Tag: life cycle cost

21 Nov

Reap the Benefits of Energy Demand Optimization

by Synergy Systems with 0 Comment in Engineering & Automation Experts
This photo, “Energy, Carol Stream, IL” is copyright (c) 2014 Daniel X. O’Neil and made available under an Attribution 2.0 Generic license

The level of sophistication automation can bring to a business’s energy management system is extraordinary. Equally impressive is the money (and energy) saved through implementation of a strategic demand control system. Look no further than Taking Control of Energy Use, an article recently published on InTech filled with examples of savings and energy conservation.

Common practice is for companies to pay a demand charge to utility companies based on peak demand. Enabling a system to moderate loads, reducing peak demand, can save thousands annually. Automation systems go beyond anything that can be achieved manually. Set to act in a specific fashion, intelligent energy management systems can root out inefficiencies, slow down cycling blowers and shut down battery charges as needed.

A key factor of energy management is reducing demand without affecting production. This is where the true brilliance of automation shines. A system can be built to react to countless factors and be programmed in such a way that it never modifies aspects of the business that need to be running at all times.

Envision every asset, tool and machine in a plant working and reacting to one another without the need for manual instruction. The whole system works in harmony, optimized to its best performance level. In order to achieve this improvement, an evaluation of the plant should be performed. This should involve identification of potential savings of the life of a system, saving opportunities and saving initiatives. It can be helpful to have automation experts evaluate your processes for you as they have been trained to notice every detail of a system. Pick the guys who will tell you the truth, not just the truth you want to hear, and you’ll be amazed at the funds you save after you achieve return on investment.

16 Oct

The Asset Management Strategy

by Synergy Systems in Industry News

Modern instruments now go beyond customization and data collection. Each device in the field, be it an analyzer, valve or otherwise, can be programmed to collect larger varieties of data and disseminate it into actionable information. Alerts and device consistency can be constantly measured and updated, automatically collecting data for audits.

The above is the heart of asset management, operating intelligent hardware in a plant to ensure the fastest reaction time and actionable information. In short, optimized asset management provides the following:

  • Maintenance which considers the entire life-cycle of an asset
  • Real-time diagnostics
  • Dissemination of relevant information to different parties in the business
  • Central location for information
  • Pro-active maintenance
  • Extension of equipment life
  • Reduced downtime
  • Documented asset history

Installing an asset management system has long term benefits, but will require a culture change. Planning is critical because staff and plant engineers act as first responders to any issues in the plant. Decide where all information assembled by assets will be gathered and how it will be collected, making sure desired information lines up with the company mission and goals. With a plan in place, explain to the staff how the system will make their job easier and more efficient. In addition to earning their support, their feedback is crucial for optimization of the asset management strategy.

Collecting data, including asset trends, operating manuals, specification sheets and alert logs, is only half of what asset management provides. The benefits extend to pro-active maintenance that can result in the optimization of the plants as a whole.  Devices can be observed by their history, allowing those prone to failure to be identified and dealt with. Every asset in the plant becomes modifiable. This coupled with a pro-active staff creates a culture where operation can be constantly improved and strategies for monetary savings are always active.

With optimally implemented asset management, even plant areas that traditionally have only used up funds, like boiler rooms, become a site of monetary gain. The data provided by the system becomes an asset in itself, to be used as a tool to save money, fuel and energy.

This article was inspired by this Intech article

 

13 Mar

New Elements of Life Cycle Cost

by Synergy Systems in Industry News
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.