Cutter Suction Dredger M28

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Chastity Atkinson
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1 Cutter Suction Dredger M28

2 Content General Arrangement Plan... 3 Cutter Suction Dredger M General... 5 Shipbuilding... 6 Machinery, Hydraulic, Electric... 7 Machinery... 7 Hydraulicsystem... 9 Elektricsystem Dredging Equipment Cutter Drive Spud Equipment Plain Suction Equipment Dredge Pump System The Under Water Pump System: Boosterpump Inboard Dredge Pump Winch System Dredge Master House Appendix: GL Survey

3 General Arrangement Plan 3

Cutter Suction Dredger M28 Name M28 Machinery Type Cutter 2 x CAT 3516 Je 1825 KW Owner Boramtec GmbH 1 x Baggerpumpe 1 x Booster Pump 2400 1473 KW KW Build Hermann Sürken GmbH 1 x Bordnetz 1x

4 Cutter Suction Dredger M28 Name M28 Machinery Type Cutter 2 x CAT 3516 Je 1825 KW Owner Boramtec GmbH 1 x Baggerpumpe 1 x Booster Pump KW KW Build Hermann Sürken GmbH 1 x Bordnetz 1x Hafendiesel KW KW Total inst. Power 9048 KW Rebuild 2008 Class GL 100 a5 K A-MC Cutter 800 KW Dimensions Underwater pump 1825 KW Length overall 75,50 m Length Pontoon 54,01 m Breadth 19,43 m Hydraulic / Jetwater 1825 KW Moulded Depth 4,24 m Draught 3,0 m Winches Structural weight 1700 t Ladder hoisting 32 t Dredging Depth 22,5 Cutter m Side 2 x 25 t Dredging Depth 45 Suction m Discharge Pipe 700 / 800 mm Measurement Systems Spudcarriage 5,8 m Production System x Spuds 41 m ACC x 4

General The dredger shown on page 2 has been constructed in 1981 according to the Rules of Germanischer Lloyd on the Yard Hermann Sürken in Papenburg, Germany.

After several jobs on a number of sites, for example as Cutter Suction Dredger, as Plain Suction Dredger and also as Cutting Wheel Dredger, the dredger has been reconstructed in the years of

5 General The dredger shown on page 2 has been constructed in 1981 according to the Rules of Germanischer Lloyd on the Yard Hermann Sürken in Papenburg, Germany. First Owner was Phillip Holzmann AG, later on owned by Möbius AG in Hamburg. After several jobs on a number of sites, for example as Cutter Suction Dredger, as Plain Suction Dredger and also as Cutting Wheel Dredger, the dredger has been reconstructed in the years of 2007/2008 for a special dredging job on the site of JadeWeserPort. The pontoon has been widened for better draft according to GL. Under water pump drive, cutter drive, hydraulic and jet water pump are complete strengthened. Capacity of diesel engines has been strengthened as well from 5059 KW up to 9048 KW, including the booster located on deck. Stone Chest, Barge Loading System and Spud Carriage are completing the dredge system. A complete measuring system is installed for the control of dredging in an economical way. On his last job as a plain suction dredge on the site of JadeWeserPort in the years of 2008 up to 2010 the M 28 worked as the main dredge at the job, pumping about 15 million m³ on shore, with a daily output of up to m³. After ending the JadeWeserPort job the M 28 has been dismounted and transported to Hamburg, where he is laying idle. HMT Analyse: JWP: M28, Tages- und Gesamtproduktion JWP: Anteilige Produktion M28 production and share production at project JadeWeserPort 5

6 Shipbuilding In 1981 the Yard Hermann Sürken built the M 28 as Ship-No. S 306 like a mono-pontoon without propulsion device. The GL Class is called EinGL A 4 K (Küstenfahrt) Bagger + A - MC and is built also according to the rules of Seeberufsgenossenschaft ( SBG). In original the main dimensions of the pontoon had been L x B x H = 48, 6 x 15, 43 x 4, 2 m and had been divided as follows: Beam 0 Beam 19 = spud carriage area Beam 19 Beam 49 = dredge pump room Beam 49 Beam 81 = machinery room To get more buoyancy for the cutter ladder part, in original the forward part of the pontoon was 15,43 m in breadth, the aft part was just 9,22 m in breadth. In the year 2008 the pontoon had been reconstructed at the Norderwerft into a rectangular form with the following main dimensions Length Pontoon = 51, 84 m Breadth Pontoon =19, 25 m Height Pontoon = 4, 24 m The GAP given in Appendix 1 shows the details of the dredge in general. All stability criteria according to GL are strictly confirmed. Above the engine room a dayroom and a kitchen is located closed to the winch deck for the ladder hoisting winch. Above this deck the Dredge Master House is located for the best view around. Cutter Suction Dredger M28 in Eversween 6

Machinery, Hydraulic, Electric Machinery As mentioned on page 2, there are diesel engines built in M 28, which will be summarized in total to 9048 KW.

