04 Equipment

4.
EQUIPMENT
BY GEERT VANNESTE
Dredging...?
Chapter 4 - p. 1
Equipment
Breakdown of the dredging process Overview of dredgers Cutter suction dredger Trailing suction hopper dredger Backhoe dredger Grab dredger Other equipment Environmental dredgers
Chapter 4 - p. 2
Breakdown of the Dredging Process

Loosening the material (and/or dislodging) Picking up the loosened material Transport through the primary dredger further transport Disposal of the material under water on shore
Means to realise the partial processes

Hydraulical (erosion, discharge pipe, etc.) Mechanical (cutter, conveyor belt, etc.) Remark The different sub-processes may require different types of dredging equipment
Chapter 4 - p. 3
Overview of dredgers
Hydraulical/mechanical dredgers (CSD) Hydraulical dredgers (TSHD) Mechanical dredgers (Backhoe, Grab) Environmental dredgers
Hydraulical/Mechanical Dredgers
Cutter Suction Dredger (CSD)
Chapter 4 - p. 4
Cutter Suction Dredgers

Cutter power Small < 600 kW
Large, 1500-3000 kW Mid-size, 600-1500 kW

Cutter power
Mega, 5500-7500 kW Heavy Duty, 3000-5500 kW
Chapter 4 - p. 5

Main characteristics Most important parts of the dredger Working principle Production limiting factors Some characteristic figures

Main characteristics Nearly all kinds of soils (sand, clay, rock) Stationary dredger: vulnerable to shipping sensitive to wave conditions Some are self-propelled for mobilisation
Chapter 4 - p. 6
Cutter Suction Dredgers - Parts

Most important parts, machinery Cutter and cutter drive Dredge pump(s) (Side-) Winches and sheaves for the side wires for swinging
Chapter 4 - p. 7

Working principle Cutter disintegrates or dislodges the material mechanically by rotating cutter head Material sucked up and transported through pipeline by use of centrifugal dredge pumps Pontoon movement by: -) swinging around working spud -) progress by successive steps (stepping) and spuds (spudding) Summary 3D
3D
CSD WORK METHOD (1)
Swing to SB
Chapter 4 - p. 8
CSD WORK METHOD (2)
Stop at SB, Push dredger forward
CSD WORK METHOD (3)
Start swing to PS
Chapter 4 - p. 9
CSD WORK METHOD (4)
Continue swing
to PS
CSD WORK METHOD (5)
Stop at PS, Push dredger forward
Chapter 4 - p. 10
CSD WORK METHOD (6)
Start swing to SB
CSD WORK METHOD (7)
Stop in Centre Line
Chapter 4 - p. 11
CSD WORK METHOD (8)
Aux. spud down
CSD WORK METHOD (9)
Main spud up
Chapter 4 - p. 12
CSD WORK METHOD (10)
Main spud forward
Main spud down
Chapter 4 - p. 13
Aux. spud up
Start swing to SB
Chapter 4 - p. 14
Continue swing
to SB
Cutter Suction Dredger

Process topics Over-cutting versus under-cutting Spill Cutter heads Anchors
Chapter 4 - p. 15
undercutting
overcutting
spillage (cutting deeper than design level)

Cutter head Back ring - arms - hub Blades - teeth: chisels / pick points Various shapes
Cutter with chisels
Chapter 4 - p. 16
Sand/clay cutter head Rock cutter head

Anchors Depending on soil type
Flipper Delta
Stevshark
Chapter 4 - p. 17

Anchors Anchor islands
Chapter 4 - p. 18

Production limiting factors Soil characteristics Available power on cutter Side winches (max. power and velocity) Thickness and width of the layer to be dredged Dredging depth (ladder angle, spuds, cavitation) Pumping distance (pump- and pump drive characteristics) Shipping
Chapter 4 - p. 19
Characteristic Figures
cutter suction dredger dimensions (L*W*Dr) total power cutter power max. swing speed max. dredging depth discharge diameter small mid-size large 120 * 20 * 5 m < 13,000 kW < 5,500 kW 32 m / min 25 - 35 m 0.75 - 0.85 m
65 * 10 * 2 m 70 * 16 * 4 m < 3,000 kW < 600 kW 19 m / min 15-20 m < 9,000 kW < 1,500 kW 32 m / min 25 m
0.35 - 0.70 m 0.65 - 0.85 m
Characteristic Figures
cutter suction dredger
dimensions (L*W*Dr) total power cutter power max. swing speed max. dredging depth discharge diameter heavy duty 125 * 22 * 5 m < 23,000 kW < 5,500 kW 19 m / min 25 - 35 m 0.80 - 0.90 m mega 140 * 24 * 6.5 m < 28,000 kW < 7,000 kW 32 m / min 30 - 35 m 0.90 - 1.00 m
Chapter 4 - p. 20
Hydraulical Dredgers
Suction dredgers Trailing Suction Hopper Dredger (TSHD) Plain suction dredger Barge unloading dredger Water Injection Dredger (WID)
Trailing Suction Hopper Dredger
Chapter 4 - p. 21
Jumbo 24,000 m3 Small & Jumbo, 975 m3 & 23,000 m3
Mid-size, 4000 m3

