Feb 27, 2015 - Tampa Bay E-Week ... ASME FWCS | February 2015 Newsletter | Page 2 .... Originally written by Engineered
Florida West Coast Section News February 2015 Inside This Issue Technical Article - A Financial Justification for Pumped System Improvements (pages 2-4) 5th Annual STEM Professional Association Event (pg. 5) Tampa Bay E-Week Banquet (pg. 6) Brain Teaser (pg. 7)
UPCOMING EVENTS (pg. 7) E-Week Banquet, th February 27 ASME Present-A-Bull: Student Papers Night, th March 19 5th Annual STEM Professional Association Event, th March 19
Job Posting (pg. 7) Stantec
New Interim ASME FWCS Chairperson – Mr. Tim Hunt Message to members of our local section: I have been given the opportunity to act as interim Chairperson because Magdalena has taken a job on the east coast of Florida and the excessive travel necessitated resignation. I hope to get elected to this position for a two year term by vote of confidence from our members. Who am I? An ASME member who has held a variety of Executive Board positions since joining after graduation from Tulane University with BSME in ‘84. I was granted license as a Florida PE after passing the test in ‘88. My background is in machine design and industrial controls. I have designed and certified pressure vessels to ASME code. I am presently Senior Engineer at HydroDyne Engineering of Clearwater, designing and building wastewater treatment equipment. What can I do (through promoting work by others) for you the average member? 1. Encourage participation in our activities. Provide interesting activities that can fit into your busy schedule. Encourage family (spouse, children over 8) participation in activities where the activity warrants. 2. Spread organizational responsibility to members of the board and other interested members so that junior members get professional experience, and more senior members stay in contact with other local engineers and firms. 3. Provide you with options and opportunities to gain continuing education credits towards PE renewal, or simply learn something valuable to you in your career. 4. Keep you informed on ASME National’s new events and opportunities. Encourage you to log into ASME.org, so you feel you have ‘gotten what you pay dues for’. 5. Chair Meetings as required, and promote professionalism in the organization while still keeping things ‘light and fun’. I am sure there are other items you would like accomplished. OK, what are they? And ask yourself - How are you going to bring your employer over to the side of ASME? How are you going to convince your spouse that we are not a bunch of ‘fuddie duddies’? How many activities can you attend this year? How are we going to keep ASME relevant in the political arena? Yes, we can get a lot better. Yes, we are in a transition with ASME National. But moreover – YES WE CAN. -Tim Hunt, PE
The Next Step for ASME FWCS Today’s digital world enables open and engrossing communication. In an effort to unify our engineering community over the next year we encourage members to frequent www.asme.org, and to represent your section by joining the FWCS group.
Technical Article - A Financial Justification for Pumped System Improvements This article will demonstrate the value of starting a proactive Pumped System Improvement program in which major pumped systems are evaluated on an ongoing basis. Prior to starting any new program there must be financial justification; this article shows how using readily available plant production data. There are two rules to follow when considering any process improvement: 1. If you do not measure it, you cannot improve it. 2. If you do not know how much a process costs, you cannot maximize its profitability. Most businesses have accounting departments tracking the flow of money into (revenue) and out of (expenses) the company. The difference between revenue and expenses is the company’s profit. Periodically all revenue and expense transactions are grouped and reported on a balance sheet providing a concise picture of the financial health of the company. Companies often do not take into account the revenue and expenses for each product. This is most likely because of the assumed complexity of a pumped system. One reason is the minimal amount of operation information available due to the expense of taking and recording the data. Another reason is that many people do not know how to use the data available to gain a better understanding of how it applies in a business sense as it rolls up. As a result, much of the operational information needed is not readily available. Objective of a Pumped System Improvement Program The objective of a Pumped System Improvement Program is to have the same attention to detail on improving pumped system profitability as is currently expended in increasing total plant profitability. Between 20% to 50% of the power consumed in a typical industrial plant is for pumping applications, and these systems have an average system efficiency of less than 45%. Is that sufficient incentive to look into improving the operation of pumped systems? To demonstrate how to determine the value of implementing a Pumped System Improvement Program we will look at a typical industrial plant in the Northwest. Industrial Process Plant Case Study In 2005, an industrial process plant scheduled to be operating for 340 days with 25 days set aside for planned shutdowns. At this schedule, the plant could operate 93% of the year. Operating records for 2005 show the plant operated for 7,440 hours (85% uptime) and during that time produced 138,500 tons of products. Based on tons produced and hours of operation the plant’s production rate was 18.6 tons/hr. resulting in a plant revenue of $72 million. Calculations were completed using the plant’s financial data, along with the 2005 production numbers to compute revenue, expense, and profit numbers per ton of product, as outlined in Table 1. Item Revenue Production Expenses Raw Material Labor Electrical Power Maintenance Other Profit
Annual / ton $72,000,000 $520 $28,700,000 $15,000,000 $8,210,000 $5,200,000 $8,900,000 $5,990,000
$207 $108 $59 $38 $64 $43
Table 1 Financial balance sheet showing revenue, production expenses, and profit for an industrial process plan t in the Northwest. Based on the product sold and production rate the production expenses and profits were determined on a per ton basis.
