Gregg Davidson - North Dakota Grain Dealers Association

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PRESENTATION

FOR

North Dakota

Grain Dealers Association

101 st 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)

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DAVIDSON GRAIN SOLUTIONS (DGS)

• Troubleshooting

• Plant Engineering

• Master-Planning

• Construction Management

• Start-up & Training

Maddock, ND ● Moorhead, MN ● Plymouth, MN

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THE GOAL TODAY…

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

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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

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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

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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

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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)

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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

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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

Weather impact

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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

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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

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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 12

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

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STEP 4 - CONSTRUCTION

Construction safety

Excavations

Fall protection

Ladders and scaffolding

Crane lifts

Electrocution

Personal protective equipment

Other hazards specific to the project

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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

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CONSTRUCTION – PAGE 3

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)

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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

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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)

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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

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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

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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

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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

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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

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DRAG CONVEY0RS – PAGE 3

Maintenance

Replace bearings, sprockets, and chain based on frequent inspection

Watch/listen for changes

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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

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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

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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

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QUESTIONS? COMMENTS?

Thank you and Go Bison!

Efficient Grain Facility Design & Operation

By: Gregg Davidson, Owner

DAVIDSON GRAIN SOLUTIONS (DGS)

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