Grain Loadout

With an increase in industry regulation, international import restrictions, and the need to maximize facility efficiency, companies in the grain load-out sector are focused more than ever on the reliability and flexibility of their process control systems.

The Solution

NovaTech’s grain export solutions power many of the largest and most complex load-out facilities in the world, helping customers routinely deliver grain across the globe. By helping customers avoid data integrity issues, unnecessary downtime and costs due to rework, unexpected system outages, and slow recovery from equipment failure, the NovaTech grain export load-out solution–based on the NovaTech D/3® Distributed Control System (DCS)–provides a reliable, scalable, and fully redundant automation platform required for an operation of this magnitude.

The ability to deliver grain from source to destination in a safe and efficient manner is only half of the story of the NovaTech Grain Export Load-out System. Proper tracking, logging and reporting of material transfers is as critical as the grain transfer itself. The NovaTech system features redundant data collectors and reporting services to ensure data integrity even in the event of a server failure. All operator activity, equipment allocations, equipment failures, re-works, blends and transfers are tracked. Order and scheduling data is received from the corporate ERP system and “actual” data is automatically transferred to corporate QA and regulatory inspection systems, such as FGIS. Since the system is fully integrated, record keeping, data integrity, reporting and tracking are optimized.

NovaTech develops grain export load-out systems utilizing modern visualization, programming, sequencing, alarming, and interlocking techniques. Operators access hierarchical visualizations featuring plant overviews, path flow, and specific equipment graphics. Additionally operators can easily access and manage reports, logs, and alarms from the intuitive operator interface. Upgrading customers can choose to mitigate risk and reduce expense by developing visualization screens and custom graphics that mimic their existing systems, resulting in faster start-ups and virtually no operator training required at cut-over.

The NovaTech system employs sophisticated interlocking and sequencing techniques to ensure the proper flow of grain from source to destination. Whether unloading barges or filling ships, the NovaTech system is constantly monitoring the state of all equipment to ensure flow path integrity. Furthermore, the NovaTech system facilitates sophisticated blending, weigh-back, and quality monitoring systems.

Most regulatory compliance systems are designed to constantly monitor the grain flow, sampling, and weighing systems. Additionally the system must provide the necessary safeguards and hard copy documentation required to operate the official weighing system without 100% physical supervision of the bulk weigh scales and grain flow system. NovaTech’s U.S. installations fully integrate the U.S. FGIS with customer systems. This approach significantly reduces errors, reworks and delays due to discrepancies between the regulatory and customer system. NovaTech has the capability to integrate with any other regulatory compliance system.

Related Processes and Experience

Dust Collection, Barge Receiving, Railcar Receiving, Grain Storage & Inventory Management, Grain Flow & Grain Path Integrity, Grain Flow Monitoring, Blending, Weighing, Rework/Weigh-Back, Ship Loading, Railcar Load-Out, Truck Load-Out, Security Gate Weigh Stations

Related Solutions

Distributed Process Control, Operator Training Simulators, Recipe-Driven State Based Control, S88 Batch Management & Control, S106 Procedural Automation & Control, Electronic Batch Reporting, ISA 18.2 Alarm Management, Data Historian, Trend Visualization, Process Analytics, Process Simulation, Asset Management, Control Loop Performance Monitoring & Optimization, Energy & Asset Management, Overall Equipment Effectiveness (OEE) Analytics, Regulatory Compliance & Validation, System Hardware & Custom I/O Cabinet Design, Product Lifecycle Services

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