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Dredge ball joints deliverd to Saudi Arabia

Dredge Yard designed and manufactured the dredge ball joints delivered to Saudi Arabia.

The ball joints can handle a working pressure of 20 bar. They are also suitable for a discharge pipe diameter of 650mm. Wear resistant liner is assembled in the case to increase the life time of the ball joint. A rubber seal is provided in the case to make the ball joint water tight during pressure. Both of them, the case liner and the rubber seal, are considered wear parts and therefore can be easily renewed.

Range of Ball Joints

These types of ball joints that have been delivered to S.A. have a 15 degrees tilting angle to all directions. The grease grooves are provided in the stiffened gland to reduce corrosion and the friction between the gland and the ball. The ball joint is provided with one locking pin to prevent the gland from any sliding movement during operation.

The ball joint will be used for transport of sand, gravel and stones from the Cutter Suction dredger.

Dredging components production facility opened

Production facility

The new dredging components production facilities are managed by Dredge Yard’s subsidiary Dredge Yard Makina San. Tic. LTD.ŞTI recently registered in The Republic of Turkey.

This is part of the Dredge Yard’s expansion plan for the production and assembly of several dredging components like ball joints, pumps, valves, turning glands, bow couplings and a lot of other dredging equipment needed for the dredgers and dredge pipe lines.

Dredge Yard Makina

Dredge Yard Makina San. Tic. LTD.ŞTI is located in the city Izmit of Kocaeli, surrounded by an industrial area including for heavy steel industry.

Dredge Yard Makina in collaboration with its partners in Turkey will be utilized for the production, assembly and quality control of all dredge components, using latest casting and machining technologies.

As part of the development of the new production facilities, Dredge Yard Makina has acquired special equipment to enhance its capability for higher production rate.

These new facilities will allow Dredge Yard to accommodate the rapidly growing demand of dredge related products with a high ratio of reliability and value for money.

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Dredge ball joints 1000 and 900 delivered by Dredge Yard to MEDCO in Qatar

The dredge ball joints for the pipes size of 1000 mm are suitable for 30 bar working pressure. While the ball joints for the pipes size of 900 mm are suitable for 20 bar working pressure.

Dredge Yard facilities

All ball joints are designed and produced in Dredge Yard’s facilities with partners in The Republic of Turkey. There they used the latest production technologies and casting expertise. Both types undergo thorough testing and inspections during and after production. Examples of these tests are simulating working pressure and dredge ball joints movements.

Dredge Yard is making steady progress with the expansion plans for the production and assembly of dredging components needed for dredgers and dredge pipe lines.

Production of dredge ball joints

Dredge Yards team of engineers managed and controlled the entire production. For that they relied on their vast experience in casting, machining, assembly and inspections. Our customers may witness any test in Dredge Yard’s production facilities.

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Dredge Yard delivered turning glands for several TSHD’s

Dredge Turning Glands

The dredge turning glands will be used on board of several TSHD and they are designed according to the customer’s requirements and applications using the latest 3D CAD technologies and Finite Element Analysis to ensure achieving an optimum strength and stiffness.

Manufacturing

The turning glands are manufactured from cast carbon steel and fabricated steel and machined and assembled with Dredge Yard partners and Dredge Yard facility in the United Arab Emirates.

The inner pipe of the turning gland is made out of one casting to make the complete design stronger and stiffer while saving weight and material. Dredge Yard quality control inspectors scrutinize all the dredge turning glands during and after their production stages carrying out various tests such as the chemical composition and mechanical properties test, measurement test of all dimensions after casting and machining, ultra sonic testing, magnetic particle, surface roughness test and dye penetrant inspection for critical parts, measurement test of all dimensions after machining, hardness test, assembly and interchange ability test, visual inspection for all parts during and after assembly.

Latest component

The Dredge Turning Gland is the latest dredge component accurately and professionally developed by Dredge Yard team of engineers and it has several interconnected benefits making it a reliable product like a compact seal design making the assembly less heavy, adjustable turning range by using dismountable stoppers, and a heavy duty wall and flange thickness.

Dredge Yard’s official web site, www.dredgeyard.com, can provide further information relative to dredge turning gland and about all the dredging equipment and technology.

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Dredge valves lauched by Dredge Yard

Dredge Valves

Dredge valves are used to control the flow of water and sand in the suction and discharge pipes of either cutter suction dredgers or trailing suction hopper dredgers.

The dredge valve is designed in such a way that there are no fasteners inside the body that can loosen and damage other parts during operation. On the other side, all the connections outside the dredge valve body are bolts and nuts that can be easily replaced without damaging any part of the body.

Two inspection holes located on both sides of the dredge valve allows an easier way of inspecting inside of the dredge valve body without dismantling any part of it.

Design

Dredge valve is designed to cope with a large amount of abrasive slurries and to close and open smoothly in these tough conditions. For this reason Dredge Yard has designed a steel reinforced rubber seal hardened at both ends to ensure long life time and interchangeable in all directions.

