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Dredge Yard delivers the Auger dredger

Dredge Yard has engineered and manufactured a compact and economic sediment dredger, also known as Auger Dredger, which will be used for a desalination plant in the Gulf region.

This piece of equipment can be used particularly in rivers, streams, harbors, ponds, bays or artificial lakes to remove the accumulated sediments in a highly efficient and environment-friendly manner.

The sediment dredger has been designed for 9m dredging depth, with high production underwater dredge pump, 2 floating pontoons stiffened from inside, a ladder made of thick pipe and also stiffened at both ends.

Replaceable components

All the components are driven by a single heavy duty hydraulic pack which is placed outside behind the cabin.

This dredger functions as a cutter suction dredger but the cutting tool is a rotating Archimedean screw set at right angles to the suction pipe.

Dredge Yard can also offer its support in replacing the whole auger head with a new one or to replace the auger head with a cutter head.

Compact design

With its compact design, the sediment dredger can be easily transported or mobilized in separate dismounted parts inside of a container or as a complete unit on the truck by road.

Auger dredger presented at Europort 2015

Dredge Yard will also exhibit at Europort 2015 in Rotterdam presenting its range of dredging and mining equipment and components, the ongoing developments of the products, updates about the projects that Dredge Yard is working at present.

The company will also showcase scaled models of the cutter suction dredgers and also offer the realistic experience for the visitors to close examine product samples of our dredge cutter head and dredge ball joint.

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Developing the largest size dredge pump in dredging industry

As the demand for larger dredgers rises, there is a growing need for developing largest size dredge pump that can reach up to 1,800 mm suction diameter.

The largest size dredge pump is one of the main components of the dredger, and it is critical to achieving production. Dredge pumps also have the biggest power consumer during operation so efforts to reduce the pump’s power needs through smarter design are critical.

Engineering challenges of dredge pumps

Dredge pumps involve more complex engineering challenge than water pumps. They must carry water filled with mixture of several types of soils like mud, fine sand, coarse sand, gravel, stones, and other debris. The mixture of those materials with pumped water doesn’t behave as homogenous fluid as the soil tends to settle down and slide on the pipe bed depending on the flow speed. Another challenge is that pump parts wear quickly. Clogged impellers and breaking vanes also pose risks to pump performance.

Dredge Yard’s largest size dredge pump design

In 2011, Dredge Yard began developing a new range of dredge pumps ranging from 200mm to 1,400mm – the largest size dredge pumps in the dredging industry. These pumps are designed to counter wear problems inherent in dredge pumps. Impellers are designed in multiple categories of 3, 4 and 5 vanes. To resist wear, the pump parts are made from high chromium iron having a hardness of 60HRC. Unfortunately these materials don’t have high elongation properties and are not impact resistant. For this reason, some dredge pumps are built with an outer casing.

The large pumps are connected in series, reaching a final pressure of 30 bar by the 3rd pump. The pumps often weight more than 100 tons for one complete assembly including wet parts, outer casing, plates, shaft, bearing assembly and pedestal.

Size, weight and component resistance, among other factors, create an imposing challenge for dredge pump designers. Demand has recently grown in the market for even bigger dredgers. Dredge pump size must increase from 1,400 mm to 1,600 mm – even 1,800 mm. Larger suction pipes and dredge pumps must be designed to fill the dredgers in less than 2 hours.

New design methods are needed to adapt to the market efficiently. Pumps must be tested and analyzed for their efficiency and performance. Foundries with casting capacity of 50 tons and heavy steel machinery 6 meters in diameter are required when casting and machining the pump case.

Performance analysis of the largest size dredge pump

The size of these dredger pumps makes building a test and analysis laboratory extremely difficult if not impossible. The manufacturer must design and manufacture the pump as a prototype and deliver the prototype to the dredger without testing and performance checks. All performance will be tested in the dredger when it starts working. The design has to be flawless, performance oriented and reliable before its production. Engineers at Dredge Yard test dredge pump performance with computational fluid dynamics (CFD) instead of physical testing. CFD software calculates and simulates the pump performance measurements like flow rate, aeration, cavitation, pumping head, efficiency, power required, and net positive suction head (NPSH).