Main characteristics Most important parts of the dredger Working principle Production limiting factors Some characteristic figures
Chapter 4 - p. 22

Main characteristics Free sailing Self-propelled Self-loading when trailing Self-unloading or -discharging Seagoing or inland waterway vessel All non-rock type soils Relatively insensitive for waves Not vulnerable for shipping
wheel house service crane
swell compensator
propulsion engine room hopper
suction pipe pump room
draghead - 70m
bow-coupling for pumping ashore or rainbowing
Chapter 4 - p. 23

Most important parts,machinery Dragheads Dredge pump(s) Hopper, loading and unloading system
TSHD Process Description

Dredging cycle Loading at the dredging- or borrow area Sailing (loaded) to the unloading area Unloading (bottom opening or pumping) Sailing (empty) to the dredging area
Chapter 4 - p. 24

Excavation (Erosion & Cutting)

Suction
Chapter 4 - p. 25
Loading
Loading (overflow)

Loading: Basic Principle
Top view hopper
Longitudinal section
Chapter 4 - p. 26

Full Load: Basic Principle
Top view hopper
Longitudinal section
Hopper loading (mud)
Total Volume [m3] Max. volume
Draught [m] (=tons) Max. draught
Mud [m3]
Chapter 4 - p. 27
Hopper loading
(sand in low specific weight hopper)
Total Volume [m3] Max. volume Draught [m] (=tons) Max. draught
Sand [m3] Overflow losses

Sailing loaded
Chapter 4 - p. 28

Discharge

Hopper Bottom Discharge
Split-hopper
Chapter 4 - p. 29

Hopper Self-discharge: system
Water Sand Jets Jets Jets
Discharge
Water inlet
Dredge pump

Jets
Jets
Jets
Discharge
Water inlet
Dredge pump
Chapter 4 - p. 30

Jets
Jets
Jets
Dischar ge
Water inlet
Dredge pump

Jets
Jets
Jets
Discharge Water inlet Dredge pump
Chapter 4 - p. 31

Hopper Self-discharge: rainbow
Rainbowing

Hopper Self-discharge: Pump ashore
Chapter 4 - p. 32

Sailing empty
TSHD Load Graph (emptying by bottom door disposal)

DRAUGHT (m) start overflow TOTAL LOAD (ton) sailing loaded stop loading sailing empty
emptying hopper next trip
VOLUME SAND (m3) TIME IN MINUTES Cycle-time per trip start dredging
Chapter 4 - p. 33
TSHD Load Graph (discharging to shore)

DRAUGHT (m) start overflow stop loading
sailing loaded
unloading hopper
next trip
VOLUME SAND (m3)
sailing empty
TIME IN MINUTES Cycle-time per trip
start dredging

Process related topics The hull The hopper Dragheads, suction pipes and belongings Centrifugal pumps
Chapter 4 - p. 34

The hull Sailing characteristics
Resistance Small keel clearance

Maximum carrying capacity versus draft, length and width Strength Stability

The hopper Carrying capacity Volume Weight Filling system Overflow system Bottom door disposal system Self-discharge system
Chapter 4 - p. 35
Hopper: carrying capacity

