Green field oil seed processing facility

Integrated project delivery profile

02/18/2013


Project Team

Electrical Engineering, Instrumentation Engineering, Electrical Construction and Installation: Interstates Companies, Sioux Center, Iowa

Process Design and Mechanical Engineering: Karges-Faulconbridge Inc., St. Paul, Minn.

Construction Management: McGough, St. Paul, Minn.


Integrated project delivery (IPD) and collaboration brought a team of companies together to design and build a green field oil seed processing facility located in the upper Midwest. The facility, with capacity to process 1,000 tons of seed per day, produces food-grade oil. Along with the processing, the facility has capacity to store 830,000 bushels of grain. The site covers 390 acres including the grains receiving, preparation, extraction, refinery, and utilities areas.

To leverage market demand for its finished product, the owner had to commit to local growers that the facility would receive grain at the next harvest. The approaching winter season created additional pressure to begin construction of the foundation and underground electrical system. These factors required that the teams collaborate early to make design decisions and proceed with construction without a fully finished design.

Reflecting on what the team did to ensure the IPD method was successful for this project, Jim Faulconbridge, PE, president of Karges-Faulconbridge Inc., said, “The team stayed focused on the critical path schedule, making sure that the decisions were made in the right order. Also, the willingness to develop design ‘workarounds’ in the absence of complete information was key.”

For a team to successfully execute IPD methods, they must work toward key areas of early budgeting, scheduling, and a strong start-up. Early dependable pricing gives the client, and those financing it, the confidence to continue with a project. Early collaboration lends itself to significant schedule advantages. When team members are collaborating and providing just-in-time design, clients are able to respond to market conditions. In this case, the client and team were focused on completing the grains receiving area by the next harvest.

“To say that every single aspect of the project was smooth sailing due to integrated project delivery would be a stretch,” said Doug Post, PE, president of Interstates Engineering. “However, early agreement to proceed with construction when design was not 100% complete enabled the project to move forward according to the owner’s priorities.”

Start-up is the moment of truth for a project. When the team has worked well together in design and delivery of the project, the owner can feel confident as start-up approaches. “A strong start-up is important,” said Post. “It’s the most recent impression on the owner’s mind when all is said and done.”  

Ultimately, success circles back to the budget. The end result of IPD should be that the project finishes within budget and meets the owner’s business needs.

IPD methods allow team members to work together with the owner to provide value that includes not only the initial construction cost of a facility, but also the long-term cost of ownership. “If the design is calling for 16 valves that need regular maintenance to be situated in locations that can’t be accessed safely and easily, the owner will be reminded of this design decision forever,” said Post. “With early design collaboration, team members have input from many perspectives and can suggest value opportunities. While it may require more piping for the initial installation, the value of future ease of maintenance gained by repositioning those 16 valves to be grounded close to the floor clearly outweighs the added expense.”

 “Early specialty contractor involvement is only as good as the early detailed breakdown of costs and schedule they provide,” said Faulconbridge. “In this case, the team was better able to understand the impacts of proposed P&ID changes as design developed, and manage budget and schedule accordingly. This had the effect of protecting contingencies.”

IPD must capture the value of collaboration. The system must reward collaboration, and the designers must be incented to seek outside perspective on the constructability of the design. To successfully execute IPD, specialty contractors must be encouraged to suggest design alternatives. This project is an example of how early collaboration facilitates better decision making and value for the owner.



No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
Each year, a panel of Control Engineering editors and industry expert judges select the System Integrator of the Year Award winners.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Learn how to create value with re-use; gain productivity with lean automation and connectivity, and optimize panel design and construction.
Go deep: Automation tackles offshore oil challenges; Ethernet advice; Wireless robotics; Product exclusives; Digital edition exclusives
Lost in the gray scale? How to get effective HMIs; Best practices: Integrate old and new wireless systems; Smart software, networks; Service provider certifications
Fixing PID: Part 2: Tweaking controller strategy; Machine safety networks; Salary survey and career advice; Smart I/O architecture; Product exclusives
The Ask Control Engineering blog covers all aspects of automation, including motors, drives, sensors, motion control, machine control, and embedded systems.
Look at the basics of industrial wireless technologies, wireless concepts, wireless standards, and wireless best practices with Daniel E. Capano of Diversified Technical Services Inc.
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
This is a blog from the trenches – written by engineers who are implementing and upgrading control systems every day across every industry.
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Control Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.