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Efficient Grain Facility Design & Operation By: Gregg Davidson, Owner DAVIDSON GRAIN SOLUTIONS (DGS) PRESENTATION FOR North Dakota Grain Dealers Association.

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Presentation on theme: "Efficient Grain Facility Design & Operation By: Gregg Davidson, Owner DAVIDSON GRAIN SOLUTIONS (DGS) PRESENTATION FOR North Dakota Grain Dealers Association."— Presentation transcript:

1 Efficient Grain Facility Design & Operation By: Gregg Davidson, Owner DAVIDSON GRAIN SOLUTIONS (DGS) PRESENTATION FOR North Dakota Grain Dealers Association 101 st Annual Convention and Industry Show January 20-22, 2013 Fargo Holiday Inn 1

2 2 Troubleshooting Plant Engineering Master-Planning Construction Management Start-up & Training Maddock, ND ● Moorhead, MN ● Plymouth, MN

3  For me:  Offer up some new ideas and some proven reminders to:  Change/improve your existing facility successfully  Build a new addition or new facility  Operate your facility better and safer  Maintain your facility better and safer  For you:  Look for new ideas that you can incorporate back home  Reinforce old ideas that are proven  Think of a question or comment  Relax and enjoy the presentation followed by questions 3

4  Step 1 - Conceptual Design  Step 2 - Front End Engineering Design  Step 3 - Detailed Design  Step 4 - Construction  Step 5 - Start-Up & Warranty  Step 6- Safety Devices, Operation, & Maintenance  Bucket Elevator Legs  Drag Conveyors  Belt Conveyors 4

5  Process flow diagram (front gate thru exit gate)  Changes to existing flow or developing new flow  Crops handled and annual bushels per crop  Total annual bushels handled  Operating hours non-harvest and harvest  In-bound truck/rail weighing and sampling  Out-bound truck/rail weighing and sampling  Receiving system(s) truck/rail flow rate  Storage type and capacities  Grain temperature monitoring  Drying system flow rate/moisture reduction 5

6  In-house transfer flow rate  Rail load-out flow rate and allowed loading time w/0 penalty  Truck load out flow rate  Equipment by-pass/duplication options  Sanitation goals  Automation goals  Operator control room scheme  Special requirements for inspectors and required certifications  Other key business goals  Other key customer goals  Interference with existing operations  Future growth considerations  Cadillac or nice Chevrolet ($$$)  Potential concerns by neighbors and public 6

7  Site plan (outside front gate thru outside exit gate)  3D for aerial perspective  2D for details  Existing structures, roads, and landmarks  Off-site improvements (drainage, public roads, traffic flow)  Site grading and drainage  Utilities (electrical, gas, water, sewer, fire, communications) 7

8  Roads and parking (traffic flow, customers, employees, surfaces)  Emergency vehicle access  Structures  Railroad  Landscape areas  Low maintenance areas  Site security (lighting, gates & fence, guard shack, public locks)  Other key business and customer goals  Construction staging area  Interference with existing operations  Future growth considerations  Cadillac or nice Chevrolet ($$$)  Potential concerns by neighbors and public 8

9  Organizational chart  Show owners, designers, contractors, & subs  Show overall responsibilities for each  Show method of project delivery for each  Design – build  Design – bid - build  Consider shared document website for info sharing  Project schedule  Weather impact  Project budget  Weather impact 9

10  Permits  City  County  Watershed district  State  Federal  Railroad  Utilities (electrical, gas, water, sewer, fire, comm.)  Determine electrical classification for all areas 10

11  Land ownership  Clear title  Easements  Site survey report  Existing topography, buildings, roads, and landmarks  Geotechnical report  Locate multiple soil borings directly under key areas  Estimated total soil settlement  Estimated differential soil settlement  Estimated water table during construction & operation  Determine geotech’s ability to perform material testing 11

12  Operational safety  Explosion prevention and venting  Fall protection guarding  Running equipment guarding  Secondary egress  Others specific to the facility  Determine construction management needs  Evaluate internal skills, experience, and time available  Consider outside help for:  Conceptual and Front End Engineering Design  Bid package development  Over-sight of Construction, Start-Up, & Warranty 12

