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Dredge Ball Joint Functional Test: video

Dredge Yard specializes in manufacturing and supplying of dredgers and dredging components. Dredge ball joint is one of the component types we specialize in. Our manufacturing process takes place in the Republic of Turkey. It includes casting and heat treatment of all components, followed by machining to the finest tolerances.

We always conduct heavy duty functional tests, in order to ensure dredging equipment of the highest quality. One of such tests is called the dynamic dredge ball joint test. During the dynamic test, dredge ball joints are tested at a pressure, which is above the required design operating pressure. Additionally, while the ball joint is pressurized, a hydraulic cylinder applies a movement of the ball joint. This is done to simulate the working conditions in the dredge field at the most severe conditions. Severe conditions can include strong currents and waves, maximum dredge pipe length and highest pressure that the dredger can achieve. Therefore, the dynamic test is done to ensure component durability under all circumstances.

In February 2019, Dredge Yard delivered 50 dredge ball joints to the United Arab Emirates. These ball joints were suitable for a pipe with internal diameter of 750mm and discharge pressure of 30 bar. Therefore, during testing, we pressurized the ball joints to over 30 bar, in order to ensure that they can withstand maximum forces.

The video below provides an insight into our dredge ball joint dynamic test:

 

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Adaptive Auger Head: Environmentally Friendly Solution

At Dredge Yard, we pay special attention to high efficiency and innovative solutions. We do this, to achieve lowest equipment prices, operational costs and minimal impact on the environment. Sustainability and green dredging solutions become increasingly important, as climate and environment are rapidly changing and must be protected. In accordance to this, our team created an innovative dredging solution, which protects the environment – the adaptive auger head. 

Specifications

The adaptive auger head has two retractable visors placed on the front, and the backside of the auger head. The visors move in and out, according to the shape of the seabed and the depth. This automatic visor movement is enabled by the hydraulic arrangement and pressure settings. See the video below for a thorough explanation of how the adaptive auger head works. 

Benefits of the adaptive auger head

The adaptive auger head achieves a variety of environmental and economic benefits, due to its automatic visor movement along the ground when dredging. Some of the benefits include:

  1. More production of sand in less time. The adaptive visors create a strong suction vacuum by continuously following the ground, which achieves high production rates.
  2. Much less turbidity than with conical (basket) cutter head types. This is achieved due to adaptive visors, which control the material spillage. Low turbidity is an especially big advantage when dredging in contaminated areas, as it protects the environment. 
  3. The adaptive system saves marine life by protecting animals from entering the suction system in the dredger.
  4. This system accurately removes only the necessary layer and ensures an even surface at all depths. Therefore, necessary materials are not removed from the ecosystem.
  5. It is suitable for unmanned dredging, because adaptive visors automatically adjust with the ground. This makes the system very useful for remote controlled dredgers, which operate in areas that are risky for operators. 

Remediation / environmental dredging

Environmental Dredging Landscape

The adaptive auger head is an especially suitable solution for environmental dredging. As mentioned, the adaptive visors protect the marine life from getting trapped in the dredging system. Additionally, they cause minimal to no turbidity. This characteristic is vital for the ecosystem, especially when contaminated soils are involved. Some of the other advantages of using the adaptive auger head system in environmental or remediation dredging are discussed below. 

  1. Adaptive auger head improves cleanup operations that are specifically aimed at removing contaminated sediments. This is especially important, as contaminants can endanger marine and human life.
  2. Remediation dredging means that the thinnest layers possible are accurately removed. As a result, the least possible quantities of contaminated material are dredged.
  3. Contaminated sediments pose a big risk to human health, the environment and may limit the use of many water bodies. However, treatment of contaminated sediment is costly and secure disposal areas are limited. Therefore, precision dredging offers a viable solution, as it removes the smallest amount possible. 
  4. The adaptive visors enclose the area being dredged. In this way, they prevent sediments from drifting into the surrounding waters. 

Other applications for the adaptive auger head

adaptive auger head dredger

Adaptive auger head on dredger ECO 200

Aside from environmental dredging, the adaptive auger head can be used for a variety of applications. For example, it is a useful tool in river and canal dredging, water intake cleaning, harbor maintenance and more. 

Overall, not all types of dredging or maintenance have to be very precise. However, certain projects demand environmental society clearance. In such cases, the adaptive auger head adds immense value to your product in terms of both – economic reasons for you and protection of the environment. We offer Auger dredger ECO 200, which features our adaptive auger head system. Additionally, the adaptive auger head can also be purchased separately, in order to upgrade your existing dredger. 

Contact Dredge Yard

If you would like more information or advice, please contact us here, or fill in the form below. We are happy to help! 

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More photos of the adaptive auger head

 

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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 upgrade 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 that 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

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

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

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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 dredge 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”.

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

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Dredge Yard in Dredging Summit & Expo 2014 of WEDA

Dredge Yard participate at WEDA

Dredge Yard participated in the 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. The summit was organized by the Western Dredging Association (WEDA) and Texas University.

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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