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EAD: Controls, Constructors, Engineering3635 S. 149th STREET | OMAHA, NEBRASKA 68144

PHONE: 402.884.8650 | WWW.EADCORPORATE.COM

EAD Catalog of Services

EAD Catalog of Services 2

TABLE OF CONTENTS

Chapter 1: Who We Are ................................................................................................................................. 3

Chapter 2: Our Capabilities ........................................................................................................................... 6

Chapter 3: Our Experience .......................................................................................................................... 14

Chapter 4: Our People................................................................................................................................. 52


WHO WE ARE

EAD was founded in early 2001 as an engineering firm. Over the years, we have recognized and responded to our clients’ needs by diversifying our services into automation and project management. Our steady growth is attributed to our dedication to find solutions that deliver value to our clients. Our projects are recognized for their quality, timeliness and commitment to success.Headquartered in Omaha, Nebraska, EAD has satellite offices around the U.S. Our professionals are sought-after solution providers who have recent, international project experience in South America, Italy, Brazil, and even Antarctica. Because we have worked with dozens of clients on hundreds of systems during the past 15 years, EAD has the experience to manage projects of all sizes and complexities to successful completion. From document control to working with construction trades, our experienced professional staff will ensure that your project is properly handled and is delivered on time and in budget.

General Information

EAD Mission Statement EAD is an experienced and proven provider of Program and Project Management. We Design, Engineer, Au-tomate and Construct innovative and sustainable solutions in an environmentally sound and safe manner. We create World-Class Experiences for our Clients.

EAD Core Values At EAD, A Trooper...

...will never quit. | ...is open to change. | ...is willing to step-up.

...has a desire to win. | ...is someone you can trust. | ...motivates you to be better.

...keeps their composure under fire. | ...is loyal to the company, the people and the cause.


EAD Footprint with Satellite Office Locations

WHO WE ARE

554 S. Yosemite AvenueOakdale, CA 85361


WHO WE ARE

EAD Safety Policy: It is the policy of EAD to ensure that all aspects of our operation are executed in the safest manner possible. EAD holds the health and safety of our employees and those exposed to our operations as a core value. We believe that all accidents are preventable and we will continually work towards establishing and maintaining an accident free and healthful workplace.

We are committed to excellence in implementing safety, health, and environmental standards that not only meet, but also exceed those set forth in Federal, State and Local regulations. By doing so, we ultimately protect our employees, clients, contractors, and communities.

We believe that accident prevention is a constant shared responsibility. EAD Management will provide the resources and leadership required for creating a work environment free of recognized hazards. EAD Management will also supply the equipment and training necessary to give employees the knowledge and tools they need to do their jobs in a safe and efficient manner. All employees are responsible for following safe work practices as outlined by EAD and the standards set forth in regulation. In addition, employees are expected to report hazardous conditions or unsafe acts to EAD Management immediately upon being identified.

By staying true to our values, and maintaining a strong personal commitment to each other and our clients, we can achieve our goal of an accident free workplace.

EAD Awarded One of Nebraska's Safest Companies: Our absolute commitment to a safe work environment and to projects that diligently follow safe protocols is central to EAD’s brand promise regarding project delivery. We have developed comprehensive and in-depth safety policies, systems and programs designed to engage the entire workforce in the delivery of safe work on all our projects. These efforts were recognized when EAD was named as one of Nebraska’s safest companies by the National Safety Council for the third consecutive year.

Total Frequency Injury Rate (TFIR):

Our TFIR for the last three years is as follows:

It is a metric calculated off of total man-hours worked by employees over the course of a year. A "1" would mean that was one injury for every 100 full time employees for the year.

2016 - 0.02015 - 0.02014 - 0.0


OUR CAPABILITIES

Program & Project Management

EAD employs the methods of the Project Management Institute (PMI), the worldwide standard for project management, as the foundation for execution of all projects. Areas of focus include:

• Scope Development & Management• Schedule Development & Tracking• Cost Management & Reporting• Quality Assurance/Quality Control• Human Resource Management• Document Management• Communications• Risk Management • Procurement• Stakeholder Management• Integration

A plan is created for each of these areas, and then the individual plans are combined to create the Project Execution Plan for the program or project. At EAD, we have developed over 300 standard procedures to help ensure we execute each and every project wisely. Following are examples of services we have provided for our clients:

• Project Risk Management• Project Due Diligence • Change Order Resolution • Constructability Reviews• Program Management (Owner's Rep)• Dispute Avoidance / Resolution• Project Management (Owner's Rep)• PM Training

Our employees have experience sitting on both sides of the table. Whether you need someone to manage a simple project or an entire program, we have the resources that can support your needs.


OUR CAPABILITIES

Engineering

EAD’s engineering and design team is capable of providing complete engineering services for your projects. We employ the latest technology to assist our engineers in preparing quality design packages that meet our Client’s needs. EAD maintains in-house expertise in the following disciplines:• Civil Engineering• Structural Engineering • Process Engineering• Mechanical Engineering• Electrical Engineering• Environmental Engineering• Industrial Engineering

Our engineers get the added benefit of field experience so they fully understand the needs of the craftspeople in the field. This helps us convey the design-intent. Following are examples of the services we have provided to our clients.

• Facility Planning

• Front End Loading (FEL) Engineering

• Process Engineering – Asset Utilization & Optimization – Debottlenecking – Plant Expansions – Process Analysis / Process Studies – Process Design & Development – Feasibility Studies – Process Modeling – Recipe Management – Waste Reduction – Material & Energy Balance – Process Narritave

• Civil Engineering – Site Planning – Site Design – Wetlands Delineation / Mitigation – Stormwater Mitigation – SWPP Inspections – Paving & Geometrics – Underground Utilities – NPDES Permitting

• Electrical Engineering – Asset Evaluation – Power Monitoring – Power System Analysis – Short Circuit Analysis – Arc Flash Analysis – Load Side Coordination Studies – Capacity & Utilization Surveys – Power Factor Analysis & Correction – Power Distribution Design – Grounding & Lightning Protection Design – Lighting Design – Equipment Specifications

• Structural Engineering – Footing & Foundation Design – Structural Steel Design – Vibration Analysis – Seismic & Wind Analysis – Forensic Analysis – Critical Lift Plan Development & Review – Structural Detailing

• Mechanical Engineering – Equipment Layouts / General Arrangements – Plumbing Design & Drawings – HVAC Design & Drawings – Process Sheetmetal Design – Equipment Specifications – Piping Design & Drawings – Equipment Setting Plans, Elevations & Details – Tank & Pressure Vessel Design – Energy Studies & Audits – 3D Modeling / BIM • Industrial Engineering – Time Studies – Process Modeling – Waste Reduction – Debottlenecking – Asset Utilization & Optimization – Manufacturing Studies

• Environmental – Air Permitting – Air Modeling


OUR CAPABILITIES

Automation

We specialize in custom control panels, control systems integration, technical services and support. Highly trained automation professionals with years of hands-on experience with today’s popular DCS, BMS and PLC systems in both process and machine control are at your disposal.

• PLC, DCS and BMS• Calibration Procedure Editing/Development• Instrument Specification• Process Documentation CFR21 Part 11• IQ/OQ and PQ Implementation• Validation Protocol Development• cGMP Audits• System Obsolescence Migration• Open Architecture Development• Computer Validation

Our automation engineers have experience across a broad array of platforms. As an open shop, we are not locked into a single platform and can offer our clients the best solution that fits their long-term needs. Following are examples of services we have provided to clients:

• Industrial Specifications • Control Panel Design• Network Architecture Design• Phone & Data System Design• Motor Control Loops• Instrument Control Loops• Control Wiring Design• HMI Programming• PLC Programming• DCS Programming• 24 Hour Service & Support


OUR CAPABILITIES

Construction Management

Construction Management isn’t just about the work in the field. Proper planning and preparation can increase the efficiency of the craftsmen in the field. EAD has the expertise to help ensure your project is completed on-time and on-budget.

• Scheduling• Estimating • Procurement and Expediting• Inspections and Testing• Field Engineering• Permits and Approvals• Contractor Pre-Qualification• Safety Programs and Audits• Earned Asset Management• Construction Supervision• Document Management• Temporary Facilities

Our construction managers understand the importance of communication and coordination on a project. They understand how important your production is to your business, and they work to ensure our construction schedule will minimally impact your business. Following are examples of services we have provided to clients:

• Pre-Construction – Develop Contracting Strategies – Constructability Reviews – Value Engineering Assessments – Temporary Protection Planning – Site Logistics Planning – Schedule Development – Pre-Qualifications – Manage Bid Process – Contractor Training – Risk Assessments – Permitting & AHJ Planning – Estimating – Temporary Facility Planning

• Construction – Schedule Maintenance – Earned Asset Management – Equipment, Material & Contractor Procurement – Plant Coordination – Construction Coordination – Construction Safety – Budget Tracking & Management – Change Order Tracking & Management – Expediting – Inspections & Testing – Project Controls & Communication – Document Management

• Post Construction – Start-Up & Commissioning – Validation – Punchlist – Warranty Support – Close Out Documentation – Asset Set-Ups


OUR CAPABILITIES

Safety Services

Process Safety• Combustible Dust Explosion Protection• OSHA Process Safety Management (PSM)• Process Hazard Analysis (PHA)• Management of Change Reviews (MOC)• Material and Chemical Compatibility Reviews• Machine Guarding Consultation and Design• Electrical Safety Consultation and Design• Arc Flash Study and Assessment

Site Inspection and Project Safety• Construction Project Safety Management and Inspections• General Industry Safety Management and Inspections

Food Safety• Food Processing Safety Inspections and Assessments• Industrial Hygienic Services• FSMA PCQI Training

General Safety • Safety Program Development• Safety Audits & Inspections• OSHA Mitigation & Support• HAZCOM Program Development• Machine Guarding Audits / Risk Assessments• Machine Guarding Design• Safety Observations - Construction • Safety Observations - General Industry


OUR CAPABILITIES

Training

• OSHA (General) 10 and 30-Hour • OSHA (Construction) 10 and 30-Hour• Red Cross First Aid and CPR/AED• Fall Protection• Scaffolding• ARC Flash• Lock Out/Tag Out• Confined Space Management• Program Design and Management• Hazcom/GHS Program Consulting and Training• Safety Management for the Job Site and Company• Workplace Violence Prevention


OUR CAPABILITIES

Fabrication

Our Panel Factory is equipped to design, assemble and test hazardous and non-hazardous UL-Listed control panels. We design panels to meet your needs, whether it’s for new processes, maintenance or future expansion.

