In any strong family structure, each member of the family has a unique and important role to play. These different roles typically complement and assist each other, and when they all work together something very special usually happens.

That’s exactly what takes place with the Global Industries Grain Pump® conveyor family from Hutchinson. The Grain Pump® conveyors can be used in many different ways, and operations can vary

significantly from installation to installation…just like members of a family.

The Hutchinson Grain Pump® systems were the first of their kind in the industry, and have served grain market customers around the world for many years. But Global Industries understands the best way to maintain leadership in any industry is through ongoing relationships and close interaction with customers. As a result, they continue to work as a team with customers to not only improve existing grain handling products… but in the development of new and innovative systems to meet ever-changing market and customer needs.

Like all Global Industries’ divisions, Hutchinson’s customer communications is a two-way improvement process. New systems are first demonstrated and explained to customers. In response, customers provide Global Industries with valuable feedback and changes they think could make the systems better, more cost-effective and easy to operate and maintain. Many of those comments are then incorporated into the systems’ final design.

Usually, new facilities require Hutchinson to design new members of the Grain Pump® Loop system or the Grain Pump® Double Run family. But before these new systems are ever released, they must first be thoroughly tested and evaluated by Hutchinson engineers at Global Industries’ state-of-the-art Research & Development Center in Grand Island, NE-USA.

A good example of this collaborative process is the facility developed in conjunction with AAFSA (Agro Acopio Fertil SA) in Durazno, Uruguay.

Originally, AAFSA planned the construction of a 1.1-million-bushel (30,000-tonne) storage facility using conventional handling

equipment, including 23 conveyors and eight bucket elevators. This design would have required the construction of concrete unload tunnels below the silos, as well as connecting tunnels and metallic catwalks to support the loading and connecting conveyors.

To reduce the overall cost of this project while enhancing productivity, Global Industries and AAFSA worked together to develop an alternative project based on the use of the Hutchinson Grain Pump Loop and Grain Pump Double Run Systems. This project design reduced the handling equipment needed to just four 10-inch Grain Pump Loops and five 10-inch Stationary Grain Pump Double Runs (each with 150-MTh capacity).

As a result, AAFSA did not need to construct concrete tunnels or install metallic catwalks as originally planned for this facility, which is primarily used to clean, dry and store maize (corn), wheat, barley, sorghum and soybeans.

The total cost of the storage and handling equipment was $1.2 million. The plant, which has been in operation since March 2008, includes 10 MFS Model S60-16 silos with a unit capacity of 3,025 tonnes. The full perforated floor aeration systems include 30-HP NECO centrifugal fans and 2-HP NECO roof exhausters. Each silo includes a Hutchinson Series 1012 Sweep Auger with a 95-MTh capacity. Both cross Grain Pump Loops were designed to allow for expansion with additional rows of silos or flat storage buildings.

Later, a second construction phase including another 5 MFS Model S60-17 flat bottom silos, one longitudinal Grain Pump Loop and a second grain dryer. This was accomplished with a minimal investment by AAFSA, and increased the overall storage capacity to nearly 45,000 tonnes.

Since the facility launch, AAFSA has been extremely pleased with its operating flexibility, simplicity of use and easy automation.

Another example of the effectiveness of close customer interactions was the addition of a Grain Pump Double Run system to load an existing flat storage building at the MYRIN facility in Nueva Palmira, Uruguay.

The MYRIN building is 50 meters wide and 100 meters long, and not originally designed to support the load of any conveyor. Global Industries, together with the MYRIN management team, developed a system to load the existing flat storage building using a 12-inch Grain Pump Double Run with a 200-MTh capacity. This system includes all galvanized Eclipse catwalk, specially designed by Sentinel Building Systems, another division of Global

The pioneering Hutchinson Grain Pump® systemsGrain Pumps have proven to be excellent long life systems. The largest members in the Global Industries’ Grain Pump® family are the Grain Pump® Loop and Double Run Systems, which are designed and manufactured by Hutchinson, a Division of Global Industries, Inc., located in Clay Center, KS-USA

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84 | April 2016 - Milling and Grain

Recommendations when planning a new Grain Pump System for your facility1. Is there room for a row of silos plus the possibility of expansion?

Consider your operating plan, location of controls, power distribution, driveway, and turn around areas.

2. If planning a flat storage building, assure the building is capable of supporting the Full load of the Grain Pump System, grain, and catwalk (this load is in addition to your regional roof load).

3. Can spouts be run to an adjoining storage area if desired?4. If there is a dryer involved, consider separate conveyors from the

wet holding to the dryer and from the dryer to storage. This enables the Grain Pump to be always free for grain from the field and keeps the low capacity, long continuous hours of use on less expensive conveyors.

