems, drop us a comment here or visit our Contact Us page and speak to our experts today.

20 Mar

Industry Recognition of CSIA Grows

An ever increasing number of industry clients are requesting CSIA certification from the businesses they hire for industrial automation projects, according to Manufacturing Business Technology.

CSIA stands for Control Systems Integrators Association. They audit their members based on 79 criteria. When they meet or exceed these criteria, they receive a certification acknowledging their accomplishment. To further maintain the certification status, CSIA members must face additional audits every three years. CSIA certainly keeps their members on their toes – which is fantastic for businesses who aspire to be at the forefront of industrial technology and efficiency.

The 79 criteria are spread throughout nine chapters that describe everything from client projects to business organization. Chapters like Financial Management and System Development Lifecycle challenge businesses to make sure they not only provide for their clients, but provide for their business a healthy and successful structure. In this way, CSIA chapters act as redundant controls, ensuring that their members achieve only the highest quality of service.

This month, Synergy has been paying special attention to business continuity, going over our plans for various hazards that may arise and how we can deal with them in a way that has little to no effect on our projects and clients. This includes plans for our own business practices as well as plans for common and uncommon natural hazards.

You may have heard radio commercials talking about ready.illinois.gov. FEMA has their own national version at ready.gov, which provides a specific section for businesses. The forms and worksheets they provide have provided us greater insight into our own continuity plans.

Whether you are looking into CSIA or want to improve your own business continuity, we highly recommend using FEMA’s resources. Many hazards happen without warning, but having procedures in place to address them will protect clients and businesses from facing the full force of negative effects.

13 Mar

New Elements of Life Cycle Cost

New Elements of Life Cycle Cost

BusinessDictionary.com defines Life Cycle Cost as the “sum of all recurring and one-time costs over the full life span… of a good, service, structure or system.” This is a term often used in our industry, where process equipment and boilers are purchased with the intention of running them decades into the future. The rapid pace of technology, along with growing environmental concerns, has added additional elements to the calculation of life cycle cost. For example, a product with a long life may become obsolete before its end. Another concern is environmental laws. While a systems may be compliant with emission laws right now, changes in the future could hold even stricter emission restrictions.

Upgrading typically requires the replacement of a few parts while maintaining a whole system or product. That is changing with technology’s ever increasing advancement. Upgrading can mean different things depending on the product you purchase. If advanced technology is already being sold in the marketplace, other products may become obsolete as the newer technology takes hold. In a few decades, an upgrade may require complete replacement of some equipment. The latest technology tends to have a higher cost, which much be weighed in terms of the product life cycle. More than likely, a plant is better off choosing the latest technology because it will take a significant amount of time before it becomes obsolete. In the end, less money will be spent throughout the life cycle with a product that remains at the forefront of technology for years to come.

Today’s cutting-edge technology, such as intelligent HMI and variable frequency drives, many benefits, which much also be taken into consideration. Greater efficiency, less maintenance and a smaller environmental footprint are all elements of new technology that save money in a system. Such benefits may be necessary in the future. Our culture has only become increasingly concerned about industrial emissions. It can be assumed, then, that the future will see a gradual tightening of restrictions on emissions. A sure way to avoid negative impacts from future emission restrictions is to ensure your plant surpasses current standards. Installing an economizer can be a simple and cost effective way to begin. In addition to reducing emissions, it saves fuel and energy cost by harnessing the energy that would otherwise be lost up the stack. For these reasons, Synergy’s Economizer Solutions provides the fastest return on investment out of all of our products. At the end of the day, any steps in upgrading or optimizing that can reduce emissions can also reduce the cost of running a system. Such ‘green’ elements should weigh heavy in any life cycle cost analysis.

When it comes to calculating the life cycle cost of your next big business purchase, remember to consider more than purchase price, maintenance and life. Additional concerns, such as environmental impact and whether or not the product will be obsolete in the near future should carry a lot of weight in your decision.