• Standard Three-Year Warranty• Rigorous QA/QC Program• 100% Energized Testing before shipment• UL and cUL capabilities for 508A and 698A/B• 48 hour turn-around on all quotations• Emergency Service and Support• Service and Maintenance Contracts• Junction Boxes/Marshalling Panels• Hazardous Location Panels• Motor Control Centers• Remote I/O Panels• Ready-To-Ship Panels• Operator Stations• HMI Stations• PLC Panels• Private Labeling• OEM Builds• AC/DC Drive Panels

In conjunction with our Engineering, Automation and Panel Fabrication capabilities, we have partnered with a local fabricator to be able to Custom Fabricate Equipment Skids that meet sanitary design standards.

• Full 3-D modeling of the skids and equipment• Total turn-key solutions• Complete sanitary design, testing and validation• Stand-alone or fully integrated into existing processes


OUR CAPABILITIES

Project Delivery Methods

Because of the diversity and experience of our team, EAD is able to execute construction projects under a variety of different approaches.

• Professional Services (A-La-Carte) — Program and Project Management — Engineering — Construction Management — Automation — Safety Services — Training• Design-Bid-Build• Design-Build• Construction Manager at Risk


BD

Nestled in the plains of South-Central Nebraska, BD Holdrege manufactures products that help 371 million diabetics worldwide.

The 350,000-square-foot facility makes insulin syringes, safety-engineered syringes and alcohol swabs. The plant manufactures 2 billion syringes per year, which totals about two-thirds of the world’s plastic diabetes syringe supply.

BD named EAD the General Contractor for one of the facility’s older additions. EAD removed dated air-handling units and installed new ones that ranged from 10,000 CFM to 20,000 CFM on structural platforms outside of the building footprint to reduce roof loads to the 37-year old structure below. EAD then removed the 32,000-square-foot roof and replaced it with a new EPDM roof system. EAD also installed a new DI Water system and humidifiers to allow BD’s manufacturing equipment to operate more efficiently.

EAD began the project by identifying portions of the construction that could be modified or eliminated, saving BD over $112,000. EAD also realized initial structural design lacked enough information relating to existing underground utilities. EAD helped identify interferences with a civil engineering assessment and provided information to the structural engineer for redesign. While this endeavor cost time, it saved more than $270,000 in structural steel fabrication.

Whether it was working within the manufacturing space or working outside, coordination was crucial in ensuring construction did not interfere with or affect plant production.

Roof Replacement - Phase I

PROFILE

Client: BDLocation: Holdrege, NEMarket Served: Pharmaceutical

SERVICES

• Project Management• Construction

Management• Engineering

OUR EXPERIENCE


BD

As part of the BD Diagnostics – Preanalytical Division, BD’s facility in Broken Bow, Nebraska manufactures the products needed to help diagnose a broad range of diseases quickly and accurately: blood collection tubes, urine collection products and anaerobic specimen collectors.

EAD replaced BD Broken Bow’s office-area HVAC system with a brand-new one.

Previously, the old split HVAC system wasn’t large enough to supply air via the existing ductwork, so EAD demolished it and replaced it with a 7.5-ton rooftop unit that fed into the existing ductwork and diffusers. EAD demolished the old suspended ceilings and put in new tile and grid, as well as provided the controls for the new unit and tied it back into the rooftop control unit so it could be programmed.

Because the three-week project occurred in an office environment, EAD’s team began work at 4 p.m. and finished at midnight.

The team also coordinated the work to occur during a summer holiday shutdown so as to avoid any interruptions to BD’s operations.

Engineering Office HVAC Replacement

PROFILE

Client: BDLocation: Broken Bow, NEMarket Served: Pharmaceutical

SERVICES




BD

Thanks to EAD, BD Broken Bow, which produces preanalytical diagnostic products, now has fewer trips to take to the garbage dump, saving valuable time and money.

EAD built a 12-foot-by-12-foot masonry building that included an 8-foot by 10-foot roll-up door. This structure, as well as the approach/dumpster slab allows forklift operations to dump trash into the hopper. Once the trash is in the hopper, it’s compressed down and pushed into the dumpster. This allows more trash to be placed into the bin, allowing BD to make fewer trips to the landfill.

The new structure also allows the warehouse to remain unexposed to the elements; prior to the new construction, employees had to open the dock doors, back up a truck to the doors, and take the load to the dump.

EAD completed the project without impacting company operations.

Trash Compactor

PROFILE

Client: BDLocation: Broken Bow, NEMarket Served: Pharmaceutical

SERVICES




CARGILL CORN MILLING, INC.

EAD was trusted with the unique assignment of replacing a 4,000-amp fused disconnect with a circuit breaker to significantly reduce an electrical hazard. The remotely controlled circuit breaker was custom designed and fabricated by EAD to ensure fit into the location of the existing fused disconnect. Execution was complicated by the necessity for precise measurements. Installation of the circuit breaker was coordinated with the plant and managed by EAD.

In addition to providing greater personnel safety due to remote operation, the breaker reduced the reaction time to clear an electrical fault by more than 13 times as compared to the existing disconnect. The incident energy level in the event of an arc flash was reduced by more than 45 times. Better coordination and quicker response to faults would reduce damage to downstream equipment in instances of major electrical fault.

Breaker Retrofit

PROFILE

Client: Cargill Corn MillingLocation: Blair, NEMarket(s) Served: Renewable fuels, agriculture

SERVICES

• Engineering• Project Management

OUR EXPERIENCE


CITY OF AMES, IA

The City of Ames, IA contracted EAD to provide professional engineering and construction management services for a power plant switching station. Design included integrating a 161kV switching station into the 161kV and 69 kV transmission loops, a 100 MVA 161/69kV autotransformer and relocation of several existing 69 kV transmission lines.

EAD was responsible for all portions of the project from conception to final checkout. EAD was also able to tackle the challenging terrain features, which included an irregularly shaped, sloped parcel of land on which the station was constructed.

Power Plant Switching Station

PROFILE

Client: City of AmesLocation: Ames, IAMarket(s) Served: Municipal

SERVICES

• Engineering• Project Management• Construction Management

OUR EXPERIENCE


LARGE FOOD MANUFACTURER

A large food manufacturer produces approximately 175,000 cases of product per day. EAD was asked to provide a solution to the high number of "No Read" conditions caused by the barcode scanning systems that resulted in cases not automatically being sorted into unit load, but instead were being sent to the hand-sorting and stacking area. The read rate efficiency was approximately 92 percent of the total cases produced. The remaining 8 percent (approximately 14,000 cases per day) had to be hand-sorted, stacked and wrapped.

EAD worked with Sick Optics, USA and installed 16 new barcode scanners throughout the sortation system. These barcode scanners were initially integrated into the control system using ASCII technology. This effort improved the read rate to 96 percent. Then EAD worked with the case manufacturer to install similar bar code systems on their manufacturing lines. This was done to ensure the food manufacturer was receiving cases that had high quality printing. This effort improved the read rates to over 98 percent, reducing the number of hand-sorted cases from 14,000 per day to approximately 1,100. This improvement in efficiency and throughput allowed this company to re-assign two employees per shift to other duties.

Sort System Efficiency Improvements

PROFILE

Client: ConfidentialLocation: GlobalMarket(s) Served: Agriculture, processing

SERVICES

• Project Management• Construction• Engineering• Automation

OUR EXPERIENCE


GREEN PLAINS RENEWABLE ENERGY

Leading ethanol producer Green Plains gave EAD the opportunity to assist them with an expansion and redesign of the dust collection of their grain-handling facility. The client recognized that grain dust was collecting in underground tunnels and truck unload bays in unsafe quantities. EAD substantially reduced the dust explosion hazard by designing new dust collection ducting and specifying air handling equipment to safely remove dust from equipment, truck bays and confined spaces.

The multidisciplinary design team included mechanical engineers and designers to specify and layout equipment, electrical engineers to develop electrical power distribution, process engineers to ensure combustible dust safety and structural engineers to design support structure for new equipment and bridging over plant roads.

