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

Davidson grain solutions (dgs) Troubleshooting Plant Engineering Master-Planning Construction Management Start-up & Training Maddock, ND ● Moorhead, MN ● Plymouth, MN

The GOAL today… For me: For you: 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

6 steps to improve your facility 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

STEP 1 - Conceptual Design 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

Conceptual design – page 2 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

Conceptual Design – Page 3 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)

Conceptual design – page 4 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

Step 2 – front end engineering design 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

Front end engineering design – page 2 Permits City County Watershed district State Federal Railroad Utilities (electrical, gas, water, sewer, fire, comm.) Determine electrical classification for all areas

Front end engineering design – page 3 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

Front end engineering design – page 4 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

Step 3 – detailed design 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

Step 4 - construction Construction safety Excavations Fall protection Ladders and scaffolding Crane lifts Electrocution Personal protective equipment Other hazards specific to the project

Construction – page 2 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

Construction – page 3 Owner mobilization Contractor 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)

Step 5 – start-up & warranty 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

Start-up & warranty – page 2 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)

Step 6 – Bucket elevator Legs 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

Bucket elevator legs – page 2 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

Bucket elevator legs – page 3 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

Step 6 – drag conveyors 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

Drag conveyors – page 2 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

Drag convey0rs – page 3 Maintenance Replace bearings, sprockets, and chain based on frequent inspection Watch/listen for changes

Step 6 – belt conveyers 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

Belt conveyers – page 2 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

Belt convey0rs – page 3 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

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