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Pumped System Improvements (continued) Now that we have the plant’s financial numbers, we can determine the value of the Pumped System Improvement Program. To accomplish this, we must first approximate the total cost to operate the pumped systems in the plant, then arrive at a realistic system saving estimate, and finally determine if the estimated savings are worth the effort to start the improvement program. Breaking out Power for Pumps Electricity is used for powering pumps, fans, compressors, and conveyors as well as lighting, heating, and drying operations. The first task is to determine the percentage of the plant’s total electrical power used for pumped systems. To determine this look at the plant's electrical distribution system. All plant electrical power goes through a system of switchgear and motor control centers. Plant designers calculated the capacity required for each plant load and sized the distribution system accordingly. The description and size of each electrical load in switchgear and motor control centers are listed in the plant’s design documents. One can easily review the list and identify the loads supplied to pump motors and compare that with the total plant electrical loads to arrive at the pump percentage. In the case study example the plant's total electrical capacity for all switchgear and motor control centers was 61,500 kW. The total capacity of all motors driving pumps was 15,400 kW. As a result, the design load for motors driving pumps is approximately 25% of the total plants electrical design loads. From this ratio, one can estimate that pumps consume 25% of the plant's total electrical power consumption, which correlates closely with information provided by the US Department of Energy. Using this ratio, the production cost attributed to electrical power to drive pump motors in this example can be broken out for the total, ($59 / ton x 25% for pumps) = $14.75 / ton for pumping power cost. Breaking Out the Pump Maintenance Cost With accurate maintenance records, one can extract the maintenance cost of the plant’s pumped systems. If pump maintenance costs are not readily available, an estimate needs to be developed. Since most mechanical equipment is supplied electrical power, one can assume the ratio of pump maintenance cost to the plant’s total maintenance cost is the same order of magnitude as the ratio of pump power consumption to total plant power consumption. Since 25% of the electrical energy consumed in the plant was used for the pumped system, assume that 25% of the total maintenance cost is for pumped systems as well. Using this estimate the maintenance costs associated with pumped systems can be approximated as ($38/ton x 25% for pumps) = $9.50 / ton for pump maintenance. Arriving at Realistic Goals Now that the operating and maintenance costs for pumped systems are isolated, establish realistic goals for the proposed Pumped System Improvement Program. These goals provide a starting point for estimating the value of implementing a system improvement program. The plant financial management team used this information to determine the risk vs. reward for proceeding with the program. When starting a Pumped System Improvement Program one can expect to reduce operating and maintenance costs while improving system uptime. Defining the Energy Saving Objectives One of the stated goals of the improvement program is a reduction of energy consumption. Knowing that pumped systems are typically oversized, establish an energy reduction goal before proceeding with the proposed improvement program. In the example, the energy savings goal was 30%. It is always best to under promise and over deliver than to not meet an excessively high goal. Defining the Maintenance Saving Objectives Another goal of establishing a Pumped System Improvement Program is a reduction in maintenance costs. Based on the direct relationship between power used and maintenance a 30% reduction goal in maintenance cost can be estimated as well. Once again, this serves as a starting point for establishing the program. (Continued on next page) ASME FWCS | February 2015 Newsletter | Page 3
Pumped System Improvements (continued) Improvements in System Uptime The last stated goal for a Pumped System Improvement Program is increasing system uptime. The improvement in plant uptime is a difficult number to estimate because of the interaction of the various plant systems. In this example, a 1% increase in system uptime was estimated. This increase in system uptime results in an additional 74 hours per year of making product. Once again when starting a program, it is a good idea to establish a realistic goal while striving to increase the value of the program over time. Calculating the Potential Saving With the goals of the improvement program stated and the pump operating and maintenance cost estimated, calculate the value of starting an improvement program. The cost savings attributed to the improvement program are: · Plant pump operating cost at $14.75 /ton of product produced and a 30% estimate in savings of energy usage resulting in savings of $4.40 in electrical power per ton of product. · Pump maintenance cost at $9.50/ton of product produced and a 30% reduction in maintenance cost resulting in savings of $2.85 per ton of product. Using the stated goals of the Pumped System Improvement Program, estimate the improvements in the plant's balance sheet. Item Sales of Product Production Expenses Raw Material Labor Electrical Power Maintenance Other Profit