CFD codes, can provide steady-state simulation, also known as multi-frame reference (MRF) simulation or “frozen blade” simulation, which put the impeller in a reference frame that rotates at the pump speed, while solving for the rest of the pump in the stationary lab frame.

3-D modeling

After achieving the hydraulic design, a basic 3-D pump model is made in several CAD programs. Once the basic design is completed Dredge Yard runs several trials on major FEA calculations on the model to ensure getting the right stiffness and strength of the pump. This model incorporates pressures output from the CFD analysis to determine the wall loadings.

The gap between the impeller and front plate must be tightly controlled in terms of geometric tolerance. If deformation widens the gap, efficiency will drop significantly. The 3-D modeling and FEA process is repeated as needed to ensure the highest safety margin and lowest weight. At 1,800 mm a dredge pump weights approximately 200 tons. Any weight savings from the FEA calculation could be significant.

Design work continues on the 1,800 mm dredge pump. Dredge Yard aims to finalize the development in 2016 and build the pumps for the dredging and mining market.

One of the examples of a geometric tolerance that needs to be tightly controlled is the gap between the impeller and the front plate. If there is a deformation in that area and the gap widens, the efficiency will drop significantly. Besides the impeller gap effect, the stiffening of the pump structure will assure a symmetrical tension on the pump case and plates. As the pump case is of a volute shape and pressure is not evenly spread, deformation could be asymmetric which is not desirable in pump structures.

The 3-D models takes into account such performance measurements as flow rate, head and cavitation for many of the pump’s components.

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Dredge Yard presents latest developments at WEDA Mexico 2015

Dredge Yard was the Gold sponsor of the WEDA Mexico 2015 Annual Meeting. That meeting took place in the Centro Asturiano de Polanco located in the heart of Mexico City’s bustling Polanco neighborhood. There Dredge Yard presented their latest developments at the WEDA in Mexico.

At the event, our Marketing Manager, Iulia Berchiu and the CEO, Basel Yousef presented our dredging equipment and dredging solutions. In addition, they provided information about Dredge Yards latest projects that are dedicated to achieving the highest performance while protecting the environment and cutting the costs. Some of these projects are:

  • Dis-mountable cutter suction dredger 450 that is under construction in the Netherlands;
  • The ECO200 dredger is designed to be compact, economic and therefore easy to transport;
  • The auger dredger is similar to ECO200 dredger but equipped with an auger head for sediment and sludge dredging. Presumably the auger dredger will be delivered at end of this year.

Dredging opportunities at WEDA Mexico

The WEDA Mexico Annual Meeting 2015 focused on the many dredging opportunities available in Mexico. These opportunities are a result of Mexico’s robust port infrastructure development and investment program. The meeting 2015 brought together professionals around the world to provide expert advice and share ideas. These professionals included Mexico’s Ministry of Transportation, Mexican port authority officials, the U.S. Army Corps of Engineers, the Panama Canal Authority.

According to Frederick Paup, Chairman of the Board Manson Construction Co., the event was informative. The company also appreciates the excellent turnout by the Mexican port authorities’ representatives.

Panama topic was brought up by the International Trade Specialist of the Panama Canal Authority, Javier Gilberto Carrillo Koo. He explained the impact and opportunities involved in the Panama Canal expansion.

Arturo Cors de la Fuente, Business & Institutional Relations Director of the CICE Group (Integral Foreign Trade Corporation) discussed the evolution of Mexican Ports. That evolution is considered a growth approach.

Open to private companies

Arturo Cors de la Fuente states: “Dredging in Mexico has changed during the last years. Before it was a Government activity and only large projects were subject of hiring private companies. Nowadays, the market has opened up to private companies and there are few exceptions. Only the Mexican Navy that holds the dredgers for their own purpose. In the last decade Mexican market has contracted an average of $90 million/year reaching a peak of about $260 million in 7 years. ”

Both foreign and local companies are getting many opportunities at the Mexican dredging market. Juan Ignacio Cruz Lomeli, the GM of Desazolves y Dragados, related that the dredging industry is an activity that demands specialization and therefore can’t be handled by companies without experience.
“The conference filled my expectations in terms of exchanging ideas and networking. And as Ricardo Hernandez, the President WEDA Mexico Chapter, said: I hope this is the first congress of many more because we need to establish a close group of dredging experience here at the WEDA in Mexico.”

