slide1 n.
Download
Skip this Video
Loading SlideShow in 5 Seconds..
Efficient Grain Facility Design & Operation By: Gregg Davidson, Owner DAVIDSON GRAIN SOLUTIONS (DGS) PowerPoint Presentation
Download Presentation
Efficient Grain Facility Design & Operation By: Gregg Davidson, Owner DAVIDSON GRAIN SOLUTIONS (DGS)

Loading in 2 Seconds...

play fullscreen
1 / 28

Efficient Grain Facility Design & Operation By: Gregg Davidson, Owner DAVIDSON GRAIN SOLUTIONS (DGS) - PowerPoint PPT Presentation


  • 174 Views
  • Uploaded on

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). Davidson grain solutions ( dgs ).

loader
I am the owner, or an agent authorized to act on behalf of the owner, of the copyrighted work described.
capcha
Download Presentation

PowerPoint Slideshow about 'Efficient Grain Facility Design & Operation By: Gregg Davidson, Owner DAVIDSON GRAIN SOLUTIONS (DGS)' - donkor


An Image/Link below is provided (as is) to download presentation

Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author.While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server.


- - - - - - - - - - - - - - - - - - - - - - - - - - E N D - - - - - - - - - - - - - - - - - - - - - - - - - -
Presentation Transcript
slide1

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
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:

    • 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
The GOAL today…
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
6 steps to improve your facility
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
STEP 1 - Conceptual Design
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 2
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 3
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
Conceptual design – page 4
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
Step 2 – front end engineering design
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 2
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 3
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
Front end engineering design – page 4
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 3 – detailed design
step 4 construction

Construction safety

    • Excavations
    • Fall protection
    • Ladders and scaffolding
    • Crane lifts
    • Electrocution
    • Personal protective equipment
    • Other hazards specific to the project
Step 4 - construction
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 2
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)
Construction – page 3
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
Step 5 – start-up & warranty
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)
Start-up & warranty – page 2
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
Step 6 – Bucket elevator Legs
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 2
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
Bucket elevator legs – page 3
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
Step 6 – drag conveyors
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 conveyors – page 2
drag convey0rs page 3

Maintenance

    • Replace bearings, sprockets, and chain based on frequent inspection
      • Watch/listen for changes
Drag convey0rs – page 3
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
Step 6 – belt conveyers
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 conveyers – page 2
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
Belt convey0rs – page 3
questions comments

Thank you and Go Bison!

Questions? Comments?

Efficient Grain Facility Design & Operation

By: Gregg Davidson, Owner

DAVIDSON GRAIN SOLUTIONS (DGS)