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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 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.

 

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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 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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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.

 

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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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.

 

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Large dredge valves supplied to Van Oord

Dredge Yard successfully handed over several large dredge valves to Van Oord, a leading contractor in dredging, marine engineering and offshore projects.

The valves have an inner diameter of 1100 and 1600 mm. They control the flow of water and sand in the suction and discharge pipes from the trailing suction hopper dredgers.

Inspection large dredge valves

The dredge valves are produced in Dredge Yard’s facilities in Turkey by using latest production technologies. Additionally, to ensure high quality, they underwent tests under 12 bars. Van Oord’s representatives also inspected the valves during and after production.

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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 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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