Corn Unload Dust Collection

PROFILE

Client: Green Plains Renewable EnergyLocation: Wood River, NEMarket(s) Served: Ethanol, processing, renewable fuels

SERVICES

• Project Management• Engineering

OUR EXPERIENCE


OUR EXPERIENCE

MAHLE ENGINE COMPONENTS USA

MAHLE Engine Components USA in Atlantic, IA is a leading manufacturer of engine bearings and bushings. MAHLE recognizes the importance of data acquisition and scalable HMI systems. However, because of the high number of stand-alone processes and the segmented nature of their plant operations, they discovered numerous challenges in implementing a SCADA/HMI package that could become the plant standard. One of the largest challenges was communication with legacy Omron PLCs in their wastewater treatment facility.

EAD Control Systems was hired to put all the pieces of the puzzle together. EAD designed and installed a redundant WinCC server application. This involved configuring both servers, designing and implementing the WinCC application and configuring an OPC server used to communicate with the Omron PLCs via a serial to Ethernet gateway. Additionally the Web Navigator functionality was enabled and a web server was configured to allow access across the plant network. Working closely with MAHLE staff, EAD was able to install, test and commission the system in only a few days and without taking the wastewater process offline.

WinCC Server

PROFILE

Client: MAHLE Engine Components USALocation(s): Atlantic, IAMarket(s) Served: Components manufacturing

SERVICES

• Project Management• Automation


OUR EXPERIENCE

MARS PETCARE

The EAD family of companies teamed up to provide a turnkey solution to a food safety and industrial hygiene problem faced by Mars Petcare. Plant operators faced issues with dust control at mixing stations where dry fine powder ingredients are manually added to the product. It also created a housekeeping issue requiring frequent attention by plant personnel.

A sanitary system of ventilation ducts was engineered to collect the fine dust and safely remove it from the system. Process control programming was developed to facilitate ease of use and provide an automated water flush of the ductwork to prevent cross-contamination between different product batches. Installation of the system was overseen by an EAD construction management team.

Fines Collection

PROFILE

Client: Mars PetcareLocation(s): North Sioux City, SDMarket(s) Served: Pet food processing

SERVICES



MERCK

Merck Animal Health in Worthington, MN is a leading animal health company, dedicated to the research and development, production and marketing of innovative pharmaceutical products and vaccines for animals.

EAD helped Merck update its SCADA system for two freeze dryers and two autoclaves to a modern platform and integrate the equipment into the plant.

The system that EAD updated collected critical data and provided remote access for monitoring without physically accessing the plant’s clean rooms.

EAD provided additional functionality for historical data collection, remote access and modified recipe management. The project also included new hardware engineering and procurement of new to replace outdated operator interfaces in the clean rooms. This new hardware allowed the plant to integrate the all the control systems into the plant network architecture.

Working closely with Merck staff, EAD installed, tested and validated each autoclave and freeze dryer individually without affecting the operations of the other autoclaves and freeze dryers.

SCADA System Modernization and Integration

PROFILE

Client: MerckLocation: Worthington, MNMarket(s) Served: Animal health

SERVICES


OUR EXPERIENCE


PROLIANT

Proliant Meat Ingredients, a manufacturer of broths, flavorings and functional proteins was faced with the challenge of substantially expanding an operating facility without impacting production. The EAD family of companies was contracted to provide a turnkey solution. The scope included a building addition, site pavement reconstruction, new production lines of equipment, sanitary piping systems, process automation, clean-in-place systems, electrical power distribution and tie-in to existing utilities.

Our team worked closely with the client to understand not only how they make their product, but also to understand the commercial and operational challenges they faced on a daily basis. The completed project resulted in a facility that exceeded the requirements of Proliant’s food safety plan while more than doubling the production rate of the existing process.

Meat Ingredient Plant Expansion

PROFILE

Client: ProliantLocation: Harlan, IAMarket(s) Served: Meat ingredient manufacturer

SERVICES


OUR EXPERIENCE


RC HYDRAULICS

RC Hydraulics is an equipment design and manufacturing firm. The company came to EAD Controls to design the controls for a new system used to construct grain bins. EAD was tasked with designing a wireless system that could monitor and lift multiple hydraulic jacks under different loads all at the same time. There are anywhere from four to 36 jacks that could be used depending on the grain bin size. RC Hydraulics had the idea to create a new way of constructing bins but wanted a partner to help them design and test this concept.

EAD Controls designed, built and installed the Siemens wireless control system and technology for each jack. The jacks are now capable of coordinating constant height evenly plus or minus 1/8 of an inch and maintains equal weight on each jack regardless of wind or uneven concrete pads. They were programmed and tested in our UL- listed panel shop. EAD worked closely with RC Hydraulics Industries to develop and deliver a system that would be reliable, user friendly and safe. Together we have been able to reduce the amount of time and equipment required when constructing a grain bin. This system revolutionizes the way grain bins are constructed and has several other applications within the construction industry.

Grain Bin Lift System

PROFILE

Client: RC HydraulicsLocation: Des Moines, IAMarket(s) Served: Equipment design and manufacturing

SERVICES

• Engineering• Project Management• Automation

OUR EXPERIENCE


TSI

TSI designs and builds equipment for today’s highly automated plants in the engineered wood and biomass industries. TSI offers solutions for dryer islands (heat energy, drying and emission control) and finishing lines.

EAD Controls was retained to design a control system for a dryer island that is comprised of two independent combustion chambers, two secondary combustion chambers, two single-pass dryer systems and a radiant heat thermal oil heater system. The project required the control system for the dryer island to easily integrate into the plant’s overall network architecture with similar programming for the PLC and SCADA to ensure plant consistency for operations and maintenance.

Working closely with the client and end user, EAD designed a control system that provided state-of-the -art user interfaces, historical data collection capabilities, robust safety monitoring systems and high-quality control panel designs to ensure the longest life cycle possible. Due to EAD’s commitment to our client’s success, EAD applied the appropriate resources and project execution techniques to ensure the client was able to provide a complete, high-quality control system design to the end user.

Dryer Island Control System

PROFILE

Client: TSILocation: Lynnwood, WAMarket(s) Served: Engineered wood and biomass

SERVICES


OUR EXPERIENCE


OUR EXPERIENCE

ABENGOA

Abengoa is a publicly traded company that applies innovative technology solutions for sustainability in the energy and environment sectors, generating electricity from renewable resources, converting biomass into biofuels and producing drinking water from sea water.

Abengoa retained EAD for the conceptual and schematic design of the front-end material handling system for the Hugoton, Kansas facility. This plant was designed to produce 25MMGPY of bioethanol from cornstover and switchgrass (second-generation bioethanol). As part of the design, EAD managed the design and testing of first-generation material handling equipment, fire and explosion protection and pneumatic conveying.

This facility was Abengoa’s first second-generation facility and seventh first-generation bioethanol facility in the U.S., bringing the company’s total biofuel production in the country to more than 400 million gallons.

Front-End Material Handling Design

PROFILE

Client: AbengoaLocation: Hugoton, KansasMarket(s) Served: Agriculture, processing, renewable fuels

SERVICES


27


OUR EXPERIENCE

ANTARCTICA

EAD Control Systems Inc. of Omaha created a command-and-control system for the drill that is essentially a large Ethernet ring that is connected to sensors that monitor the whole system and allow the drillers to control it from laptop computers. EAD’s Adam Melby deployed to Antarctica to see the drill through its crucial testing phase on the ice shelf near McMurdo.

EAD was recommended by another consulting firm to be part of the research team associated with the WISSARD project. During this project, there was a specially designed hot-water drill to cleanly bore through a half mile of ice, a National Science Foundation (NSF)-funded team of researchers has become the first ever to reach and sample the “grounding zone”, where Antarctic ice, land and sea all converge. Data gathered from samples of sediment taken in the grounding zone will provide clues about the mechanics of ice sheets and their potential effects on sea-level rise.

EAD’s part in this project included design and build of the control system for the hot water drill. All instrumentation was specified and mounted in shipping containers to be sent directly to the drill site in Antarctica. EAD staff completed the command and control installation on the ice as part of the acceptance testing and commissioning of the WISSARD hot water drilling system.

UNL - Hot Water Drill

PROFILE

Client: University of Nebraska - Lincoln Location: AntarcticaMarket(s) Served: Higher education, environmental science

SERVICES


28


OUR EXPERIENCE

ALTEN ETHANOL FACILITY

AltEn retained EAD to provide engineering services related to the installaton of a 5.3 MW gas turbine and heat recovery steam generator (HRSG). This installation includes a new building to house the HRSG, 4160V switchgear, 480 V MCC, and turbine accessories. The system also includes a 1000 Hp, 4160 gas compressor. A new building with 13.8 kV switchgear including protective relays was also included to interface with the local utility and meet the local utility’s distributed genearation system interconnection requirements.

The completed combined heat and power (CHP) system will take advantage of the biogas produced by the anaerobic digesters to generate enough electrical power to meet the ethanol facility demands. The HRSG will produce 24,000 lbs. per hour of steam at 150 psig to augment the plant’s process boilers.

Combined Heat and Power Facility

PROFILE

Client: AltEnLocation: NebraskaMarket(s) Served: Ethanol, biogas

SERVICES

• Project Management• Construction• Engineering


OUR EXPERIENCE

AVENTINE RENEWABLE ENERGY, INC.