Restriction by volume (full hopper)
MUD 5,000 m3 6,000 ton SAND 3,500 m3 7,000 ton HOPPER HULL
Restriction by weight (max. draught)
HOPPER HULL
Low density soils e.g.: Mud - 1.2 ton/m3 5,000 x 1.2 = 6,000 ton
High density soils e.g.: Sand - 2.0 ton/m3 3,500 x 2.0 = 7,000 ton
Hopper: loading & dumping facilities
Overflow System
Bottom-doors
Conical bottom-valves
Chapter 4 - p. 36
Dragheads
Sand Draghead
Chapter 4 - p. 37
Different dragheads
Suction Pipe
Chapter 4 - p. 38
Workability Weather Delay
Swell Compensator
Swell Compensator Draghead Winch
Oil
Draghead
Pressure Jar
Seabottom
Chapter 4 - p. 39
Centrifugal Pumps
Hardware Types & sizes Basic parts
inboard pump
under water pump
Centrifugal Pumps
Working principle Energy Distribution Propulsion Pumps Boardnet Centrifugal pump
Chapter 4 - p. 40
Centrifugal Pumps
Density & velocity meter
Engine-room with 2 pumps in line
Chapter 4 - p. 41

Production limiting factors Soil characteristics and hydraulic conditions Available propulsion power Drag head size and weight Keel clearance when loaded Dredging depth Pumping distance (pump- and pump drive characteristics) Production may vary a lot due to these factors
Limiting factors
A drag head grid damaged by boulders
Chapter 4 - p. 42
Limiting factors
Debris
trailing suction hopper dredger dimensions (L*W*Dr) max. dredging depth hopper capacity sailing speed propulsion power diam. suction-pipe
small
mid-size
large
jumbo
55*10*4 m 90*18*7 m 130*23*9 m 180*32*13 10-35 m <4,000 m3 8 knots 400 kW 0.35-0.9 m 25-55 m <8,000 m3 12 knots 3,500 kW 0.80 m 25-75 m 50-120 m
<15,000 m3 <30,000 m3 14 knots 8,000 kW 0.90-1.00 m 17 knots 18,000 kW 1.20 m
Chapter 4 - p. 43

Mega L x W x Dr. Max. dredging depth Hopper capacity Sailing speed Propulsion power during dredging Suction pipe diameter
225 x 38 x 12-15.5 m 55 / 155 m 30,000 - 46.000 m3 16 - 18 kn 25.000 kW 1.2 1.4 m
Chapter 4 - p. 44
Other Hydraulical Dredgers

Suction Dredgers Plain Suction Dredger Barge unloading dredger Injection Dredger (WID)
Chapter 4 - p. 45
Plain suction dredger

Suction of free running material (sand) Jet water for dislodging and fluidising material Deep suction pit necessary Stationary dredger, not swinging, only intermittently moving forward
Barge Unloading Dredger

Unloading of barges by suction Jets for dislodging and fluidising Barge to be shifted alongside the dredger during suction
Chapter 4 - p. 46
Water Injection Dredger

Injection of water into bottom Low pressure and high capacity Fine sand and silt Movement of material due to gravity forces (density current)
Backhoe Dredger
Chapter 4 - p. 47
Backhoe Dredger
Large, 1900 kW
Backhoe or Hydraulic Excavator

Main characteristics Typical parts Dredging cycle Production limiting factors Some characteristic figures
Chapter 4 - p. 48
Backhoe
Main characteristics Normal backhoe/front-shovel on pontoon or Specially built pontoon (with spuds) with backhoe on rotating table Dredged material is loaded into barges Reasonable cutting force can be generated Suitable for: Non-rock type soils with stones Blasted rock Precision dredging
Backhoe
Dredging blasted rock
Chapter 4 - p. 49
Backhoe - parts
Bucket Spud Stick Boom
Backhoe
Different types and sizes to be fitted: Sticks Buckets Booms
Positioning with spuds
Chapter 4 - p. 50
Backhoe
Dredging cycle Lowering bucket Filling bucket by cutting and tilting Hoisting bucket Turning crane towards barge Emptying bucket into barge Turning back
Working Method Backhoe

Nett dredging width overlap Centre line Reach
Barge
Chapter 4 - p. 51
Production Limiting Factors

