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Reliable dredge valves to upgrade dredgers

Dredge Valves

Dredge Yard has successfully delivered dredge valves of sizes 600, 700 and 750 mm internal diameter, which were needed for the discharge pipeline on board of 2 trailing suction hopper dredgers.

Dredge gate valves are highly sophisticated components and for proper functioning and maintenance, it is very important to select the right type with the right material and pressure handling capability for long life.

Design

All the dredge valves have been designed by Dredge Yard’s team of engineers using the latest design software. Fabrication was done in-house at Dredge Yard’s production facilities.

One of the special features of the valve is the steel reinforced rubber seals making the seal very durable, making it easy to cope with the large amount of abrasive slurries and to be able to open and close smoothly in tough working conditions.

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.

Inspection

The inspection hole placed in the both sides of the valve’s body, allows for easy inspecting the dredge valve without dismantling it.

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.

The dredge valves had to be delivered in a short time for replacement of an existing valve during maintenance of the dredgers.

 

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Dredge Yard supports Oranjecommittee Dubai

Dredge Yard is proud to support the Oranjecommittee Dubai during all their major events. They celebrated “Oranjefeest” last Thursday in the enchanting Emirates Golf Club.

Orange hearts

The party gathers many Orange hearts every year and was again a great success. Hermes House Band and Johan Kettenburg, very popular acts in the Netherlands, made sure that it was an unforgettable evening.

 

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Dredge Yard delivers dredge equipment for upgrading TSHD’s

Dredge equipment for TSHD’s

Dredge Yard has successfully supplied key dredge equipment for the upgrading of two existing TSHD’s, the dredging capacity needed to be increased to enable the operator to complete dredging works in shorter time periods and in a more cost effective manner.

Complete modification

The TSHD’s underwent complete modification at a dockyard in Dubai. The modifications were done with dredge equipment designed and produced by Dredge Yard using the latest CAD technologies and production methods.

The TSHD’s were upgraded by installing a shore discharge line on board and a bow coupling system on each dredger. The new discharge line will allow the dredgers to offload the material through a floating pipeline that will be connected to the bow coupling. The bow coupling also has the option for rain-bowing through a nozzle if required.

Components

The various components supplied with the discharge line include hydraulic gate valves, a complete bow coupling with structure, dredge pipes and bends. In addition, all hydraulic cylinders for the bottom doors were replaced by Dredge Yard.

The dredge bow couplings allow the dredgers to couple and decouple the floating discharge pipeline in the fastest and safest way. Locking parts of the couplings were made of stainless steel and the wet parts were made of high wear resistant material to increase the life time of couplings.

The dredge valves supplied are all hydraulically operated with the gates made from stainless steel and an innovative rubber seal reinforced internally by steel rings.

 

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Dredge Yard at International Conference of EADA in India

Participation at EADA

EADA (India), in association with Department of Harbour & Ocean Engineering AMET university (Deemed) organized The International Conference on waterways, port engineering and dredging technology that took place on 2nd  March 2015 in Chennai, India.

Some of the topics that were covered in the conference were about the new Dredging Techniques and Equipment, Contracts, Legislation and Engineer Determination , Planning and Execution of the Dredging Projects  and of course Opportunities of Dredging in India.

Sponsorship

Dredge Yard, main sponsor of the event, was represented by Manish Jangir, Senior Design Engineer, that spoke about the latest trend in dredging industry: converting and upgrading dredgers. ”All type of dredgers can be subject for modifications that can vary from replacing a single pump with more efficiency to the whole suction/discharge system of the dredger or literally converting existing barges and vessels into dredgers.”

Upgrading

Upgrading of existing dredger systems is quite practical as it offers reusability and functionality of the old dredger with low investment.

Conversion of existing vessel into dredger can help in increasing the capacity and capability of the dredging companies in much lesser time with a huge saving in investment.

Modification of dredger is also needed when the dredger supplied may not meet up the requirements and slight changes in the parts or system can make it appropriate for the project requirements.

“Modifying or converting old vessels will always be considered the most convenient alternative due to the cost cuts, less time involved in the makeover of an old ship than building a new one and the possibility of customizing the vessel according to the customers’ needs.” added Manish Jangir.

EADA (India) is a national chapter of EADA that provides a forum for the exchange of quality information on dredging techniques, technology and dredged material management, and for the development of good practice guidance.