Aventine Renewable Energy, Inc. is a leading producer and marketer of ethanol and related by-products. Through their own production facilities, they market and distribute ethanol to many of the leading energy companies in the U.S.

EAD served as the Construction Manager for this project. Aventine required a large scale conveyor system design for ethanol input and outputs for plants under construction in Aurora, Nebraska and Mt. Vernon, Indiana.

EAD’s engineering and construction teams designed and managed the installation of a 1,600-foot corn conveyor system. This system delivered 20,000 bushels of corn per hour from a nearby co-op to their facility under construction in Aurora.

For both the Aurora and Mt. Vernon plants, EAD also designed the conveyor system to transfer wet distiller grains from process centrifuges to a storage and load-out location.

Conveyor System Design

PROFILE

Client: Aventine Renewable Energy, Inc.Location: Aurora, Nebraska and Mt. Vernon, IndianaMarket(s) Served: Agriculture, processing, renewable fuels

SERVICES



OUR EXPERIENCE

CARGILL CORN MILLING

EAD was contracted to construct a new Visitor Center for the Blair Bio-Refinery Campus operated by Cargill Inc. The Visitor Center is used by Cargill’s security contractor to process all visitors to the 600-acre facility and provide training classes for all contractors working on site. The building also includes a garage to house the emergency response vehicles for the campus.

The building itself is a pre-engineered metal building with a standing seam roof and brick wainscot. The hip roof design sets it apart from the average metal building.

Construction began in the spring of 2011, but was interrupted by the threat of flooding from the nearby Missouri River. Construction resumed when the threat abated, and the project was completed in November 2011.

Visitor Center

PROFILE

Client: Cargill Corn Milling, Inc. Location: Blair, NEMarket(s) Served: Commercial facility

SERVICES



OUR EXPERIENCE

ARTIFICIAL SWEETENERS PROCESSING PLANT

EAD acted as owner’s representative during project execution. We were responsible for FEL 3 Electrical and Instrumentation (E&I) construction cost estimate and bid package development. We also conducted pre-bid meetings, evaluated proposals, selected contractors, conducted pre-mobilization meetings, and coordinated shutdowns. We managed the development of process narratives compliant with ISA 88 standards.

EAD also developed and maintained metrics that tracked applications engineering progress from document development and user acceptance testing through implementation. The project was executed with zero recordable injuries, within budget and on schedule.

Electrical and Instrumentation Project Management

PROFILE

Client: ConfidentialLocation: NebraskaMarket(s) Served: Agriculture, processing, renewable fuels

SERVICES



OUR EXPERIENCE

CARGILL CORN MILLING, INC.

EAD was contracted to take an existing fully operational plant and replace the inadequate control system with a new one. The switchover was to be done with minimal impact to normal operations and production while the existing control system consisted of 8,000 I/O points was changing almost daily from a programming standpoint.

EAD applied a project management team that worked closely with the Client to manage project funding, logistics, scheduling, budget and manpower. The team developed time-saving techniques of gleaning current process information and applying it to the programming of the new system. This time-saving measure cut the estimated programming duration from two years to 13 months. The team also implemented enhanced documentation review procedures to ensure there was no loss of functionality or safeties. This documentation then served additional duty as training and living process narratives for future use.

In addition to the project processes, EAD managed the physical switchovers during downtimes and worked with the client to keep both systems fully functional until the end of the project.

PROFILE

Client: Cargill Corn Milling, Inc.Location: Blair, NEMarket(s) Served: Renewable fuels, agriculture

SERVICES

• Project Management• Engineering• Construction

Management

Control System Switchover


OUR EXPERIENCE

CARGILLLSR

The challenge EAD faced was to supplement client’s construction management team with electrical and instrumentation management on an aggressive schedule while implementing new automation techniques. EAD was tasked to manage multiple electrical and instrumentation subcontractors as well as, QA/QC inspection, budgets, change orders, schedule, checkout & commissioning, and safety.

Electrical and instrumentation contractors were new to the client and its processes; therefore, EAD had to ensure that all Client specifications for installation were met while overcoming challenges of an unfamiliar work environment. EAD ensured that all contractors performed to the high expectations of the client.

Shared utilities and a raw product stream with an existing facility added further challenges to the project as planning and utilization of downtimes to make utility connections were crucial.

EAD’s solution was to ensure installation was in compliance with the client’s global standards, specifications and requirements. During the final phase of construction, EAD coordinated a temporary power solution that allowed the facility to run particular product lines, which allowed the client to go into partial production.

PROFILE

Client: Cargill Location: Omaha, NEMarket(s) Served: Industrial

SERVICES


Management


OUR EXPERIENCE

E3 Biofuels

E3 Biofuels was the first commercial plant to make ethanol with virtually no fossil fuels for heat; instead using manure to make bio-gas.

E3 Biofuels, a 22 MGY ethanol plant located in Mead, NE, asked EAD to identify design and installation issues with the facility so that bugs could be corrected prior to start-up. There were 800 I/O points throughout the plant that needed to be commissioned. There were control systems for the digesters, grain handling, ammonia purification, the ethanol plant proper and utilities that were not integrated.

EAD developed the entire automated controls installation punch list and managed the correction of each issue. We identified, designed and installed control systems that were left out of the original scope of work. The team worked extensively on the I/O checkout, instrumentation set-up, calibration and verification of the control systems throughout the plant. EAD partnered with another third-party vendor on the DCS configuration and integration while they designed the controls for the hammer mill area and fabricated the heat trace and fire water control panels. EAD personnel were present during commissioning and start-up.

Controls Integration & Start-Up

PROFILE SERVICES

• Controls Automation• Project

Management

Client: E3 BiofuelsLocation: Mead, NebraskaMarket(s) Served: Agriculture, processing, renewable fuels


OUR EXPERIENCE

GLOBAL FOOD PROCESSING PLANT

EAD was engaged to plan and manage the removal and replacement of 40,000 square feet of deteriorated roof and decking due to high acidity levels from active food processes below. Interior scaffolding and double containment enclosures were constructed for isolation.

Through extensive investigation and pre-planning, working with plant management and maintenance personnel, EAD successfully managed the construction phases of this project while allowing client operations to continue. EAD focused on schedule and safety management of contractors, providing oversight for the client.

EAD provided safety orientation training for all contractor employees and facilitated daily supervisor safety and schedule meetings to increase safety awareness and coordination between trades. The project was completed within budget and on schedule without any contamination to the process.

Roof Replacement

PROFILE

Client: ConfidentialLocation: GlobalMarket(s) Served: Agriculture, processing

SERVICES



OUR EXPERIENCE

GLOBAL FOOD PROCESSING PLANT

EAD was requested to provide engineering, technical and construction support to replace the existing interior and exterior sanitary sewer systems at an operating facility. The project spanned seven years with a total installed cost of approximately $13 million.

The facility’s existing sewer system had been in place since the 1960s and was deteriorated beyond repair. Since the majority of this project occurred within an operating food plant, EAD had to replace the system and at the same time meet critical food safety standards.

EAD implemented double wall containments constructed of metal studs and poly, along with providing negative ventilation for the construction area to ensure no cross contamination issues could occur. Gowning rooms, travel route planning and strict sanitation procedures also aided in being able to perform without incident.

Sanitary Sewer System

PROFILE

Client: Company ConfidentialLocation: GlobalMarket(s) Served: Agriculture, processing

SERVICES



OUR EXPERIENCE

FRONTIER COOP

EAD was engaged to provide an automated controls solution for a 24-bin grain elevator with grain drying capacity and two large dry grain storage bins. This ongoing, multi-million dollar project is located in Osceola Nebraska.

The site consists of eight concrete storage silos that have been refurbished and automated. The EAD project added two large capacity dry grain storage bins, a continuous grain dryer, four bucket elevators and multiple drag and belt conveyors. Operators were given full automated control, with a manual override, of the grain conveyance and distribution system from all HMI locations. The controls system also monitored the equipment status utilizing speed switches, plug switches and belt tracking switches to minimize equipment damage. EAD was responsible for the design of the control system, fabrication of all HMI and control panels, programming of the

Schneider PLCs and HMIs for the entire site, as well as the configuration of the Schneider MCCs. EAD also performed the commissioning and startup services for the entire site expansion. This was done in partnership with the client’s on-site electrician.

Automated Controls Solution; 24-Bin Grain Elevator

PROFILE

Client: Frontier COOPLocation: Osceola, NEMarket(s) Served: Grain

SERVICES

• Automation• Panel Building • Programming• Startup


OUR EXPERIENCE

GREEN PLAINS RENEWABLE ENERGY

Green Plains Renewable Energy, Inc. is an ethanol producer based in Omaha, Nebraska with the current ethanol production capacity of approximately 790 MMGPY (spanning across 10 plants). At capacity, Green Plains produces approximately 2.2 million tons of distillers grains annually to be used as a high-protein, high-energy animal fodder and feed supplement. Corn oil is also a co-product of ethanol production.

EAD was responsible for designing and installing a system to remove corn oil from stillage. At project onset, EAD met with Green Plains Renewable Energy, Inc. to acquire a thorough understanding of the current plant environment as well as the goals for the new system.

We specificied pumps, tanks, and heat exchangers, and also designed piping, power, controls and wiring. Additionally, we provided field engineering support where we managed the team of contractors.