Work method Excavation force at large depth Slope dredging (bucket positioning) Precision dredging along quay-walls Soil and obstructions Hard material (no rock) Big boulders Removal of debris or vegetation Workability Waves Shipping
Backhoe
Backhoe Length Draught Dredging Depth Bucket size
Power Installed
Small m1 m
1
Medium 45 2.0 15 - 20 2-8 < 1,000
Large 50 2.5 20 - 30 5 - 20 < 2,000
Mega 65 3.5 20 - 30 15-40 < 4200
30 1.5 10-15 1-3 500
m1 m
3
kW
Some Characteristic Figures
Chapter 4 - p. 52
Grab Dredger
Grab Dredger
Main characteristics Dredging characteristics Typical parts Dredging cycle Production limiting factors Some characteristic figures
Chapter 4 - p. 53
Grab Dredger
Main characteristics Can also be used for construction works (shore & bank protection)
Normal grab-crane on pontoon OR Specially built pontoon (with spuds) with fixed grab-crane on rotating table Small grab dredgers for difficult accessible areas
Grab Dredger
Dredging characteristics Dredging up to large depths Cannot create an even bottom Dredged material is loaded into barges Non-rock types of soil Suitable for debris and vegetation
Chapter 4 - p. 54
Grab Dredger
Areas with difficult access
Grab Dredger
Shore Protection Work
Chapter 4 - p. 55
Grab Dredger
Typical parts Different types and sizes to be fitted: Grabs Booms Positioning with spuds or anchors
Grab Dredger
Standard grab (sand, clay, mud)
Cactus grab (stones)
Chapter 4 - p. 56
Grab Dredger
Dredging cycle Lowering grab Closing grab Hoisting grab Turning crane towards barge Emptying grab into barge Turning back
Grab Dredger
Production limiting factors Hard material Big boulders, blasted rock Removal of debris or vegetation Dredging depth Waves Shipping
Chapter 4 - p. 57
Grab Dredger
Some Characteristic Figures
Grab Dredger Dimensions Dredging Depth Grab size L x Dr. m1 m3 Small 30 x 1.5 25 2.5 - 5 Mid-size 45 x 1.7 40 5 - 15 Large 50 x 2 50 15 - 50
Other Mechanical Dredgers

Bucket ladder dredger (BLD) Dipper dredger Rock breaker Plough or bottom leveller
Chapter 4 - p. 58
Bucket Ladder Dredger

Revolving chain of buckets Swinging like a cutter suction dredger No spuds, position fixed by wires Buckets turning upside down to empty Discharge into barges
Bucket Ladder Dredger
Buckets are turning upside down to discharge into barges
Chapter 4 - p. 59
Dipper Dredger
Digging with a spoon Discharge into a barge Emptying spoon through bottom Working method like a backhoe and grab
Rock Breaker
Hydraulic power to break rock Assists dredger on small spots Broken rock to be removed by excavator
Chapter 4 - p. 60
Plough or Bottom Leveller

Towed by tug Assisting TSHD with removal of ridges and high spots Removal of soft material from small harbours Low production Cheap
Other Equipment
Water based Barges Work boats and launches Anchor pontoons, floating line pontoons Booster station
Chapter 4 - p. 61
Multicat for handling and transport
A-frame for anchor handling
Survey launch
Floating pipeline pontoons
Use of floating pipeline
Rubber floating pipeline
Chapter 4 - p. 62
Female
Ball Joints
Male
Floating cover
Rubber Floating Line
Booster station
Chapter 4 - p. 63
Other Equipment
Land based
Pipelines and valves Bulldozers, shovels, etc.
See chapter 9, Hydraulic Fills
Environmental Dredgers
Objective Types Typical Aspects
Chapter 4 - p. 64
Objective:
Optimise precision Accurately dredging of thin layer Minimise disposal capacity by high concentration (minimisation of dilution) Minimise turbulence and turbidity Safety: bring dredged bottom material via closed system to barge or disposal area
Accuracy Aspects
Contaminated
Clean H H D
Contaminated material is left behind, and falls in overdepth
Chapter 4 - p. 65
Accuracy Aspects
H H
H D H D D H
H (contaminated) removed
D increased, H not removed
Principles of Turbidity Generation
Chapter 4 - p. 66
Typical aspects
Automation necessary
Maximising concentration Controlling excavation level Controlling layer thickness