~You aren’t alone in this decision. Synergy’s expert combustion engineers are always available to provide advice on whatever project you may be planning. Contact us at 630–724-1960, extension 12.

06 Mar

Prepare for Cyber Security in 2013

Prepare for Cyber Security in 2013

According to a recent newsletter from Invensys, responses to cyber-attacks on America’s critical infrastructure by the Industrial Control Systems – Cyber Emergency Response Team (ICS-CERT), a department of Homeland Security, rose by 52 percent in 2012. The biggest target was energy firms, accounting for 40 percent of attacks. Also on the list of industry sectors that fell victim to cyber-attacks in 2012 are the water sector, oil and natural gas sectors, nuclear sectors and chemical organizations. The frequency of these attacks is expected to increase, making the cyber security of America’s infrastructure firms paramount.

Using the internet can often be a necessary evil. One the one hand, it allows people to communicate instantly across countries any time of day. In our world, where entire businesses can be created and maintained online, these same businesses can be taken over by hackers with malicious intent.

Control systems devices that are directly connected or controlled through the internet are of particular concern to ICS-CERT, as malicious control over these systems could have catastrophic consequences. Consider a simple boiler, with control systems that enable a delicate combustion process to safely produce steam. If something happened to the formula, or if the burner or fan cannot be turned off when they need to, serious injury can result to the boiler and to plant employees.

This issue is so serious, the United States has an entire division, the National Cyber Security Division, to protect the U.S. from and fight against cyber-attacks. Cyber security is a national security issue, with recent news reports claiming The New York Times was hacked by Chinese hackers. In 2012, Iran is allegedly responsible for a large number of cyber-attacks against major U.S. banks. Cyber security is now more than simply guarding files or even guarding a business. Increasingly, cyber security is essential for protection against terrorist, be they local or abroad.

The looming question, then, is what to do at your business. The first step is to have solid policies and procedures in place that every employee is trained in. About 25 percent of malware attacks came from USB drives. In addition, no matter how much money you throw at cyber security, none of it matters if you don’t have employee compliance. Making sure procedures are in place and are followed can be greater security than any program you pay for.

Securing your control systems is also crucial. This can be done through remote support systems, such as our diagnostic support we provide, code named SORA. In this way, the internet connection used by the control systems is no longer your responsibility. It is the responsibility of the remote support provider. With such a system in place, even if malicious software makes it onto your business computers, it won’t be able to access your control systems and a certain amount of safety can be maintained.

Another great cyber security tip is what the Invensys newsletter calls “defense in-depth” security. This type of security involves have multiple security programs working on one system, where one programs vulnerability is made up for by having an additional program that does not have that vulnerability.

Lastly, secure passwords are a must. Someone with malicious intent has no need to use viruses or hacking software if they know the password they need to gain access to the system. Some sites, like Facebook and Google, are catching on. Facebook provides the option to have a text sent to the profile owner’s cellphone whenever an unauthorized computer accesses the account, allowing people to act quickly if they are not the ones accessing the profile. Google has an optional two step security measure on their email. After typing in the correct password, Google sends a secret code to the account holder’s cell phone. The number must be entered to access the account.

Even Apple can no longer claim its devices are spared from viruses and hackers. In the coming weeks, Synergy will be exploring the most popular free and paid security programs for computers and smartphones.

What type of security do you have at your home or business? Do you have any concerns going into 2013?

27 Feb

On Display: The ISA Will-DuPage Tabletop Show

On Display: The ISA Will-DuPage Tabletop Show

If you were at Harrah’s Casino and Hotel Ballroom in Joliet, Illinois last Thursday, you hopefully made time to see our display at the ISA Will-DuPage Tabletop Show. Our presenters put together a diagram of a boiler, show how each of our solutions fit into the combustion process.

The show was a huge success, with more than 50 exhibitors showing off their industry expertise.

~In other news, our Vice President, Marc Hunter was recently interviewed by Naperville Community Television for his participation in a charty at Eco Gym.