The body of the dredge valve is made of cast steel and fabricated high tensile steel. The dredge valve gate is made of corrosion resistant and hard steel, protecting it against the rust and wear.

The dredge valves are designed in three different working pressures varying between 10, 20 and 30 bars according to the customer’s requirements and applications.

All dredge valves are designed, produced, assembled, tested, painted, greased, packed and transported under close super vision of Dredge Yard team of engineers and quality control.

Dredge Yard emphasizes on after sales and tries to surpass customer expectations.

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Dredge turning gland launched by Dredge Yard

Dredge turning glands

Dredge Yard, a company dedicated to the market of dredge equipment and dredging technology has announced the launch of the dredge turning gland. Dredge turning gland is a TSHD component that is attached to the lower suction pipe allowing a radial rotation in both directions. Due to this feature the dredge turning gland enables the dredge drag head to follow the sea bottom without losing vacuum.

The Dredge Turning Gland is the latest dredge component accurately and professionally developed by Dredge Yard team of engineers. All dredge turning glands products are designed according to the customer’s requirements and applications using the latest 3D CAD technologies and Finite Element Analysis.

Quality control

Dredge Yard attaches high importance to the quality control, the production process, the materials of the parts, and the equipment used for the manufacturing of all the dredge components. Therefore all the dredge turning glands are manufactured at high quality manufacturing facilities and undergo strict tests under ISO and ASTM standards.

Dredge Yard quality control inspectors scrutinize all the dredge turning glands during and after their production stages carrying out various tests such as the chemical composition and mechanical properties test, measurement test of all dimensions after casting and machining, ultra sonic testing, magnetic particle, surface roughness test and dye penetrant inspection for critical parts, measurement test of all dimensions after machining, hardness test, assembly and interchange ability test, visual inspection for all parts during and after assembly.

Benefits

The materials used for the production of the dredge turning glands are cast iron for sliding pieces and carbon steel for pipes and flanges.

The dredge turning gland has several interconnected benefits making it a reliable product like a compact seal design making the assembly less heavy, adjustable turning range by using dismountable stoppers, and a heavy duty wall and flange thickness.

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Dredge suction mouth developed by Dredge Yard

Dredge suction mouth

Dredge Yard, a specialized company in dredging technology and dredging equipment based in the Netherlands and United Arab Emirates has announced the launch of the dredge suction mouth. The dredge suction mouth is a dredge component positioned behind the cutter head of a Cutter Suction dredger during extraction of non-cohesive material from the sea bed.

CAD & FEA

Dredge Yard team of engineers designed the dredge suction mouth using the latest 3D CAD technologies, latest production methods and they entirely scrutinized the designs using Finite Element Analysis. External and internal forces are examined and all maximum possible scenarios are simulated.

Production and design

In order to provide the most reliable dredge equipment with high accuracy and precise dimensions to fit in the cutter head and the suction pipe, Dredge Yard is using only one cast piece for the production of the dredge suction mouth that eliminates many operations, such as machining, forging and welding. Casting the suction mouth in one piece allows producing the most intricate shapes, both external and internal that can follow the shape of the flow. In this way competitive prices and shorter delivery times can be achieved.

The dredge suction mouths as well as the other components are designed, produced and tested under strict ISO and ASTM standards and double tested at third party for verification.

Materials

The following materials are being used according to the customer’s requirements: Carbon Steel that allows easy welding and hard facing if required; Carbon Manganese Steel that increases depth of hardening and improving the strength and toughness; and Alloy Steel in order to obtain higher performance in wear resistance.

Inspection

Dredge Yard performs numerous testing that occur during and after production process of the dredge suction mouth. Before making the pattern, casting simulation software is run to verify that all thickness, curves and radii will be obtained and the material will cool down in a good way preventing internal and external shrinkage. For all casting the mechanical and chemical properties are verified at the third party. A final inspection is performed by the Dredge Yard team of quality control in order to assure that the product is according to customer’s and Dredge Yard’s specifications.

After inspection, the cast surfaces are painted while the machined surfaced are greased. Dredge Yard team supervises the packing and transport to ensure the release of products in the right way.

Sizes of dredge suction mouth vary according to the customer’s dredgers, dredge cutter heads and dredge pipe arrangements.

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Various dredge pipe pieces launched

Dredge pipe pieces

Dredge Yard, a company based in the Netherlands and United Arab Emirates, provider of latest dredging technology and equipment, is proud to announce the launch of complete line of dredge pipe pieces.

The dredge pipe pieces are used on board of dredgers to connect the dredge pump with the discharge pipe. Dredge Yard specialists designed the dredge pipe pieces in different variety and different thicknesses in order to meet customers’ requirements, to provide them the best proper solution and the lowest costs.

Range of pipe pieces

The dredge pipe pieces provided as Bend Pipe, T-Pipe, Pitched T-Pipe, Y-Pipe, Cross Pipe, Straight Pipe, and Conical Pipe are produced at high quality and experienced foundry with the latest production facilities to ensure a very high quality of casting and a quick delivery time.