Output level low due to:
High accuracy Avoiding turbulence
Types
Environmental disc cutter dredger Disc cutter head with closed bottom plate and shields Environmental auger dredger Dual active rotating auger in enclosed area Horizontally closing grab Grab sealed off when closed Encapsulated Bucket Ladder Dredger
Chapter 4 - p. 67
Disk bottom (cutter) dredger disk cutterhead with closed bottom plate and shields
Environmental Auger Dredger
Chapter 4 - p. 68
Grab is horizontally closing Sealed off after closing
Bucket Ladder Dredger with encapsulated bucket line
Chapter 4 - p. 69
Dredging requires TEAMWORK on water and on land!
Additional Information
Theory and Practice of Water Injection dredging by A.L.P. Estourgie, T&A 38, December 1988 The Use of Ploughs or Bed-levellers in Maintenance Dredging by C.J. van de Graaf, Maintenance Dredging, TTL London 1987 The Planning of Maintenance Dredging Work by Marian Veltman-Geense, T&A 47, January 1992 The Trend Towards Larger Trailing Suction Hopper Dredgers: Evaluation of Some Design Parameters of Todays Trailing Suction Hopper Fleet by C. Kramers, R. Ouwerkerk, J. Koert, Proceedings 15th World Dredging Congress, Las Vegas, Nevada, USA, June/July 1998 Irruption of the Trailer Jumbo in the Dredging Industry by Roberto Vidal, T&A 83, June 2001
Chapter 4 - p. 70
Environmental Auger Dredger
Bucket Ladder Dredger in Action
Chapter 4 - p. 71
CSD: Cutting & Pumping
The dredged is sucked the dredge The mixture is material pumped through a by pipeline to head thepump disposal area The material is dislodged by the cutter
CSD: Swinging with tight side wires
Often In order a braking to swing, force one is side exerted wire is with hauled the paying in while out the winch other in one order is paid to create out a stiffer The dredge moves along concentric arcs around the work spud. system.
Chapter 4 - p. 72
CSD: Stepping forward at the edges
The dredge When the end moves of cut one is reached, step ahead one by has pushing to move theforward spud carriage (step) backwards (= the pontoon forwards) over the desired length. The spud carriage is used for this purpose
CSD: Spudding
Spud When The dredger auxiliary spud work swinging carriage the spud carriage spud is spud process stroke: positioned is carriage lowered is put lowered 4 can to is in in 8 restart exhausted, its m the initial centerline position one of has the tocut reposition and thethe spudding work spud. procedure can start. The auxiliary spud is hoisted work spud is hoisted
Chapter 4 - p. 73
Cutter Suction Dredger:

cutting & swinging 3D
Water Injection Dredger
Chapter 4 - p. 74
The drag heads
Backhoe
Chapter 4 - p. 75
Horizontally Profiling Grab
Standard Grab
Chapter 4 - p. 76
Centrifugal Pumps
Working principle
6 Bar
3 Bar
0 Bar -1 Bar
Chapter 4 - p. 77

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4.

Breakdown of the Dredging Process

Means to realise the partial processes

Cutter Suction Dredgers

Large, 1500-3000 kW Mid-size, 600-1500 kW

Cutter Suction Dredgers

Mega, 5500-7500 kW Heavy Duty, 3000-5500 kW

Cutter Suction Dredgers

Cutter Suction Dredgers

Cutter Suction Dredgers - Parts

Cutter Suction Dredgers

Cutter Suction Dredgers

CSD WORK METHOD (1)

CSD WORK METHOD (2)

Stop at SB, Push dredger forward

CSD WORK METHOD (3)

CSD WORK METHOD (4)

CSD WORK METHOD (5)

Stop at PS, Push dredger forward

CSD WORK METHOD (6)

CSD WORK METHOD (7)

Stop in Centre Line

CSD WORK METHOD (8)

Aux. spud down

CSD WORK METHOD (9)

CSD WORK METHOD (10)

Main spud forward

CSD WORK METHOD (11)

Main spud down

CSD WORK METHOD (12)

CSD WORK METHOD (13)

CSD WORK METHOD (14)

Cutter Suction Dredger

Cutter Suction Dredger

spillage (cutting deeper than design level)

Cutter Suction Dredger

Cutter with chisels

Cutter Suction Dredger

Sand/clay cutter head Rock cutter head

Cutter Suction Dredger

Cutter Suction Dredger

Cutter Suction Dredger

Cutter Suction Dredger

0.35 - 0.70 m 0.65 - 0.85 m

Trailing Suction Hopper Dredger

Trailing Suction Hopper Dredger

Jumbo 24,000 m3 Small & Jumbo, 975 m3 & 23,000 m3

Trailing Suction Hopper Dredger

Trailing Suction Hopper Dredger

Trailing Suction Hopper Dredger

wheel house service crane

propulsion engine room hopper

suction pipe pump room

bow-coupling for pumping ashore or rainbowing

Trailing Suction Hopper Dredger

TSHD Process Description

TSHD Process Description

TSHD Process Description

TSHD Process Description

TSHD Process Description

TSHD Process Description

Hopper loading (mud)

Total Volume [m3] Max. volume

Draught [m] (=tons) Max. draught