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Combustion Monitoring and Alerting 

Monitor air:fuel ratio at the burner, pressure, flow, temperature, and more, anytime, from any device.

CMA+ GIF
 
BURNER BY BURNER COMBUSTION DATA
Furnace Management Data at Your Fingertips
Industrial furnaces are inherently inefficient and degrade over time due to high operating temperatures. PSNERGY's Combustion Monitoring and Alerting (CMA) system provides actionable data to help your team maintain optimal furnace performance. Join the growing list of customers worldwide who have reduced emissions and gas consumption costs by over 20% by monitoring combustion, temperature, pressure, and more.
 
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Why Choose PSNERGY's CMA?

If you’ve experienced the benefits of a well-tuned radiant tube furnace, PSNERGY’s CMA system takes it further by providing complete visibility into your furnace’s performance on one screen. This visibility allows for:

  • Proactive Maintenance. Identify and resolve issues before they cause downtime.
  • Improved Planning. Plan maintenance more effectively.
  • Increased Uptime. Maintain higher operational uptime.
  • Consistent Quality. Achieve consistent heating for higher quality output.
  • Enhanced Safety. Reduce the need for unsafe manual inspections.
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PSNERGY CMA

Comprehensive Monitoring and Reporting

Our system offers daily reports on combustion performance, real-time reviews, and historical data. You can monitor:

  • Time to Time Variations. Track performance over time.
  • Tube and Zone Variations. Identify inconsistencies within and across zones.
  • Burner Utilization. Ensure all burners are functioning optimally.
  • Regulatory Compliance. Verify gas regulator and MCV function performance.
  • Tube Integrity. Detect and address tube breaches in real-time.
  • Excess Oxygen. Monitors excess oxygen to ensure a solid air:fuel ratio.

Benefits of Furnace Monitoring

SAFETY, QUALITY, DELIVERY & COST

Safety

  • Reduce Exposure to Hazards. Minimize your crew's exposure to high heat, CO, or oxygen-depleted environments.
  • Automate Combustion Checks. Replace manual checks with automated gas sampling.
  • Lower Emissions. Reduce emissions caused by poor combustion conditions.

Delivery

  • Reliable Shipments. Ensure timely delivery of thermally processed materials.
  • Increased Throughput. Achieve faster delivery times by improving furnace efficiency.

Quality

  • Consistent Performance. Eliminate poor furnace performance, nonuniform heating, and process variability.
  • Real-time Data. Receive real-time, data-driven reports for consistent combustion quality.

Cost

  • Lower Gas Consumption. Decrease gas consumption per ton while maximizing BTU output.
  • Prevent Downtime. Avoid unplanned downtime with real-time maintenance alerts.
  • Enhanced Efficiency. Improve furnace efficiency and throughput by 10-20%.

Predict to Prevent. Are You Ready?

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The Advantage

  • Productivity. Less downtime, more uptime.
  • Consistency. Reliable, consistent heating.
  • Quality. Superior quality with no environmental surprises.
  • Preventative Maintenance. Proactive maintenance for all critical components.
  • Safety. Ensure personnel safety by reducing exposure to hazardous conditions.
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Real-Time Notifications

  • Burner Adjustments. Get notified when burners are out of range and need adjustment.
  • MCV and Gas Regulator Monitoring. Ensure all components are functioning correctly.
  • Tube Integrity Checks. Detect and respond to tube breaches immediately.
  • Zone Analysis. Capable of a full zone analysis.

On-Site Support

Part of our package includes bi-annual on-site visits to certify, upgrade, and verify system performance. Our experts balance the system, set MCVs, and document turndown, ensuring continuous optimal performance. Along with this, we offer cloud connectivity. This allows not only the service team on-site, but any of our engineering team to participate remotely in trouble shooting.

 

Frequently Asked Questions

Have Question? We are here to help

What's the ROI?

Short Answer: Most customers see an ROI in 9 to 12 months. PSNERGY can help quantify your ROI across the business.

 

Long Answer: Considering the savings begin immediately after the furnace is adjusted to the proper air-fuel ratios, the ROI can be much quicker.
- How much additional product can be produced with ~20% more energy in the furnace?
- What is one day of downtime spent troubleshooting combustion worth?
- When considering emissions reductions, customers have shared that their ROI calculation has been measured in months.

 

What if we don't set our furnaces at 3%

Some applications operate with a different target ratio than 11.5:1, especially when creating a reducing atmosphere. In these situations, knowing exactly how combustion is performing is even more critical due to the safety and quality impacts of running off the target ratio.

How do we network this?

One ethernet connection is all that is required to run CMA! CMA is commonly operated on an "IoT" network. 
WiFi, 4G, even Starlink are optional.

Reach out to schedule a call with our system engineers about how a system could be deployed at your facility.

Can the system directly make adjustments or change furnace settings?

No, CMA does not physically adjust furnace settings or valve position at this time. CMA is a retrofit measurement system first designed to drive targeted action and take combustion off the table!

What kind of KPI's could be set with CMA data?

Short answer: BTU/Ton, Total cycle time reduction, Tons / time-period,

Long answer: Ultimately these are up to you, and we always encourage tracking BTU/ton, cycle time, and total production.  Additionally, you can measure downtime attributed to combustion issues.  Combustion often gets blamed first for furnace performance issues. We see customers leverage immense value from the CMA data by being able to determine that it’s not a combustion issue and troubleshoot other issues in record time.

Does this work on my existing furnace?

CMA is designed to be a retrofit installation on any type of furnace!

Is combustion that big of a deal?

Remember the target range for most furnaces is 2.8-3.2% excess oxygen. 

3% o2 provides 8% more energy than 5% o2 and
3% o2 provides 21% more energy than 7% o2!!

Sustained o2 values below 2% significantly increase risk for carbon buildup, excess harmful emissions, and premature equipment failure!

How can I see and use CMA Data?

CMA includes purpose-built user interfaces.

 

PSNERGY iOS App
- See all furnaces at a glance
- View live data
- Message the PSNERGY team

Combustion Report Email
- Automated combustion sampling combined with powerful data processing sent straight to your inbox with simple, "Green, Yellow, Red" combustion reports for each burner!

 

PSNERGY Cloud Dashboard
- View live and historical data
- Powerful view of all the raw data from the system

Can't find what you're looking for? 

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Taking your furnace from a maintenance
cost to a strategic resource. Are you ready?

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