EAD interfaced with Green Plains Renewable Energy, Inc.’s third-party automation contractor. We led the engineering project that managed the controls, structural engineering and design.

We continue to support Green Plains Renewable Energy, Inc.’s facility and systems at their various sites.

Corn Oil Extraction

PROFILE

Client: Green Plains Renewable Energy, Inc.Location: Work performed in Superior, IAMarket(s) Served: Ethanol, processing, renewable fuels

SERVICES


Management• Field Engineering


OUR EXPERIENCE

KIEWIT

Kiewit was building two 110 MGPY ethanol plants for Aventine Renewable Energy. EAD Engineering was contracted to design and furnish wet distillers grain conveyors to serve the plants under construction in Aurora, NE and Mt. Vernon, IN.

EAD Engineering produced two nearly identical designs that would take the wet distillers grain discharge from the stillage centrifuges and deliver to a wet-cake pad for storage and load-out. Our mechanical, process, electrical and controls engineers teamed up to execute the design for this project. Each system consisted of drag conveyors and augers totaling approximately 400 feet in length. EAD Engineering also made an installation verification during construction.

Wet Cake Conveyor Design

PROFILE

Client: KiewitLocation(s): Aurora, NE and Mt. Vernon, INMarket(s) Served: Agriculture, processing, renewable fuels

SERVICES



OUR EXPERIENCE

MINNESOTA SOYBEAN PROCESSORS

Minnesota Soybean Processors is a membership cooperative that owns and operates a soybean crush facility and biodiesel operation. They provide the latest soybean processing technologies and a high quality renewable fuel source.

EAD performed the unloading and repair of a field fabricated storage tank that had been subjected to fire damage.

EAD was engaged by the client to get the damaged tank back into safe service after the fire incident. Using a team of experts in the management of waste material and tank construction, EAD could unload the tank of approximately 500K gallons of crude sludge to ready the tank for repair.

In the repair segment, safety was the primary concern. EAD developed multiple procedures specific to the job to mitigate both personnel and process incidents. Extensive structural and civil repairs were necessary, and were executed safely.

The EAD team hit the mark when the return-to-service deadline allowed the client pre-sell product.

8MM Gallon Crude Oil Storage Tank Repair

PROFILE

Client: Minnesota Soybean Processors (MNSP)Location: Brewster, MNMarket(s) Served: Agriculture, processing, renewable fuels

SERVICES



OUR EXPERIENCE


Minnesota Soybean Processors (MNSP) is a membership cooperative that owns and operates a soybean crush facility and biodiesel operation. They provide the latest soybean processing technologies and a high quality renewable fuel source.

EAD performed engineering, project management, controls and automation services for a 30-million-gallons-per-year addition to an existing soybean oil extraction facility located in Brewster, MN.

This plant was co-located next to an existing 70-million-gallons-per-year soybean oil extraction facility. In conjunction with this project, EAD also designed a 60-million-gallons-per-year refined and bleached oil plant to produce feedstock for the biodiesel plant and RB oil as a commercial product.

The project was driven by speed to market which required a fast-tracked schedule. Additionally, since MNSP broke ground in the winter months, the weather presented scheduling challenges that EAD overcame through communication and flexibility.

This project marks the first large-volume biodiesel producer in the United States, and established EAD as a pioneer in the biodiesel fuel industry. EAD continues to serve MNSP with engineering services, HAZOP revalidations, maintenance management services, troubleshooting and as a PSM consultant.

Soybean Oil Refinery and Biodiesel Plant

PROFILE

Client: Minnesota Soybean ProcessorsLocation: Brewster, MNMarket(s) Served: Agriculture, processing, renewable fuels

SERVICES



OUR EXPERIENCE


Minnesota Soybean Processors is a membership cooperative that owns and operates a soybean crush facility and bio-diesel operation. It provides the latest soybean processing technologies and a high quality renewable fuel source.

This project consisted of the design-build delivery of a replacement multi-product, load-out unit at an existing biodiesel plant in Brewster, MN.

The project presented two distinct challenges: the aggressive operational date and construction scheduled during the winter months. Second, plant operations could not be disrupted and EAD had to design and construct a temporary loadout unit.

With a focus on construction logistics combined with the synergy of in-house design, EAD could maintain the design just in front of the execution through to a successful completion.

The project’s success was due to the teaming relationship that was in place from the client down to the individual trades. All team members rallied around the common goal of delivering a safe, high-quality installation.

Truck Load-Out Project

PROFILE

Client: Minnesota Soybean ProcessorsLocation: Brewster, MNMarket(s) Served: Agriculture, processing, renewable fuels

SERVICES



OUR EXPERIENCE

NORTHWEST MISSOURI BIOFUELSBiodiesel

TESTIMONIAL

EAD was responsible for the design and build of our storage tank farm. We partnered with them throughout the planning, civil and structural design phase and through execution of our storage tank farm facility. From beginning to end, EAD’s execution, communication, project and vendor management was excellent. - Mark Vermeer, Progressive Energies

Northwest Missouri Biofuels, located in St. Joseph, MO produces 15 million gallons of biodiesel per year. Animal fat is the main feedstock for this company.

EAD designed and constructed a new storage facility for this existing biodiesel plant.

The storage facility was to include hazardous chemical storage and loading, and a total of 1.5mm gallons of finished product capacity all located in a concrete containment structure. EAD was also responsible for the structural steel required for tank top access and utility racking.

EAD was presented with challenging subgrade conditions on this project and utilized Rammed Aggregate Piers as a solution. We were able to get out of the ground quicker and put our concrete and tank building teams to work toward successful completion.

The amount of elevated work in the running facility also presented some unique opportunities for logistics and safety planning. EAD leaned on its safety department for many different procedures to accomplish many complex tasks safely.


OUR EXPERIENCE

“Our relationship with EAD has continued to grow as we work together to make Novozymes project deliverables a success. EAD is all about helping the client be successful and their biggest attribute is their personnel. They truly believe in ‘boots on the ground’ and ‘doing whatever it takes’.” - Cindy Campbell, Senior Project Engineer, Novozymes

Novozymes is an enzyme production facility co-located at the bio-refinery complex in Blair, NE. It provides the biofuels industry with a critical component to efficiently bring ethanol to the marketplace. As production processes advance, Novozymes is uniquely positioned to meet the needs of next-generation biofuels.

As an on-site Project Engineering resource, EAD provides assistance in executing capital projects.

In early 2013, Novozymes began a project to improve the efficiency of their cooling tower system, providing the site with a critical utility for sustainable operation. EAD was tasked with management of project scope, schedule, and budget, working closely with a refrigeration contractor based in Florida.

Project success was driven by the ability to execute a fast-track project in a predetermined plant shut-down window. Novozymes, EAD and contractor personnel were all heavily involved in project scheduling and construction, which ultimately provided Novozymes with an on-time and on-budget deliverable.

PROFILE

Client: NovozymesLocation: Blair, NebraskaMarket(s) Served: Renewable Fuels

SERVICES

• Project Management• Engineering• Automation

NOVOZYMESCooling Tower Improvements


NOVOZYMESSolid Biomass Handling

When Novozymes needed to upgrade its bulk solids conveying and treatment system to handle spent filter cake from fermentation product filters, it contracted EAD to create the design from conception through completion over multiple years and through all project phases. Each phase required a design review, construction cost estimate of increasing accuracy and rescoping for the next phase.

Conceptual design basis work included processing equipment testing, material properties analysis, production rate requirements and project execution planning. Basic design added equipment selection, layouts, power supply, automation, operability and occupational safety. The detailed design ran concurrent with preliminary construction, which required the development of several drawing packages that allowed contractors to begin work before the final equipment submittals and construction package were available.

The equipment layout faced several design constraints, from physical space availability to installing around operating equipment to chemical exposure isolation requirements. EAD’s design team used 3D CAD to create a design free of interferences that required no existing building modifications. All process equipment, piping, HVAC units, electrical equipment, cable tray and new interior structures were added to a 3D model of the existing building created by EAD just for this project.

The building model became the plant’s master drawing/model for this building, which EAD will maintain throughout future projects.

PROFILE SERVICES

Client: NovozymesLocation: Blair, NebraskaMarket(s) Served: Renewable Fuels

• Project Management• Engineering• Automation

OUR EXPERIENCE


OUR EXPERIENCE

GLOBAL PET FOOD PROCESSOR

EAD performed engineering, project management, controls and panel building services for a pet food manufacturing plant. EAD was asked by this core client to replace an obsolete PLC panel so the client could update the programming software. EAD designed a new panel with a Modicon Quantum system.

To provide the client with a new panel, EAD developed a panel layout, parts specification, parts lists control schematics and provided them to EAD’s panel shop. EAD’s panel shop purchased all parts needed, fabricated, tested, and shipped the PLC control panel to the client.

To install the panel in the field EAD compiled a bid package that included electrical drawings, bid legal documentation, specifications, and scope of work. EAD obtained bid pricing from electrical contractors and worked with the electrical contractors to install and test the new PLC panel.

This is an example of just one of several ongoing factory automation upgrade projects that EAD continues to work with the client to perform engineering, automation, and design services.