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New trend: upgrading & converting dredgers

Modification, conversion and upgrading

Engineering is continuously providing new technologies and solutions with time. It is therefore creating new options for users to be well-efficient and highly proficient. In the recent times, modification, conversion and upgrading of existing dredgers are proving to be good solutions for users. These solutions increase capacity and capabilities with a reasonable amount of investment. Companies which cannot invest in a new dredger can convert their existing dredger, barges to a more functional and efficient dredger.

Upgrading of existing dredger systems is quite practical as it offers re-usability and functionality of the old dredger with low investment.

Conversion of existing vessel into dredger can help in increasing the capacity and capability of the dredging companies in much lesser time with a huge saving in investment.

A dredger also needs to be modified when the supplied dredger does not meet the requirements. Slight changes in the parts or system can then make it appropriate for the project requirements.

All type of dredgers can be subject for modifications that can vary from replacing a single pump with more efficiency to the whole suction/discharge system of the dredger or literally converting existing barges and vessels into dredgers.

Upgrading Dredge Pumps

Dredge pump or sand-slurry pump is considered as the heart of the dredger and plays the most vital role on the efficiency of a dredger.

 Dredge Yard’s Senior Design EngineerManish Jangir, says: “Latest tools in the market like CFD and optimum design calculating software have widen the paths of having an efficient pump design for the same old pump without changing any fitting parameters or the connections like the flange.

After achieving the final design of the pump, the manufacturing is done by using the latest production techniques, molding software for casting, and strict metallurgical testings.

Suction and delivery lines upgrades

Suction and delivery lines of a dredger are the means of transport of slurry and the line design and components vary between dredgers. The efficiency of the dredger depends on the pump and the pumps efficiency certainly depends on the pipe line. And the maintenance cost depends on the quality and capability of the components. The major components involved in the pipe lines are: pipe pieces, gate valves, suction mouth, swivel bend, bow coupling, turning glands, ball joint couplings, etc.

New trending components

Kabi Eisa, Production Manager at Dredge Yard describes the double wall dredge pipe as the newest trending product in the dredging market. He also adds that the double wall pipes are highly wear resistant due to their special design where three layers of material have been used. It consists of wear liner, concrete and steel pipe where wear liner being the layer that will be in contact with the sand or slurry.

Double Wall Dredge Pipe

Dredge Gate Valves are highly sophisticated components and for proper functioning, maintenance, it is very important to select the right type with right material and pressure handling capability for long life.

Upgrading split suction trailing hopper dredger

“For example, the dredger in the image didn’t have a discharge line and could only offload the material through its bottom doors. Dredge Yard developed the complete suction and discharge line on the ship which includes several pipes, bends, dredge valves, and bow coupling. The nominal diameter of pipe is 750 mm.” says Michel Debo, Dredge Yard’s Operational Manager.

Converting hopper barge into trailing suction hopper dredger

Another example shows a barge in Brazil, capacity 800 m3, which is in process of conversion into trailing suction hopper dredger. A complete trailing suction system has been installed on the barge. The system consists of drag head, turning gland, gantries, sliding piece, pipes, bends, valves, pump and bow coupling.

Discharge line on TSHD

Many hopper dredgers are upgraded by adding complete discharge line on the ship as pipes, bends, valve and bow coupling structure.

Modifying or converting old vessels will always be considered the most convenient alternative due to the cost cuts, less time involved in the makeover of an old ship than building a new one and the possibility of customizing the vessel according to the customers’ needs.

 

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Dredge Yard at the 2nd International Forum Of Dredging Companies

2nd International Forum of Dredging Companies

Dredge Yard was sponsor for the second year of The International Forum of Dredging Companies, organized by the Media-Group Port News with the assistance of the Ministry of Transport of Russian Federation.

The forum was held on February 19, 2015 in Moscow, in St. Regis Moscow Nikolskaya, distinguished in its rich history and surrounded by historical buildings with a centralized location at the corner of Nikol’skaya Street and Bolshoi Cherkassky Lane.

Specialists

The International Forum of Dredging Companies brought together specialists from around the world to share their expertise in new dredging and land reclamation technologies, state-of-the-art equipment for operations in seaports’ water area and to present the audience with Russian ports’ demand of dredging and land reclamation works.