13  Civil package  Site plan  Railroad plan  Structures and machinery package  Process flow diagram  General arrangements  Concrete structural  Steel structural  Miscellaneous  Equipment list  Electrical package  Controls package 13

14  Construction safety  Excavations  Fall protection  Ladders and scaffolding  Crane lifts  Electrocution  Personal protective equipment  Other hazards specific to the project 14

15  Construction contract  Format (design-build, build only)  Project schedule  Responsibility for final engineering  Construction safety  Responsibility for material testing and review  Insurance and bonding  Retainage  Liquidated damages  Start-up  What triggers final payment?  Warranty 15

16  Owner mobilization  Pre-mobilization meeting (per organizational chart)  Construction staking  Temporary electrical service  Temporary water service (fire protection?)  Temporary communications  Contractor mobilization  Critical meetings and inspections  Daily, weekly, monthly  Progress photos  Final punch list (substantial completion) 16

17  Operator training materials  Hard copies & electronic version of manuals  Operator training  Start-up plan to SAFELY meet phased goals  Process equipment  Process safety devices and instrumentation  Dust collection balancing  Building-related devices and instrumentation  Engineered silo/bin loading plan 17

18  Final written acceptance by Owner  Contractor de-mobilization  As-built documentation  Hard copies & electronic version of as-built drawings & specs  Post-project de-briefing meeting  Problems and praises  Future maintenance and project needs  Potential reference and marketing testimony  Issue final payment  Warranty period (solve problems together) 18

19  Recommended safety devices  Speed monitor on boot shaft for alarm and shutdown  Belt alignment switch on each side of boot  Bearing temperature sensor on each side of boot  Belt alignment switch on each side of head  Bearing temperature sensor on each side of head  Plug switch at leg discharge  Guarding over all exposed shafts  Explosion panels 19

20  Operation  Install outside if possible  Maximum 650 feet per minute (fpm) belt speed = 7mph  Wear liner selection based on crops, bushels, & years  Spout feeding leg inlet plays huge role in filling cups  Height of leg inlet with respect to boot shaft is critical  Class II drive with backstop capable of starting leg under full load  Reduced voltage starter (soft start) capable of starting leg under full load 20

21  Maintenance  Replace head pulley lagging if belt will not track or crown (1/8” per foot from edge to center of pulley) is gone  Belt replacement guideline based on 1.5% stretch  Example: 100 ft tall leg = 200 ft belt x 1.5% = 3 ft = 1.5 ft take up  Replace bearings based on frequent inspection  Watch/listen for changes 21

22  Recommended safety devices  Speed monitor on tail shaft for alarm and shutdown  Slack/tight chain switch on tail  Plug switch at conveyor discharge  Guarding over all exposed shafts 22

23  Operation  150 to 180 feet per minute (fpm) chain speed = 2 mph  Wear liner selection based on crops, bushels, & years  Class II drive capable of starting drag under full load  Reduced voltage starter (soft start) capable of starting drag under full load 23

24  Maintenance  Replace bearings, sprockets, and chain based on frequent inspection  Watch/listen for changes 24

25  Recommended safety devices  Speed monitor on tail shaft for alarm and shutdown  Belt alignment switch on each side of tail  Bearing temperature sensor on each side of tail  Belt alignment switch on each side of head  Bearing temperature sensor on each side of head  Plug switch at conveyor discharge  Guarding over all exposed shafts 25

26  Operation  Maximum 700 feet per minute (fpm) belt speed = 7 mph  Wear liner selection based on crops, bushels, and years  Spout feeding the loader plays huge role in feeding belt  Class II drive capable of starting conveyor under full load  Reduced voltage starter (soft start) capable of starting conveyor under full load  Side wall inspection doors recommended 26

27  Maintenance  Inspect tail section often for grain re-loading  Replace head pulley lagging if belt will not track  Belt replacement guideline based on 1.5% stretch  Replace bearings based on frequent inspection  Watch/listen for changes 27

28  Thank you and Go Bison! Efficient Grain Facility Design & Operation By: Gregg Davidson, Owner DAVIDSON GRAIN SOLUTIONS (DGS) 28


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