Flanges of the pipes are cast together with the pipe aiming to give a strong connection. Others feature of the dredge pipe pieces are the lifting lugs making them easily for handling. During production more attention is paid to smoothen the inner surface of the dredge pipe pieces in order to lower the friction loses. Also all dredge pipe pieces are designed in such a way that their shapes and curves follow the flow pattern to lower friction losses and avoid vortexes.

Dredge Yard offers dredge pipes according to customers’ applications and requirement in different materials like manganese alloy that is providing high elongation and impact value and high chromium, nickel and molybdenum alloy that is providing high tensile, high yield and high hardness values.

Casting

All castings of dredge pipe pieces are heat treated according ISO and ASTM standards and all the products are measured and tested before machining, after machining and before releasing for transport. All these measurements and tests are recorded at Dredge Yard database.

Dredge Yard emphasizes on after sales and ensures total customer satisfaction delivering dredge related products with a high ratio of reliability and value for money.

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Wide range of dredge ball joints introduced by Dredge Yard

Dredge Ball Joints

Dredge Yard, the provider and manufacturer of dredging equipment, has now introduced a very wide range of dredge ball joints engineered and developed in Dubai, United Arab Emirates.

In order to provide customer with the best suitable solution and lowest cost, Dredge Yard specialists designed the dredge ball joints in 6 different types, giving variations of tilting angle from 15 to 18 degrees and duties for operating from 10 bar to 30 bar. The materials used for the production depends on each part of the dredge ball joints. Because the case and the ball need a high elongation and impact value, cast iron of a manganese alloy is used. The material needs for the gland are cast iron of a chromium, nickel and molybdenum alloy that provides a high tensile strength, high yield point and high hardness values. For wear resistant properties of the liner, ductile manganese iron or hard chromium iron is used.

Production

The production of dredge ball joints is done at a high quality and experienced foundry with the latest production facilities to ensure high quality casting and quick delivery time. To ensure that all parts are identical and interchangeable, the patterns are made from aluminum or hard wood. All castings of dredge ball joint are heat treated according to ISO and ASTM standards and they are measured and tested before machining. After machining and before releasing for the transport, all the products are measured and tested again. During and after production all products undergo a systematically testing including chemical composition and mechanical properties test, measurement test of all dimensions after casting, ultra sonic test, magnetic particle test, surface roughness test and dye penetrant inspection for critical parts, measurement test of all dimensions after machining, hardness test, assembly and interchange ability test, and visual inspection for all parts.

Dredge Yard management has related that: “All measurements and tests are recorded in our database and our customers are welcome to witness any test in our production facilities”. Dredge Yard also offers the opportunity of choosing additional options for the production of dredge ball joint as they can be provided with welded pipe and flange execution, with gland liner, ball liner, extra or special lifting lugs or only with different type of locking.

Assembly or dis-assembly

This wide range of dredge ball joints bring a lot of benefits such as easy assembly or dis-assembly, low required maintenance, quick fix and release of locking. The replaceable liners are made from wear resistant materials and there is a very low friction between ball and gland due to grease grooves and polished ball and gland face. All dredge ball joints are designed, produced, assembled, tested, painted, greased, packed and transported under close super vision of Dredge Yard team of engineers and quality control.

Dredge Yard emphasizes on after sales and ensures total customer satisfaction delivering dredge related products with a high ratio of reliability and value for money.

 

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Extending the lifetime with Finite Element Analysis

FEA

Dredge Yard’s dredge components and equipment are designed using Finite Element Analysis in order to optimize the design and ensure low stress forces in the material. In this way the life time of the equipment is increased and the cost price is reduced.

By the late 70’s, FEA – Finite Element Analysis was limited owned by the aeronautics, defence, nuclear and automotive industries. Later, due to a impressive increase in computing power and a drop in the cost of computers, FEA was technologically advance to a very high accuracy. Nowadays, the computers have the capability to give precise results for all type of parameters.

FEA – Finite Element Analysis is one of the most dominant numerical methods used to check how the structure will react to certain loading conditions. Theoretically speaking, FEA is using a system of points called nodes that together create a grid called mesh. The mesh contains the material and structural properties that shows how the structure will react to certain loading conditions. Depending on the stress levels anticipated of a particular area, the nodes are assigned at a certain density all over the material. Generally a higher node density will be found in the areas that will receive large amounts of stress. The areas that will receive little or no stress it will usually have a lower node density. So, FEM provide detailed visualization of where structures twist or bend and gives precise indications of the distribution of stresses and displacements.

Testing

Dredge Yard related: ’’All our components are tested in Finite Element Analysis as one part after that all parts are assembled and tested under pressure and maximum movements. Worst cases scenarios are simulated and peak loads are applied. After analysis, the design might be reviewed couple of time to find out the most optimal shape and lowest stress in material. For wear parts, a Finite Element Analysis is run for worn out parts as well allowing our engineers to design the dredging components for the longest life time by adding material where necessary.’’

In summary, FEA’s benefits include enlarged accuracy, intensified design and enhanced perception into critical design parameters, virtual prototyping, amplified productivity and increased revenue.