Pre System Improvement Post System Improvement Per ton Per ton $520 $520 $207 $108 $59 $38 $64 $43
$207 $108 $55 $35 $64 $51
Table 2. The before and after financial b alance sheet showing the estimated value of starting a Pumped System Improvement Program based on the case study.
Implementing the improvement program should reduce the operating and maintenance costs by $8 / ton, which will go directly to the plants profit number. Based on the estimates, profit at the facility should increase from a measured value of $43 /ton to an estimated value of $51/ton after implementing the improvement program. Finally, implementing the improvement program should increase plant uptime by 1%. Using the new estimated profit per ton, see how the additional 1% in estimated system uptime affects the plants profitability as outlined below: Profit $/ton*Capacity tons/hr*Plant operation hrs/yr=Annual Profit $ /yr 51 $/ton*18.6 tons/hr*7514 hrs/year = 7.1 million $/yr With a 2005 plant profit of $6.0 million and an estimated profit of $7.1 million after establishing a Pumped System Improvement Program within this plant, one could expect to achieve an annual increase in profit of $1.1 million per year. - Originally written by Engineered Software Inc., edited to remove commercialization
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You are invited to the following event:
5th Annual STEM Professional Association Event Event to be held at the following time, date, and location:
Thursday, March 19, 2015 from 5:30 PM to 7:00 PM (EDT) Middleton High School 4801 North 22nd Street Tampa, FL 33610
Register Here
Middleton High School, a Pre-Collegiate STEM Academy, Stewart Middle Magnet School and Young Middle Magnet School would like to invite you to our 5th annual “STEM Professional Association Event”. This event is held on an annual basis to connect Tampa Bay area students, parents, educators and professionals in order to promote student interest in science, technology, engineering and math (STEM) careers. Our guest speaker is Dr. William Tyson, Principal Investigator, NSF PathTech and Associate Professor at the University of South Florida. Dr. Tyson will be speaking on the topic of "Successful Academic & Employment Pathways in Advanced Technologies".
A robotics demonstration will be conducted by Middleton High School robotics club students, winners of the 2012 World FTC Robotics Championship and 2013 & 2014 Florida State FTC Robotics Championships! Middleton's Electrathon Car, powered only by commercial rechargeable batteries, weighing no more than 73 pounds, designed and built by students, will be on display. Guests are encouraged to bring their family members to join us for this awesome Science, Technology, Engineering and Math event! We hope you can make it! Middleton High School "Land of the Tigers"
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Tampa Bay E-Week Banquet Keynote Speaker: Dr. Story Musgrave Story was an NASA astronaut for over 30 years and flew on six spaceflights. He performed the first shuttle spacewalk on Challenger's first flight, was a pilot on an astronomy mission, conducted two classified DOD missions, was the lead spacewalker on the Hubble Telescope repair mission and on his last flight, he operated an electronic chip manufacturing satellite on Columbia. Join us to what will surely be an entertaining and inspirational presentation from one of NASA's greatest astronauts. The Tampa Bay E-Week Banquet will be: Friday, February 27, 2015 4:30 – 6:30 PM Networking & Exhibition 7:00 - 9:00 PM Dinner Program & Awards At the: A La Carte Event Pavilion 4050 Dana Shores Dr. Tampa, FL 33634
Background This Engineers Week, the engineering societies of the Tampa Bay area have put together the fifth annual Tampa Bay Engineers Week Banquet on Friday, February 27, 2015, at the: A La Carte Event Pavilion (4050 Dana Shores drive, Tampa, Florida, 33634) This premier event brings together local leaders and engineering professionals to recognize the outstanding achievements of Engineers, Science Teachers, Math Teachers, and Students in our community. Additionally, awards will be presented to outstanding engineers in each discipline, as well as local engineering students excelling in their engineering related studies and Young Professionals. The banquet also features the Lignell Awards. These awards, named after a former Chairman for the Institute of Electrical and Electronics Engineers (IEEE), are given to local High School educators who are performing outstanding work in the instruction of the STEM topics (science, technology, engineering and math). The organizers of the event recognize the important role these individuals play in encouraging students to pursue technological degrees in college.