Dredge Yard, represented in the forum by Iulia Berchiu and Basel Yousef, brought up the topic of the modification and conversion of existing vessels that is the best solution for companies which have limited time and budget to invest in the building of a new dredger.

“All type of dredgers can be subject for modifications that can vary from replacing a single pump with more efficiency to the whole suction/discharge system of the dredger or literally converting existing barges and vessels into dredgers. “ said Basel Yousef, Dredge Yard’s CEO.

Modification

Moreover modifications can be done during the replacement of the old equipment like the pump for example without any additional expenses.

Modifying or converting old vessels will always be considered the most convenient alternative due to the cost cuts, less time involved in the makeover of an old ship than building a new one and the possibility of customizing the vessel according to the customers’ needs.” added Iulia Berchiu, Marketing Manager of Dredge Yard.

Dredge Yard has gained vast expertise in various projects by upgrading or converting existing vessels or dredgers and knows what positive impact are bringing all these modifications.

Dredge Yard gave an interview in Dockyard Magazine

Dredge Yard interview in Dockyard Magazine

Dockyard magazine is a monthly publication with regular up to date news feeds and technological developments from maritime industry.

It has always been a demand for state-of-the-art dredging equipment to meet the requirements in the market. Dredging equipment are influenced by a variety of factors such as the location of the area that needs to be dredged, the placement side of the sediment, type of soil, environmental conditions, safety hazards, lead time, leakage proof systems, etc. The discharge line in dredging has become the prime focus for engineers to optimize the quality of dredging and reduce overall cost. Improved efficiency of the components used in the discharge line has significantly affected in lowering the cost of a project. The discharge line depends on the project size and requirements. A survey conducted on the power consumption areas of the dredger shows that the discharge line is taking the biggest part of the used power generated on board.

Factors upon which Power Consumption of the dredgers depends

• Discharge length
• Bends and height of discharge area
• Type of pipe joints

Power consumption in percentage

• For Cutter Suction Dredger(CSD) 40% – 70%
• For Trailing Suction Hopper Dredger(TSHD) 30% – 60%

What’s trending in dredging?

The components involved in discharge line are mainly pipe spools and coupling systems.

Dredge Yard is giving an insight into the coupling systems solutions available for discharge line to have better production depending on customers’ needs.

1. Quick coupling Ball joints

There is a range of cost effective, high strength and wear resistant steel ball joints from size DN 400 to 1200 mm. These ball joints are designed and produced by Dredge Yard with latest CAD technologies and years of experience in the dredging field.

Benefits:
• Quick coupling
• High strength
• Easy assembly
• Easy maintenance

2. Ball joints with open liner

To prevent blockage of flow and acceleration of fluid inside the ball joint an addtional liner can be installed in the ball instead of welding the pipe through the ball.
Dredge Yard CFD simulations shows a huge improvements on pressure drop saving up to 50%. Concave liner has one end with the same size as the pipe inner diameter. Other end of the concave liner is bigger than the pipe inner diameter. The diameter of the liner depends on the turning angle of the ball joint.

The benefits are:
• Less pressure drop
• Replaceable liner
• Less wear due to lower speed
• Cost-effective
• Flow friendly
• Eco friendly

3. Bearing Ball Joint

This is a ball joint that is provided with two bearing rings made either from bronze or from duplex steel. This must be done in combination with a duplex ball.

The benefits are:
• No need for use of grease or lubricants
• The ball is more flexible than carbon steel ball joint
• The ball joint has longer life time as duplex is harder than carbon steel
• The liners are replaceable
• Easy dismanteling cause there is no rustweld

4. Spine Hose

A more flow friendly solution is the use of a new introduced spine hose by Dredge Yard that has rubber on the outer side and steel rings (ball and gland) in the inside.

The benefits are:
• Flow friendly resulting in less friction
• Wear resistant inner core
• Lower in weight compare to ball joints
• Easy maintenance by replacing only worn out rings
• Flexible (15 degrees per meter)
• Can’t be folded or collapsed
• Flexible in all directions
• Greaseless
• Environmental friendly

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New ECO200 dredger from Dredge Yard

ECO200 dredger

Dredge Yard, one of the world’s leading manufacturers of dredging and mining equipment, took part at the “Dredging in India” conference, held in Mumbai from 3-4 September 2014, and presented its new model, the ECO200 dredger.