PLC Panel Design

PROFILE

Client: Company ConfidentialLocation: GlobalMarket(s) Served: Pet food processing

SERVICES

• Project Management• Building Management• Engineering• Automation


OUR EXPERIENCE


This leading global pet food processor faced a food safety and cross contamination issue with their five mixing stations. The addition of hand added ingredients to four of their product mixers and their gravy mixer was creating an airborne dust contamination within the mixing room and adjacent areas and creating unsatisfactory working conditions for their personnel. EAD provided this client with a turn-key solution utilizing hygienic design.

EAD worked to fully understand the existing mixing system and conditions of normal operation. A sanitary design was created that met the expectations of the plant sanitation and operation requirements. EAD installed the dust collection system which utilized a Roto-Clone suspended above the ceiling of the mixing room. The mixers were connected to the Roto-Clone using a sanitary ducting system that could be easily disassembled and entirely sanitized at scheduled preventative maintenance periods.

During normal operation, our design utilized automated rinse-in-place components and programming that provided a rinse cycle after each batch of product was mixed. Automated slide gates controlled which leg of the system was being utilized and a barometric damper balanced the airflow through the varying duct sizes.

Hygienic Design

PROFILE

Client: ConfidentialLocation: GlobalMarket(s) Served: Pet food processing

SERVICES

• Engineering• Project Management• Risk Management• Automation


OUR EXPERIENCE

GLOBAL PET FOOD FACILITY

This leading global pet food facility needed to increase production and volume of its 5.5-ounce cat food lines.

EAD Engineering doubled the plant's production and packing line for its 5.5-ounce cat food products. We initially designed the warehouse, tripling its space from 70,000 to 210,000 square feet.

We prepared the equipment and system layouts for the liquid material and meat slurry handling. We designed CIP and pigging systems. We added fillers/seamers and a 13-ounce and 5.5-ounce pal/depal and added two 5.5-ounce labelers. We handled the equipment layouts for high-speed labeling, tray packing, and shrink-wrapping and Alvey case palletizing.

Plant Expansion

PROFILE

Client: ConfidentialLocation: GlobalMarket(s) Served: Pet food processing

SERVICES

• Engineering• Project Management


OUR EXPERIENCE


This leading global pet food processor asked EAD to provide engineering services for an ammonia system upgrade project. The plant obtained several audits that updates to their current ammonia safety system, which included detection, ventilation and equipment updating.

EAD worked directly with the plant to develop a scope, budget, and schedule to obtain funding for the project. EAD then designed a custom ammonia alarm detection system that interfaced with the current detection system, designed necessary control panels, and also designed a ventilation system to meet the PHA & PSM audits.

EAD provided project management for the client by working with various contractors to solve large issues like re-piping the ammonia lines to the roof to make the control banks accessible and prevent forklift damage. Details were also addressed like tagging and P&ID updating.

Ammonia System Upgrade

PROFILE

Client: Company ConfidentialLocation: GlobalMarket(s) Served: Pet food processing

SERVICES

• Engineering• Project Management• Automation


OUR EXPERIENCE

PETROALGAE, INC.

PetroAlgae’s aquaculture technology enables producers to grow, harvest and process locally available micro-crops to create feed and food products for global markets.

PetroAlgae (located in Melbourne, FL) asked EAD to partner with them on the development of leading-edge technology for the production, harvest and processing of microalgae and aquatic plants.

PetroAlgae had the initial concept, but they desired a proven partner’s expertise in renewable energy to assist them in bringing it to commercialization.

EAD began with process-development consulting. Laboratory scale processes were increased to pilot scale. At that point, we performed the site-specific engineering, which included grading and building design, facility layouts, code compliance and electrical power supply for the demonstration facility in Indian River County, FL.

EAD also developed the conceptual design of this first-generation, commercial-scale, full-license aquatic plant farm.

Aquatic Biomass Production Facility

PROFILE

Client: PetroAlgae, Inc. (Now Parabel USA, Inc.)Location: Melbourne, FLMarket(s) Served: Agriculture, processing, renewable fuels

SERVICES



OUR EXPERIENCE

PONCA PUBLIC SCHOOLS

Ponca Public Schools selected EAD for construction on its Addition and Remodel Project. Original bids came in at $1.4 million over the district’s budget. EAD brought the project under budget and reduced the overall cost of the project by $20 per square-foot through value engineering. We maintained the original square footage, met the bond requirements and retained “green” options. Quality, durability, original design, functions and capabilities were maintained throughout the value engineering process.

The project was completed in two phases over a duration of approximately two years. Phase one consisted of construction of the new high school, parking areas, a new drive and student drop-off area. It also included new classrooms, a kitchen, commons area, library and administrative offices. After completion of phase one, school staff and students were relocated to the new facility and demolition of the existing two- and three-story structures commenced, making way for construction of the new gymnasium, locker rooms, restrooms, vocal and instrumental music rooms and a community wellness area.

PROFILE

Client: Ponca Public SchoolsLocation: Ponca, NE Market(s) Served: Education

SERVICES


Management


OUR EXPERIENCE

RENTECH, INC

Rentech retained EAD to perform the engineering, project management, construction management, and design to convert two decommissioned fiber mills into wood pellet plants. The mills are located in Wawa and Atikokan in Ontario, Canada.

Wawa FacilityRentech acquired an idle strand board processing mill located in Wawa, Ontario, which was converted for wood pellet production. The repurposed plant was designed to produce 400,000 metric tons annually. The facility is expected to consume approximately 890,000 tons of certified sustainably managed fiber annually.

Atikokan FacilityRentech acquired a former particle board processing mill located in Atikokan, Ontario, which was converted for production of approximately 90,000 metric tons of pellets annually. The facility is expected to consume approximately 200,000 tons of fiber annually.

These projects had aggressive timelines in order to meet Rentech’s contractual delivery dates. EAD worked to overcome multiple challenges such as designing to Canadian safety standards (CanOSH) and sub-zero degree weather during critical foundation work. EAD worked with the client to structure a team that was collaborative, goal-oriented and adaptive.

Wood Pellet Processing Plant

PROFILE

Client: RentechLocation: Wawa and Atikokan, OntarioMarket(s) Served: Renewable Fuels

SERVICES



U.S. ARMY CORPS OF ENGINEERS

EAD was awarded a contract from the U.S. Army Corps of Engineers (St. Louis District) for the Melvin Price Locks and Dam control upgrade project. EAD designed, built, programmed and tested 17 new panels and custom-engineer NEMA 12 electrical enclosures ranging in size from 32”x38”x18” up to 96”x36”x24.”

All panels and enclosures were designed, custom-engineered and completed by EAD design personnel. The manufacturing and assembly of all systems were completed at one time so that the testing of all 17 enclosures could be

networked together for three days of burn-in and factory acceptance testing (FAT). EAD personnel performed the operation with acceptance from on-site St. Louis District personnel. Once FAT was complete, all units were processed for shipping and installation on-site. This project was fast-tracked and completed within 60 days.

EAD earned an exceptional performance rating in 90 percent of the categories. This project was completed on time and within budget.

Control Panel Upgrade Project

Client: U.S. Army Corps of EngineersLocation: St. Louis, MOMarket(s) Served: Engineering, municipal

• Project Management• Engineering• Panel Fabrication• Automation

SERVICESPROFILE

OUR EXPERIENCE


OUR PEOPLE

Jeffrey Kious offers experience working primarily in consulting for both mechanical and electrical systems in the processing industry. His expertise includes construction management, construction cost estimating, feasibility analysis, process/utility systems and equipment sizing and selection.

Jeff’s mechanical design experience includes dust collection, material handling and conveying, utility and process piping, industrial ventilation and HVAC systems in food and agricultural processing facilities. He is also a PCQI for Human Food.

Jeff has also designed power systems from the substation level down to individual loads in the industrial sector including “Class Rated” environments. His experience includes power system monitoring/analysis, arc flash, short circuit analysis and over-current device coordination. Jeff also has experience in project management and holds a Bachelor’s of Science in Aerospace Engineering and a Master’s of Science in Mechanical Engineering.

Jeff Kious, P.E., Chief Technical Officer

Education:B.S. Aerospace EngineeringM.S. Mechanical Engineering

Certification:PCQI for Human Food

Project Experience:• Proliant Harlan Expansion• Rentech Wawa • Rentech Atikokan • Confidential Client Corn Line• Confidential Client Main Lift

Stephen Lichter brings experience as a practicing engineer, primarily in the heavy industrial and processing industries serving the chemical, petrochemical, pharmaceutical, food ingredient, animal food, fermentation, and soybean processing industries.

Mr. Lichter has worked in consulting and plant operations in varying capacities such as program manager, project manager, design engineer, and director of operations. He offers technical expertise in pipe stress analysis and design, pressure vessel and heat exchanger design, fluid flow analysis, and material handling.

Mr. Lichter's background and business experience provide him with tremendous resources to draw upon allowing him to bring a common sense approach to engineering, project management and designing new or revamping existing facilities.

Stephen Lichter, P.E., Chief Executive Officer

Education:B.S. Mechanical Engineering


OUR PEOPLE

Ed Gaither offers extensive experience in helping launch innovative technologies in the renewable energies market. He has managed operations of an ethanol plant, responsible for staffing, training, quality and production control. His background also includes developing a biodiesel pilot plant and managing its laboratory.