To purchase tickets please visit www.tbewb.org Call for volunteers for the Tampa Bay Engineers Week Banquet Outreach Project!
The banquet is a combination of efforts by all the Engineering Societies of West Central Florida. This event brings together professionals in all fields from all around Tampa and Florida’s west coast.
The Tampa Bay Engineers Week Banquet Outreach Committee is teaming with MOSI to present a program for students and their parents. We are looking for at least one volunteer from each society to volunteer to talk to students one-on-one about your profession and conduct a hands-on activity. For details follow the link here . - Information taken from www.tbewb.org
- Information taken from www.tbewb.org
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UPCOMING EVENTS Tampa Bay E-Week Banquet When: February 27, 2015 4:30 – 6:30 PM Networking & Exhibition 7:00 - 9:00 PM Dinner Program & Awards Where: A La Carte Event Pavilion 4050 Dana Shores Dr. Tampa, FL 33634 5th Annual STEM Professional Association Event When: March 19, 2015 at 5:30- 7:00 PM Where: Middleton High School 4801 North 22nd Street Tampa, FL 33610 ASME Present-A-Bull: Student Papers Night When: March 19, 2015 at 6:00 PM Where: Room TBD, University of South Florida 4202 East Fowler Avenue Tampa, FL 33620 Stay Tuned for Information and Dates Regarding the: General Body Meeting Future Events
Brain Teaser Word Ladder: Starting with the initial word, change one letter at a time to create a new word until the final word can be created. EXAMPLE: RoadRoarSoarStar
__ __ __ __
1.) BRUSH __ __ __ __ __ __ __ __ __ __ __ __ CLAPS
__ __ __ __
__ __ __ __
2.) TAKEN __ __ __ __ __ __ __ __ __ __ __ __ MILLS
__ __ __ __
Last Month’s: AdoreAdornAcornScornScoreStore FixedFiledFilesMilesMillsMalls
General Messages
Click any of the links to follow us on Linkedin, If you have career opportunities or events you would Facebook, or join our group on ASME.org. like to share/explore with us please contact the Newsletter Chair by email (
[email protected]). Job Posting If you can solve the brain teaser in fewer words than Stantec (Ybor Office) There are positions in the Urban Land Development team, allotted please email me your solution which would be mainly civil site work (
[email protected]). Thank you! (grading/paving/drainage). There are also positions in our Transportation group. If you know of any students still seeking employment, please have them send their resume to me at
[email protected].
ASME FWCS | February 2015 Newsletter | Page 7
“So much of what we call management consists of making it difficult for people to work.” - Peter Drucker, a Presidential Medal of Freedom recipient
FWCS-Officers and Committee Chairs Chair: Timothy Hunt PE
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Vice Chair, Secretary, and Social Media: Nyssa Masters
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Programs Chair: Mike Krawczyk PE
Treasurer: Matthew Montgomery
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Student Liaison: Paul Stevenson
Director: Billy Adkins
Director: Robert Andrew
Preceding Chair/Director: Stephen Elting
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Preceding Chair: Magdalena Krstanoski
Director: Pete Grotsky
Director: John Mulvihill
Webmaster: Dr. Autar Kaw
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Newsletter Chair: Christopher Martinez
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ASME FWCS | February 2015 Newsletter | Page 8