5. Consider two drive-over dump receiving hoppers for grain pump systems that will have many trucks or wagons dumping grain. This will result in more continuous operation which can almost double capacity.

6. If larger/wider drive-over pits are desired consider the following:a. The wider the inlet is for the drive-over pits, the deeper or taller

it will need to be to maintain angle of flow in the hopper. The options are to lower the tube or raise the driveway.

b. To lower the tubes, spouts will have to be added to the inlets for the intermediate wells, and the loop will have either a deeper trench or higher elevated silos.

c. If the drive is raised, carefully consider the ramp grade, load design, side personnel access, safety rails, and overhead clearance.

7. A grain pump loop must have a climbable tower at each end and access to every overhead drop. Catwalk can be considered for the full length, but it is generally not necessary if every silo has a ladder extending to the overhead drop area. When catwalk is not used full length, some catwalk may be needed to reach the drop over the driveway.

8. Every component of a grain pump loop system should end up located above grade to avoid water issues that can rust the conveyors’ housing and chain. If located below ground level in a trench or pit, adequate drainage to daylight or sump pump is required. Assure landscaping diverts drainage away from pit; covers should be used over any open areas to shed water.

9. When choosing a system size, consider capacity required now as well as into the future. These units will handle a lot of grain before major part’s replacement is necessary. The loop is modular, as length can be added in the future up to the maximum designed length for the particular system.

10. Plan for enough space between silo foundations to allow space for silo well controls (this is outside space between silos). Concrete foundations, trenches and floors need to have maintenance access and clearances considered in the design layout. Refer to the equipment/component specifications to plan adequate space and clearances.

11. If concrete is placed before the system arrives, the corner support pads should be lower than the bottom of the horizontal tubular housing; there are support feet on the bottom corners (refer to the equipment specifications). Again, if concrete trenches or pits are utilized, assure maintenance access is adequate.

12. Make sure there is suitable electrical power available. Single phase power may be used if HP requirements allow.

13. Make sure amp meters are used so motor loads can be observed by the operator. Soft start electrical motor starters are recommended.

14. Chain inspection ports are recommended. Utilize one inspection port between the drive-over pit and the first loop corner to monitor physical tube fill. Utilize ports after each silo if possible. Ports are for horizontal tubes only.

15. Chain access section kits are available for use on the horizontal tubes only.

Industries, Inc. that is used with both the Grain Pump Loops and the Grain Pump Double Runs

Grain Pump Loops are designed to move grain in one direction only and in a direction that does not allow grain to flow through the take-up corner. Electric drive corners are located on the top of the grain pump loop. If your system only requires one drive corner, it needs to be positioned above the take-up corner. The conveyor will handle a wide range of free flowing grain. It should not be used with highly corrosive material, such as fertilizers.

Grain Pump Loop Systems are usually installed around rows of storage structures or flat storage buildings, with access for vehicle or rail traffic. Grain silos may be conventional or elevated on a supporting structure with hopper bottoms. It is necessary to evaluate what other equipment may need access to the conveyor system, such as grain dryers or grain cleaners. Systems have been used to transfer between trucks and rail cars with several temporary storage silos included. A layout should be made to determine the exact location of conveyors, inlets, outlets, power sources, supports and mounting locations.

In order to select the right Grain Pump Conveyor System for your application, it is important to analyze the following:• Determine the adequate volume flow rate to support the intended

input and output. The systems are rated in Bushel per Hour/ Tons per hour capacity.

• Calculate the expected annual operating hour’s usage: Total Storage Volume x Storage Turns ÷ Rated Capacity of Loop.

• Consider the material to convey, and its abrasive characteristics as this may be the determining factor for Usage Classification:

Standard FarmStandard Farm with upgrades: (Standard Farm model with tubing thickness upgrades)

CommercialCommercial with upgrades (12” and 16” loops)Tubing thickness upgrade on 12”The 16” is standard with highest classification

Usage classifications are a suggestion only, and even though an application may only call for a standard duty Grain Pump based on the hours of operation, it may be desirable to use a Commercial Grain Pump for other reasons.

www.globalindinc.com

Operating Hours Chart - for considering the Grain Pump System Model

Usage Classification* Annual Operating Hours

Standard Farm 0 - 250

Standard Farm with upgrades 250- 500

Commercial 500 - 750

Commercial with upgrades 750 and greater

* Classification is dependent on operating conditions and practices

Milling and Grain - April 2016 | 85

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