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Dredge Yard at Dredging in India Conference 2015

For the second year Dredge Yard was the key sponsor in India’s biggest Dredging Conference that was hold in Taj Mahal Palace in Mumbai.

The annual event focused on analyzing the key trends and developments, highlight recent government initiatives and discuss the best practices and the most promising technologies related to the dredging industry.

Innovative design

Dredge Yard’s representatives, Teun Boerma (the company’s Sales Manager) and Michel Debo (Operations Manager) explained the high importance in innovative designing and building up efficient and cost effective dredger and dredge equipment.

Michel Debo has also stated that due to the growth demand of dredgers in the Indian region, Dredge Yard considers to start building up in India different ranges of cutter suction dredgers and trailing suction hopper dredgers that will contribute to cutting the costs and ensure time delivery.

“There are numerous dredging projects going on at the moment in India and many others in the upcoming future. The construction of new major ports at Sagar, West Bengal, Andhra Pradesh or Dugarajapatnam will only increase the demand for dredging operations and we are ready and have the expertise to offer our support by starting building up all type of dredgers needed for the Indian demands.” – Michel Debo

Teun Boerma, Dredge Yard’s Sales Manager, shared with the audience all the information about the dismountable cutter suction dredger that is the first of a complete series of versatile cutter suction dredgers with a discharge pipe diameter of 450 mm and that will be complemented with the 350, 500 and 650 versions in the near future.

“Dredging in national waterways is another area of opportunity and the union government has announced plans to convert 101 plus rivers across the country into national waterways which expects an increase in demand for high efficiency dredgers. Dredge Yard range of CSD’s are easy to maintain, affordable and foremost dredgers with high productivity that can be the best option for dredging in India.” – Teun Boerma

 

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Dredge Yard is showcasing at WEDA Mexico Chapter

The WEDA Mexico Chapter, representing all regions in Mexico, will at its 2015 Annual Meeting bring together dredging contractors and manufacturers from across the globe, senior U.S. and Mexican government and port officials, experts in the infrastructure, energy and dredging sector.

Dredge Yard, the dredging and mining manufacturer, is participating in the Mexican Chapter held in Mexico City, as a Gold Sponsor of the event.

The event will be a great opportunity for Dredge Yard to exchange ideas and experiences, share projects related information and find solutions for the Mexican dredging and port infrastructure development programs.

Meet our support team at WEDA Mexico Chapter

Dredge Yard’s support team will be present at the event to give all the information needed about the latest dis-mountable EURO DREDGER 450 that is under construction.

The company will also present the ECO200 dredger that has been designed after the advice of several dredging companies that have a need for a compact, economic and easy to transport dredger; as well as the auger dredger which is similar to Eco200 dredger but equipped with an auger head for sediment and sludge dredging.

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EXCLUSIVE: Dredge Yard attended WEDA Dredging Summit

Dredge Yard, a supplier of dredging and mining components, equipment and technologies, took part in the WEDA Dredging Summit and Expo, held from June 22-25, 2015 at the Westin Galleria in Houston.

The event hosted numerous technical sessions and gave the opportunity for all the leading organizations in dredging and port industry, dredging contractors and experts in environmental issues to exchange the knowledge in fields related to dredging, marine, engineering and environment.

Maximizing potential

Dredge Yard’s technical paper was about how companies can maximize their potential by converting or upgrading existing dredgers.

Basel Yousef, Dredge Yard’s CEO, said: “New technologies are being developed more rapidly than ever before, thus providing a constant stream of new solutions and options for users, enabling them to become even more efficient and meet the ever growing demands of our industry. The modification, conversion and upgrading of existing dredgers are proving to be good solutions for users to increase their capacity and capabilities with a reasonable amount of investment.”

Many opportunities at WEDA Dredging Summit

The Summit had an outstanding program with many opportunities to connect with others in the dredging and maritime industry during reception, site tours and other event functions.