Ed is also experienced in the implementation and auditing of OSHA Process Safety Management programs. He has participated in and facilitated Process Hazard Analysis meetings for several different processes utilizing highly hazardous chemicals and flammable liquids and vapors. His process safety knowledge also includes combustible dust safety in accordance with NFPA standards and the OSHA Combustible Dust National Emphasis Program. He is a Professional Chemical Engineer in the state of Nebraska and a PCQI for Human Food.

Edward Gaither, P.E., MBA, Director of Corporate Development

Project Experience:• Proliant Harlan Expansion• Richardson Milling Warehouse and

Line Product• Rentech Wawa• Rentech Atikokan• Cargill HAZOP• PetroAlgae - Aquatic Biomass Facility• Novozymes Solid Biomass

Education:B.S. Chemical EngineeringMBA Agribusiness

Denis Hernandez-Granda offers over 20 years of experience in a wide range of industries, including industrial construction, project management, calibration, metrology, and industrial sales and marketing. His specific expertise is in most aspects of industrial automation and FDA compliance with adaptability in cGMP and pharmaceutical construction.

Denis’ construction experience includes a well-versed selection of industries, including bio-pharma, power, oil and gas, industrial and water treatment facilities located in the U.S., Mexico, and Puerto Rico. Denis' diverse background has provided him with strong analytical skills, with attention to details to successfully manage a wide range of individuals. His ability to recognize the importance of team work and communication make him an excellent leader with supervisory skills and technical abilities to help growing companies be successful.

Denis Hernandez-Granda, Chief Business Officer

Education:B.S. Industrial Engineering TechnologyMinor in Engineering Management

Project Experience:• TSI PLC Programming• Amgen AML High Speed Packaging

Line• PREPA 600 MW Gas Fire Power Plant• PRASA Plant Automation Island Wide

Program• Merck Substance P• Abbott Humira


Mike started his career as a detailer with a specialized agricultural equipment manufacturer before taking a position with an Omaha consulting engineering firm in the early 1980s where he worked for over 16 years. As a Project Manager and Lead Designer, Mike gained valuable experience in Foods, Pet Foods, Ag Processing, and several other industries. Mike also managed several contracts for the U.S. Army Corp of Engineers working on many multi-disciplined engineering projects for Army & Air force bases as well as the Main Stem Dam sites along the Missouri River.

In 2007, as Tech21, his own company, Mike joined Syngenta Crop Protection as an independent design contractor supplying CAD design, structural design, fabrication detailing and surveying services for most of the capital expansion projects. Mike gained valuable experience with detailed design of chemical processes, formulation, storage, packaging and facility design for crop protection, bio-technical and the seeds divisions of the company.

Mike Tietze, Project Management Director

Industries Served:• Food Processing & Sterilization• Pet Food Processing• Ag Chemical Processing• Ag Equipment Manufacturing• Structural Steel & Precast Concrete

Fabrication• Industrial, Commercial & Residential

Subdivision Planning• Wastewater Treatment

Jamie DeWispelare joined EAD as Corporate Controller in 2010 and was named Chief Financial Officer in 2013. He provides leadership in the areas of financial services, strategic business development and growth initiatives. His corporate finance duties include financial reporting, financial planning and analysis, financial operations, divisional finance, contract administration, audit, treasury and taxes.

Prior to joining EAD, Jamie was the Chief Financial Officer of Paragon Construction where he was responsible for operations, personnel, accounting and regulatory reporting. Prior to that, he was employed by Peter Kiewit & Sons’ as a Division Controller in Chicago, IL.

Jamie holds a bachelor’s degree in Accounting from Doane College in Crete, NE.

Jamie DeWispelare, Chief Financial Officer

Education:B.S. Accounting

Areas of Expertise:• Strategic Business Planning• Financial Operations & Planning• Cash Management• Tax & Regulatory Compliance• Systems Integration• Training & Development

OUR PEOPLE


Dean Epperson has experience in construction engineering and management. He has extensive knowledge in heavy industrial and civil projects as well as commercial construction projects.

Dean has served in many capacities including engineering layout, project engineering, equipment operating, estimating and scheduling, site supervision and project management. Building every project with a commitment to safety, quality and budget/schedule control attributes to his success.

Dean serves as a project liaison between EAD and our clients. He quickly evaluates and understands the construction processes that needs to be in place for project success. He helps clients understand the importance of planning the work and working the plan.

Dean Epperson, Operations Director

Education:B.S. Construction Engineering Technology OSHA 10-Hour CertificationCombustion Gases Certification

Project Experience:• Rentech Wood Pellet Facility• ConAgra Oakdale, CA• ConAgra Trenton, MO• JC Excavation Unlimited• Leuck's Drilling Co.

Alan Winkelbauer has experience in the design and detailing of process facilities. He has worked as a structural, mechanical and electrical designer for most of his career.

Alan is skilled in designing structures, process and instrumentation diagrams, equipment layouts, piping plans and elevations, electrical one line diagrams and control schematics in a variety of disciplines. He is also experienced in the food processing industry and food safety.

At EAD, Alan serves as a member of the leadership team providing strategic and tactical leadership to ensure the delivery of the highest levels of service and quality.

Alan Winkelbauer, Chief Designer

Education:Associate degree in Manufacturing Engineering

Certification:HACCP

Project Experience:• Rentech Atikokan• Rentech Wawa• Proliant Harlan Expansion• Novozymes Solid Biomass• Confidential Client Corner Stone• Confidential Client Steam Line P&ID

OUR PEOPLE


OUR PEOPLE

James B. Worden II offers over 36 years of experience in the design and construction phases of structural engineering applied to large industrial facilities. His experience includes the design of civil, aerospace, automotive, and laser test facilities for the federal government and commercial clients.

Jim brings extensive design experience in the application of common structural engineering techniques with unique materials for rocket propulsion systems and the use of common structural materials for unique applications for test facilities. He has managed structural projects from cradle to grave, performing the design activities, working with the fabricators, and finally managing the installation activities.

Jim Worden, P.E., Civil and Structural Engineering Manager

Areas of Expertise:• Concrete• Structural Steel• Structural Aluminum• Welding• Seismic Design and Analysis• Structural Dynamics

Education:B.S. Civil Engineering with Architectural OptionM.S. Civil Engineering

Adam Melby offers electronic and industrial automation related experience. He was trained in the U.S. Navy as an Electronics Technician and later as an Instrumentation and Controls Technician at a leading manufacturer of food packaging products.

Adam specializes in the design, programming, implementation, troubleshooting, repairs, operations and maintenance of associated equipment and programming.

Adam has performed work in multiple industries designing and programming PLC and PC based controls, operator interfaces and data collection systems for processing, packaging, machine safety and material handling systems.

Adam Melby, Controls Engineering Director

Certification:CCST Level 2

Project Experience:• Proliant Harlan Expansion• Rentech Wawa • Rentech Atikokan • UNL Antarctica Drill• Darling MCC Migration • TSI Burner and Dryer

Controls


Jonathan Fant offers over 33 years of experience in the design and construction phases of electrical engineering of large industrial, commercial and power-generation facilities. His experience includes the design of food processing, upstream and midstream oil and gas projects, light rail projects, various government military installations, hydroelectric power plant rehab projects, medical facilities, schools, office buildings and warehouses.

Jonathan brings extensive design and management experience in the application of electrical engineering techniques for both new facility construction and rehab or upgade of existing facilities. He has managed electrical projects from conception to startup, performing initial studies, detailed design, coordination with fabricators and manufacturers, and supporting the installation and startup activities.

Jonathan holds a Safety Trained Supervisor raiting with the Board of Certified Safety Professionals. He is a Professional Electrical Engineer in seven states.

Jonathan Fant, P.E., Electrical Engineering Manager

Education:B.S. Electrical Engineering Power Option Project Experience:

• Arctic drill pads• AltEn CHP Unit• Crude oil pipelines• Grain-drying system• MUD main entrance

preparation• Oil field storage tanks

OUR PEOPLE

James Krumwied offers diverse experience in several industries. He became a Mechanical Engineer after serving as a nuclear power plant operator on a ballistic missile submarine in the U.S. Navy for over eight years. As a Certified Energy Manager (CEM), he specializes in energy-related projects such as biogas cogeneration, digester gas conditioning systems, boilers, hot water systems, and energy efficiency evaluations. He has performed energy audits for diverse industries including municipal wastewater treatment, water treatment, railroads and ports.

He has designed several biogas powered Combined Heat and Power (CHP) systems with internal combustion engines or micro turbines as the prime movers. He has also designed several standby and emergency power systems with diesel generators ranging from 200 kW to 5 MW.

James is a licensed Professional Mechanical Engineer, registered in California, Nebraska and Washington.

James Krumwied, P.E., CEM, Senior Process Engineer

Education:B.S. Mechanical EngineeringNaval Nuclear Power School Project Experience:

• Combined Heat and Power Addition• Merck Elkhorn Electrical Upgrade • Merck Utilities Survey


Nicholas D. Obbink offers over 17 years’ experience in the civil and structural engineering, design and construction of large food processing and industrial facilities. His experience includes the designing all types of food processing facilities, clean rooms and refrigerated spaces. Nicholas has completed many projects for manufacturing products that are prominent in the public eye.

