19 Mar

Top Three Ways Automation can Reduce Raw Material and Fuel Usage

Energy PatriotThe ability to procure sustainable value within a process system, boiler room or plant provides a huge advantage to business. By their very nature, these industries use up fuel and raw materials to create products and energy. The less material you need for any given process, the less you have to pay for. When it comes to the production of consumer goods, such as food products, using less material to create the same result means you can create more product.

The secret to sustainability in the process industry is reliability. Instruments should be calibrated for optimized performance and communicate all valuable information to plant engineers. This is where automation’s abilities thrive. Harnessing automation technology in the following ways will generate reliable and sustainable plant instruments.

  1. Preventative and Predictive Maintenance
    This sustainability issue doubles as a safety issue. The worst kind of safety maintenance a plant can have is reactive. Control systems should be optimized in such a way that plant engineers are made aware of potential errors before they have a chance to wreak havoc. This kind of automation, however, is only preventative. If you want to take your reliability and sustainability a step further, you will calibrate for predictive maintenance as well. An intelligent control system can record and remember the continuous activities of a plant and learn the signs of a potential problem before an error ever occurs. When preventative and predictive maintenance work in tandem, they create an optimized environment with few, if any, major malfunctions.
  2. Alarm Management and Reduction of Nuisance Trips
    Last week, we discussed the importance of alarm prioritization as a method of measurement within the process industry. Alarm management is equally important for sustainability. Every nuisance trip wastes energy and employee time.  At the same time, an overabundance of alarms can confuse plant workers and create misunderstandings of which alarm is the most crucial. Control systems can be automated in such a way that all this is resolved. The system will run smoothly and communicate all information in an actionable manner to the plant engineers. This avoids wasted time, materials and cost.
  3. Instrument Reliability Experts
    All the above will be for naught if the system isn’t put in place with the kind of care instrument reliability experts provide. Make sure you find an engineering consultant with an in-depth knowledge of what reliability and sustainability mean for your business.
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.