05 Jun

The Numbers behind Safety, Efficiency & Reliability

The Numbers behind Safety, Efficiency & Reliability

We are always ready to discuss how our various solutions and services save clients time, money and resources. The fact that our work is often customization to client demands gives us a significant edge in the control systems industry. Perhaps even more impressive are the numbers behind all we have to offer. From average savings to return on investment, our solutions boast substantial benefits.

Boiler Optimization and Burner Management
Improved controls result in reduced air and fuel flows, allowing for an improved boiler turn down ratio. Synergy clients see a return on investment within a year. By year two, the savings is significant.

Economizer Solutions
Our economizer solutions provide the fastest return on investment. Often ROI takes little more than six months and increases the efficiency of a boiler by 3 percent. This is achieved through the economizer’s purpose of recovering waste heat and cooling the temperature in the stack. For every 40 degree drop in temperature, clients see a one percent increase in efficiency.

Combustion Air and Burner Management Solutions
When there is unnecessary oxygen in the stack, the combustion formula in a boiler is inefficient and may be wasting energy and fuel.  For every 15 percent decrease of oxygen in the stack, fuel efficiency is improved by 1 percent.

Water System Solutions
Operational constraints can create parasitic electrical loads that waste money. With a variable frequency drive, of VFD, adjustments can be made based on demand, saving money overall. Most clients see immediate savings in electrical cost and receive return on their investment in less than a year. VFDs can also be used to control air flow and result in similar savings.

The above are some of our most popular solutions, and with such rapid return on investment, it’s not hard to understand why. Significant improvements can be made in plant efficiency that translates quickly into monetary savings.  If you are curious about how much you have the potential to save, have one of our experts perform and boiler evaluation. Uncover the hidden savings in your plant.

 

29 May

NFPA 85 Committee Welcomes Synergy’s Own as new Principal Subject Expert

Synergy Vice-President, Marc Hunter, has recently become a part of The Committee of NFPA 85 Boiler and Combustion Systems Hazards Code. He is a Principal Subject Expert on the committee and participates in votes that determine the standards of NFPA 85.

“Now, more than ever, our clients are assured they get a compliant solution and a superior level of safety in our control systems and boiler optimization,” said Hunter.

Hunter insist he is just happy to be considered, but the rest of us here at Synergy know the committee is lucky to have his 20 years of automation experience there to guide the committee on votes. His experiences on the committee will undoubtedly further our commitment and expertise in our core values of safety, reliability and efficiency.

NFPA-85 Combustion-systems-hazards-code
Marc Hunter proudly displays his certificate naming him a Principal Subject Expert for the NFPA 85 Committee.

More about NFPA 85 (from http://www.nfpa.org )

Document Scope:

1.1* Scope. This code shall apply to single burner boilers, multiple burner boilers, stokers, and atmospheric fluidized-bed boilers with a fuel input rating of 3.7 MWt (12.5 million Btu/hr) or greater, to pulverized fuel systems, to fired or unfired steam generators used to recover heat from combustion turbines [heat recovery steam generators (HRSGs)], and to other combustion turbine exhaust systems.
1.1.1 This code shall cover design, installation, operation, maintenance, and training.
1.1.2 This code shall cover strength of the structure, operation and maintenance procedures, combustion and draft control equipment, safety interlocks, alarms, trips, and other related controls that are essential to safe equipment operation.
1.1.3 Coordination of the design and operating procedures of the boiler furnace or HRSG system and any flue gas cleanup systems downstream of the post-combustion gas passes shall be required. Such coordination shall include requirements for ensuring a continuous flow path from the combustion air inlet through the stack.
 
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.

 

 

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.