Iulia Berchiu, Markering Manager of Dredge Yard, added: “We were very excited to hear that WEDA will take place this year in Houston. The city is well known as a world capital of oil and gas industry and the Port of Houston ranks first in the United States in international waterborne tonnage handled and second in total cargo tonnage handled.“

The event concluded with a technical tour by visiting Houston Ship Channel, one of the busiest waterways in the United States.

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Dredge Yard will attend WEDA 2015 Dredging Summit in Houston

Dredge Yard will participate in the Dredging Summit and Expo during June 22-25 2015. The expo is held in the Westin Galleria Houston, United States.

Visit us at the Dredging Summit in Houston

You can find Dredge Yard at the dredging summit in booths number 52 & 53. Dredge Yard is showcasing their innovative solutions for the dredging and mining industry. These innovations include the latest complete series of versatile Cutter Suction Dredgers such as the EURO-Dredger. It also features smaller the economical, compact and low cost ECO Dredger.

 

Dredge Yard has ISO 9001 Certification

ISO certification

Dredge Yard, a company dedicated to the market of dredge equipment and dredging technology, has received ISO 9001 certification, the internationally recognized standard for the quality management of businesses worldwide.

Dredge Yard’s Finance Officer, Syed Aalishan, said: “By implementing ISO 9001 Quality Management System in Dredge Yard we didn’t only aim for International Quality Recognition, Consistency in Operations and Increase in Customer Satisfaction. It is also a way of empowering employees by providing them with clear explanations, procedures instructions and of course feedback on their performance.”

By getting the certification, Dredge Yard wanted to make sure that there is a conformance to customers’ requirements, consistency in operations, good quality services and products that all leads to customer satisfaction.

Due to that Dredge Yard performed a physical ISO 9001:2008 certification audit for checking the quality of management system.

 

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Dredge Yard & Neptune Shipyards introduce EURO DREDGER 450

Euro dredger 450

Dredge Yard is furthering their steps to enter into the dredging market for modular dredging equipment with the Euro Dredger 450.

Co-operation

Dredge Yard and Neptune Shipyards based in The Netherlands have found exciting opportunities to partner in order to develop innovative products and exploit operational synergies.

Iulia Berchiu, Dredge Yard’s Marketing Manager, said: “The dismountable EURO DREDGER 450 is one of their first projects that started in March 2015 with detailed engineering and is planned to be ready for delivery in the 4th quarter of 2015.”

Dredge Yard’s Sales Manager, Teun Boerma, added: ”It is our focus to create a first class dredger, which will meet the requirements of our customers, which is reliable and easy to maintain, affordable and foremost a dredger with high productivity. In addition, we want to meet the highest safety standards for our customers and best work environment for the operators.”

Cutter suction dredger

The EURO DREDGER 450 is the first of a complete series of versatile Cutter Suction Dredgers with a discharge pipe diameter of 450 mm.

The EURO DREDGER 450 will be complemented with the 350, 500 and 650 versions in the nearest future.

All dredgers will have an inboard dredge pump and a hydraulic driven cutter head and a wide range of options will be made available such as a spud carrier system, anchor booms, submerged dredge pump and dredge automation & control.

Here are some of the main Features of the EURO DREDGER 450:
Length overall : 25.1 [m]
Dredging depth : 10 [m]
Suction pipe diameter : 500 [mm]
Discharge pipe diameter : 450 [mm]
Dredge pump diesel engine : 634 [kW]
Cutter power : 112 [kW]
Total installed power : 866 [kW]

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Dredge Valve production by Dredge Yard

Dredge Yard recently delivered dredge valves of sizes 600, 700 and 750 mm internal diameter. The valves are needed for the discharge pipeline on board of two trailing suction hopper dredgers. Fabrication was done in-house at Dredge Yard’s production facilities.

Dredge valve fabrication

The body of the dredge valve was fabricated from high tensile steel and the valve’s gate is made of corrosion resistant and hardened steel, protecting it against the rust and wear. For conservation of the outer surface of the valve a high quality marine type paint was applied to protect it against corrosion.

These types of dredge valves can be produced for three different working duties varying between 10, 20 and 30 bar according to the customer’s requirements and applications.