At the event, the company’s Operations Manager, Michel Debo introduced a compact and economic cutter suction dredger, the ECO200. The vessel was designed by Dredge Yard’s engineers by using the latest CAD technologies, FEA analysis, CFD analysis. The main aim of the company was to make an economic dredger that is low cost at initial acquiring and in daily use as well as robust and efficient in design.

Benefits

This dredger will offer many benefits to operators like an underwater dredge pump placed on the front part of the ladder which will allow the dredger to handle higher dredge mixture and high volume of mixture flow. The complete ECO200 is transportable by standard closed top 40 feet containers, the complete spud assembly together with its hydraulic cylinders is able to be tilted on its pontoon.

This allows the dredger to be towed easier under very low bridges and other obstacles. For the drive of all components being the dredge pump, cutter head, winches and spud cylinders, one hydraulic power pack is provided on the central platform.

Feature

Lastly, the ECO200 will feature the cutter head with replaceable teeth what is unusual for this size of dredgers in the market. Dredge Yard will offer strong support, onsite assisting end users with their projects, training if required, maintenance and transport. All spare parts will be available on stock ready for shipment at any time to prevent downtime of the dredger and delays in the project.

“The aim of the design was to make an economic dredger that is low cost at initial acquiring and in daily use,” concluded Manish Jangir, Design Engineer.

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Dredge Yard participates in Latin American Congress of Ports

Latin American Congress

For Dredge Yard would be the first time to participate in the Latin American Congress of Ports that will be held in less than a week in Puerto Iguazú in Argentina.

Dredge Yard’s objectives are to showcase its latest innovations in realm of dredging and mining equipment, to exchange the ideas and experiences between the port authorities, dredging companies, operators, service providers and maritime industry leaders.

AAPA Congress

Argentina, Puerto Iguazú is the host city of this summit convened by the American Association of Port Authorities (AAPA) under the motto: “The pivotal role of Latin American Ports in the integration of the hemisphere and regional development”

AAPA Congress is the annual meeting par excellence and it is considered to be one of the most important events of the sector because it gathers leaders and company representatives of the activity in the whole Continent.

Sponsorship

The participation of Dredge Yard will be through a stand (booth number 10) and the sponsorship of the event. Representatives of Dredge Yard will accompany its visitors and provide any information related to the Cutter Suction dredgers, Trailing Suction Hopper dredgers, mining equipment and dredging components needed for the dredgers and dredge pipe lines.

 

Dredge Yard expands its fabrication capacity

New machines

Dredge Yard recently acquired and installed additional new machines in its fabrication facility in Turkey like CNC vertical lathes and CNC Pattern Maker. This is to increase its capacity in the machining and assembly shop and to align with the capacity of the casting and fettling.

Focus on production

Dredge Yard with its subsidiary in Izmit city in Turkey is focusing on production of components and equipment needed for the dredging and mining industry. Some of the main components supplied from Dredge Yard Makina are dredge pumps, dredge ball joints, turning glands, swivel bends, dredge valves, tumbler blocks, cutter heads and many others.

Dredge Yard is also co-operating with many partners in the region for the casting and machining in order to cope with the high demand of Dredge Yard’s products and keep its short delivery times.

Dredge Yard is able to supply components in several cast steel and cast iron, in soft and hard wear resistant materials that can be used in dredge pumps, ball joints, bends and many others. Those components are cast with Dredge Yard’s partners and fettling is done in the facility in Izmit. Once the machining is done, all products are thoroughly tested, inspected and assembled at Dredge Yard work shop and made ready for transport.

Shorter delivery time

The recent capacity increase will allow Dredge Yard to make its own casting patterns and machine more parts up to the size of 2.5 meter by itself and shorten the delivery time and save transport costs. The shorter delivery time and the cost saving will contribute to the benefit and satisfaction of Dredge Yard’s customers.

Dredge Yard’s Production Manager, Kabi Eisa says: “Dredge Yard is pursuing to procure more machines in the near future that will increase the manufacturing capacity aiming to become faster, flexible and more efficient maintaining the same high quality of the products”.

Beside Turkey, Dredge Yard is producing dredge components and equipment in other countries as The Netherlands, Romania and UAE.