Nicholas is trained in Sanitary Design Principles and their application to common plant issues, as well as specialized materials for the processing environment. He has managed both small and large projects across the U.S., performing and coordinating the design activities, procurement of materials and labor, and working with fabrication and supervising project installation.

Nicholas earned a Bachelor of Science degree in Construction Engineering from Iowa State University. He achieved Professional Engineering licensure in Civil Engineering with a Structural Emphasis in Iowa in 2009, and has a Civil Engineering License in Arkansas, Iowa, Nebraska, Oregon, Ohio and Oklahoma. Nicholas is also a LEED-accredited professional, holding the Designation of LEED AP BD+C.

Nicholas Obbink, P.E., Senior Structural Engineer

Education:B.S. Construction Engineering

Certifications:LEED AP BD+CAIC Associate ConstructorICC Building CodeOSHA 10-Hour

Areas of Expertise:• Concrete & Pre-Cast

Conrete Construction• Structural Steel

Construction• Steel Connections,

Erection and Welding • Building Renovation,

Modifications and

Equipment Platforms • Thermal Construction• Equipment Installation,

Handling and Rigging • Civil Site, Site Utilities,

Grading and Permitting• Preliminary Process,

Mechanical, Electrical and Refrigeration Design

OUR PEOPLE

Suparat (Poom) Pavavicharn’s past experience includes power systems engineering, construction and commissioning/start-up for power generation plants and substations in different countries.

Her experience over the past ten years has focused on all facets of protection including design, fault studies, setting and testing, and on-site commissioning. Providing protection training and writing technical papers were also part of her roles in the past six years.

Pavavicharn received a Bachelor of Science Degree in Electrical Engineering from Khon Kaen University Thailand and a Master of Science in Sustainable Energy and Management from Flensburg University Germany.

She is also an active member of IEEE PSRC and IEEE IAS working groups. Pavavicharn is a registered professional engineer in the State of Nebraska.

Suparat (Poom) Pavavicharn, P.E., Senior Electrical Engineer

Education:B.S. Electrical EngineeringM.S. Sustainable Energy & Management

Areas of Expertise:• Protection & Control• Power System Analysis


Mark Monday has over 25 years’ experience in project management, construction administration, project engineering, packaging and processing equipment, and HVAC and control system design for projects primarily in the process, sorting and packaging industries.

During his many years in project management, Mark has led both engineering service provider-only and integrated teams on his many assignments and capital projects. He has led projects in both new facility construction and existing facility improvements. Mark has been able to bring more than 70 major projects to fruition under budget and on schedule. He also leads business development in the Southeast region.

Mark has his Bachelor of Science degree in Electrical Engineering from the University of Toledo in Ohio.

Mark Monday, Business Manager

Areas of Expertise:• Food Processing Systems &

Equipment• Packaging Systems & Equipment• Control System Engineering &

Architecture• Electrical Engineering

Education:B.S. Electrical Engineering

OUR PEOPLE

John Molgaard offers industry service and management experience, primarily in the industrial field. He previously worked for a Fortune 200 company, successfully completing projects in the pipeline industry as well as institutional renovations. In addition, John offers extensive expertise in the renewable fuels industry.

Project logistics, scheduling and commitment to a safe effective workplace are John’s specialties. His broad background lends itself to a team building leadership style while maintaining focus on the client’s values and requirements.

At EAD, John serves as a member of the leadership team providing strategic direction and leads business development efforts in the Midwest.

John has completed the OSHA 10 Hour and 30 Hour Safety Training courses as well as the Project Managers Masters certification course.

John Molgaard, Business Manager

Project Experience:• Cargill Control System Conversion • Rentech Wawa• Rentech Atikokan • Cargill Renaissance • Confidential Client Retort Cooling Project • Confidential Client Palletizer and

Stretchwrapper• Proliant Harlan Expansion

Education:Iowa State University - History and International Business


OUR PEOPLE

Ron Fendrick is a certified Professional Project Manager and a certified Six Sigma Green Belt with over 18 years of industry experience.

Ron has managed over 150 robotic automation systems and designed over 200 custom machines and tooling applications. He has supervised many projects from concept to completion.

Ron has expertise in energy savings, preliminary engineering, project management and energy, utility, equipment and control upgrades.

He holds a Bachelor of Science degree in Industrial Engineering from the University of Nebraska at Lincoln.

Ron joined EAD in 2007.

Ron Fendrick, PMP, Senior Project Manager

Education:B.S. Industrial Engineering

Certifications:Certified Project Management Professional (PMP) #190158 HACCP

Areas of Expertise:• Project & Construction Management• Budget Management• Scheduling

Barry Hale has over 20 years of construction experience, 15 of which were in a supervisory role. He has a successful history of working on projects ranging in size and scope.

Barry’s expertise is in budget management, scheduling and procurement services. He understands the importance of bringing projects in under budget and within the allotted schedule. He also maintains relationships with clients by keeping them informed of the progress on their projects.

In addition, Barry has experience working on commercial and industrial projects including tenant improvement, restaurants, school renovations and high-end residential.

Barry is certified as a Project Management Professional. He has completed training in AGC Superintendent Classes and the OSHA 30-Hour Safety Class. Barry is a member of the Institute for Supply Management.

Barry joined EAD in March 2009.

Barry Hale, PMP, Senior Project Manager

Certifications:Project Management Professional (PMP) #1678567 OSHA 30-Hour CertifiedAGC Superintendent Classes Areas of Expertise:

• Procurement• Project and Construction Management• Budget Management• Scheduling


OUR PEOPLE

Tom O’Sullivan offers over 37 years of experience in industrial design and construction and project management.

His management experience includes front-end and gate planning, project planning and execution, design development, scheduling, cost control, job site management, safety, quality and commissioning. Tom also possesses experience in the following technical areas: site and plot development, equipment and piping layout and design, civil and structural layout and design, and electrical and instrumentation installation and inspection.

Over his career, Tom has been involved in mechanical design, installation, remediation, renovation and demolition of complex piping systems, buildings, modular structures, railroad tracks, spurs and loadout spots, drainage and support systems, and intricate low-voltage and high-voltage electrical and control systems.

He holds a Bachelor of Science in Engineering Technology from Almeda College and University in Boise, ID, as well as two associate degrees in Mechanical Engineering Technology and Applied Science and Technology from Saddleback College in Mission Viejo, CA. Tom has also completed the OSHA 30-Hour Certification.

Tom O'Sullivan, Senior Project Manager

Education:B.S. Engineering TechnologyAssociate degree in Mechnical Engineering TechnologyAssociate degree in Applied Science and Technology

Certification:OSHA 30-Hour Certified

Areas of Expertise:• Project & Contract Scope of Work Development• Mechanical/Piping/CSA Design• Electrical & Control Systems• Contract Administration• Safety

Todd Berger offers over 10 years of experience in project management, engineering, product design and development.

His expertise is in pneumatic conveying and air filtration systems, where he has refined such skills as process improvement, machine design, product development, maintenance support and leadership.

In addition, Todd offers experience in project logistics, scheduling, team management, reducing manufacturing time and increasing production.

Todd holds a Bachelor of Science in Mechanical Engineering from Kansas State University and received his P.E. in the spring of 2008.

Todd joined EAD in August 2012.

Todd Berger, P.E., Senior Mechanical Engineer

Education:B.S. Mechanical Engineering Areas of Expertise:

• Project Management• Air Filtration• Pneumatic Conveying• Material Handling


OUR PEOPLE

John Dries is a senior mechanical project engineer with 27 years of experience in providing plant engineering support, 20 of which are in the food industry. He has seven years of combined experience in the hazardous waste disposal and chemical industries.

Throughout his time in the food industry, John has handled assignments and projects of different sizes and complexities from maintenance-oriented requests to large corporate initiatives. His involvement included process design, pneumatic conveying, belt conveyors, dust collection, sheet metal design, machine design, process layout and more.

During his years in the hazardous waste disposal industry, John had overall responsibility for working with site environmental regulators to compile engineering projects and oversee construction-related activities, maintenance support and trouble-shooting.

John Dries, Senior Mechanical Engineer

Education:B.S. Mechanical Engineering

Areas of Expertise:• Food Safety Engineering• Pneumatic Conveying • Dust Collection• Equipment Layout &

Installations• Food Process Engineering• AutoCAD 2013

William Crowe has over 25 years’ experience in the EHS consulting industry. The primary focus has been in commercial and industrial consulting services for safety and industrial hygiene. These services include employee workplace exposure assessments and sampling, safety plan and procedure development, and implementation of measures to improve safety culture. His environmental experience is in due diligence, National Environmental Policy Act studies, environmental assessments, and air quality monitoring. He has performed numerous projects on Commercial and Industrial buildings including asbestos management, mold investigations and indoor air quality assessments.

William holds Bachelor’s and Master’s of Science degrees in Biology/Chemistry from the University of Nebraska-Kearney and a MBA from the University of Nebraska-Omaha. He is also a Preventive Controls Qualified Individual (PCQI) Instructor for Human Food.

Bill Crowe, Safety Director

Education:B.S. and M.S. in Biology/ Chemistry MBA

Certification:PCQI Instructor for Human Food

Project Experience:• Oil Spill Response – BP Oil

and Gas• Tank Inspections – Eglin,

Patrick and Cape Canaveral Air Force Bases

• Fort Street Improvement Project Environmental Assessment

• Street Improvement Project Environmental Assessment

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