Gregg Davidson - North Dakota Grain Dealers Association

Report
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)
1
DAVIDSON GRAIN SOLUTIONS (DGS)
•
•
•
•
•
Troubleshooting
Plant Engineering
Master-Planning
Construction Management
Start-up & Training
Maddock, ND ● Moorhead, MN ● Plymouth, MN
2
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

4
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
5
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


Project schedule


Consider shared document website for info sharing
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
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STEP 3 – DETAILED DESIGN

Civil package



Structures and machinery package








Site plan
Railroad plan
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:
 Replace
100 ft tall leg = 200 ft belt x 1.5% = 3 ft = 1.5 ft take up
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)
28

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