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Efficient Grain Facility Design & OperationBy: Gregg Davidson, Owner

DAVIDSON GRAIN SOLUTIONS (DGS)

PRESENTATION FOR

North DakotaGrain Dealers Association

101st Annual Convention and Industry ShowJanuary 20-22, 2013

Fargo Holiday Inn

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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

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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 & OperationBy: Gregg Davidson, Owner

DAVIDSON GRAIN SOLUTIONS (DGS)