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Dredge Yard builds ECO200 dredger in stock

Dredge Yard built the ECO200 dredger in stock as part of a program for building several medium size and small dredgers in stock. We can equip the dredger with a cutter head, plain suction dredge or an auger head. These various options make the ECO200 a very versatile dredger. Using an underwater heavy-duty dredge pump can extend the dredging depth. A hydraulic drive controls and drives the heavy-duty dredge pump.

Easily transportable

The entire dredger fits inside standard containers for safe and cost-effective transport to any port in the world. Dredge Yard experts or the clients technical staff can assemble the dredge on site. The ECO200 is designed for one operation and can be easy controlled from the air-conditioned cabin. The underwater dredge pump provides a high ratio of mixture and increased slurry flow that optimizes the production output. The dredger is available for use in May 2017. Contact us for more information

Dimensions of the ECO200 dredger in stock

Length overall 16.2   m
Length of pontoon 11.5   m
Breadth overall 3.0    m
Depth of pontoon 1.2    m
Dredging depth 6.0    m
Design draught 0.8    m
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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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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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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 in Dredging Summit & Expo 2014 of WEDA

Dredge Yard participate at WEDA

Dredge Yard participated in the Western Dredging Association (WEDA) and Texas University’s Dredging Summit and Expo 2014 that took place at the Fairmont Royal York Hotel in Toronto, Canada.

The participants of the event were mostly leading organizations in dredging and port industry, maritime professionals and experts on environmental issues that exchanged the knowledge in fields related to dredging, marine engineering and environment.

Dredge Yard’s representatives were Basel Yousef, the CEO and Iulia Berchiu, the Marketing Manager of the company.

Two solutions

“Expanding the dredging world” was the theme for the event in which Basel Yousef has covered the “Fuel Saving Solutions” topic that is one of the most debated subject among all the industries.

Dredge Yard presented two solutions for solving major problems, one of them being the inflexibility of the dredge ball joint and the other one being the blockage of the flow.

Blockage

To solve the inflexibility of the ball joint that occurs due to the rustweld that follows after rusty surfaces, Dredge Yard presented a new design called bearing ball joint. This dredge component is featured with additional bearing liners allowing the ball joint to move easier and to have less friction against tilting moments.

For the blockage of the flow that is created by the ball joint when it is tilted up to its maximum bend angle, Dredge Yard presented a new design having a concave ball liner that allows the mixture to flow easier and have no blockage.

Blockage of the mixture results in local increase of flow speed that has a positive effect in pressure drop.

This new ball joint is producing less friction than conventional ball joint and is saving fuel for the entire dredge operation as the most power is consumed by discharging mixture over the dredge pipe line.

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Dredge Yard develops new design for water ball joint

Water ball joint 700

Dredge Yard has successfully delivered water ball joint 700 to Baku, the capital and largest city of Azerbaijan, as well as the largest city on the Caspian Sea.

These ball joints have been produced by using new innovative design developed by Dredge Yard’s team of engineers which makes it much more economical and suitable for transporting water.

Water ball joint 700 mm is suitable for 10 bar working pressure and has been tested up to 18 bars. They have a tilting angle 15 degrees to all directions. The grease grooves are provided in the case which makes the lubrication work much easier and effective than before.

Design

A new design of rubber seal is provided in the case to make the water ball joint tight even at higher pressure than working pressure. All the ball joints have been produced in Dredge Yard’s facilities by using latest production technologies and casting expertise.

To assure high quality and hence, better life, all the ball joints underwent through thorough tests and inspections during and after production. They were delivered in 4 batches by trucks directly from Dredge Yard’s facilities to Baku in Azerbaijan, to ensure shortest delivery time.

Dredge Yard is currently producing heavy duty water ball joint for I.D. 1200 mm using the same design principle and new sealing design.

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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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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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Quality control of dredging equipment

At Dredge Yard we see quality control as one of our top priorities. We specialize in dredging technology and dredging equipment needed for the dredgers and dredge pipe lines. We have the reputation of providing high performing products. This reputation is earned due to controlling all phases of the development process like design, manufacturing and testing.

In-house quality control

Our engineer team designs all dredge components by using the latest CAD technologies. We produce components in co-operation with partners with high quality control on manufacturing facilities. After that they are tested under strict ISO and ASTM standards and double tested at third-party for verification.

During and after production, Dredge Yard tests the components rigorously:

  • The chemical composition and mechanical properties test.
  • Measurement test of all dimensions after casting.
  • 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 interchangeability test.
  • Visual inspection for all parts during and after assembly.

We record all measurements and tests in our own database.

Dredge Yard management explains:

“We want to involve our customers and suppliers in all our activities in a very early stage of the projects. To ensure on time delivery, cost-effective production, low maintenance, low operation cost and high-grade of reliability of the products, we implement customer’s experiences in the design. Our customers are encouraged to witness any test in our production facilities.”

This is why Dredge Yard grabbed the attention of many dredging companies from all over the world.

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