Type Power Application on M28 Remarks 1 CAT 3516 1825 KW Underwater Dredge Pump Special Gearbox 2 MAN 12SV25/30 2400 KW Inboard- Dredge Pump Out of use 3 CAT 3516 1825 KW Cutter, Jetpump, Hydraulic

7 Machinery, Hydraulic, Electric Machinery As mentioned on page 2, there are diesel engines built in M 28, which will be summarized in total to 9048 KW. Only CAT engines are used for reinstallation - This means maximum power supply, reliability and maintenance friendly. In detail, following engines have been installed: No. Type Power Application on M28 Remarks 1 CAT KW Underwater Dredge Pump Special Gearbox 2 MAN 12SV25/ KW Inboard- Dredge Pump Out of use 3 CAT KW Cutter, Jetpump, Hydraulic Drive choosen 4 CAT KW Generator for Winches 5 CAT KW Generator for Power Supply 6 CAT KW Haborgenset 7 CAT 399 TAs 839 KW Drive Booster in Tandem Container on Deck 8 CAT 398 TAs 634 KW Drive Booster in Tandem Container on Deck 9 CAT KW Servicepump for Booster Container on Deck On October 11th 2012 Germanischer Lloyd did a Survey on board M 28, in Appendix 2 are the copies of survey. All engines are under Class and have been running for test on 12th of November by Caterpillar. CAT 3516 Drive for underwater dredge pump CAT 3512 for winch generator To use the power of diesel engines in economical way, there are distribution gear boxes istalled. This gives the possibility to use the power either for cutter drive or for the jet water pump drive by dredging as plain suction dredger. 7

Distribution gear box for jetwater and cutter hydraulic

systems like Cooling water Lubrication Fuel Ballast and

flushing Dredge pump seal flushing had been checked during

8 Distribution gear box for jetwater and cutter hydraulic Distribution gear box for winch hydraulic All auxiliary systems like Cooling water Lubrication Fuel Ballast and fire-extinguisher Air pressure Heating Sanitary Cutter seal flushing Dredge pump seal flushing had been checked during test on 12th of November 2012 and functioned all. Harbordiesel CAT 3304 in workshop 8

Hydraulicsystem Following operation parts are driven by hydraulic systems: Cutter Drive Winches partly Stone Chest Spud carriage system Spud hoisting system Several Valves in

Spud Carriage and Spud Hoisting system not have been used during dredging at the JadeWeserPort. Therefore these parts had been dismounted and transported to stock.

9 Hydraulicsystem Following operation parts are driven by hydraulic systems: Cutter Drive Winches partly Stone Chest Spud carriage system Spud hoisting system Several Valves in dredge piping Mainly the hydraulic parts are manufactured by Rexroth, and are renewed partly during reconstruction in Cutter drive is of Staffa Hydraulic. Spud Carriage and Spud Hoisting system not have been used during dredging at the JadeWeserPort. Therefore these parts had been dismounted and transported to stock. After another reconstruction to use the systems again, the hydraulic has to be repaired. The drive of the hydraulic pumps are mainly be done via distribution boxes. Hydraulic for spud carriage Hydraulic cylinder control 9

Elektricsystem The electric system has been built by Zoller, originally in 1981 as well as

Generators are made by AEG, main switch board complete built by Zoller too.

2012, all electrical systems have been checked, no main parts are defect.

10 Elektricsystem The electric system has been built by Zoller, originally in 1981 as well as during reconstruction in Generators are made by AEG, main switch board complete built by Zoller too. CAT 3512 diesel motor with 1020 KW is for the main generator, CAT 3412 is for the power supply. CAT 3512 for winch electric CAT 3412 for power supply During test phase on November 12th 2012, all electrical systems have been checked, no main parts are defect. Just starter batteries are to be renewed. The newly installation of spud carriage system has to be wired. Switch board and desks in dredge master house are checked, measuring system partly to be renewed. Desk in dredge master house Main switch board for power supply 10

Dredging Equipment Cutter Drive The cutter drive has been constructed for dredging depth up to 22, 5 m and is with

The complete cutter part with hydraulic drive of about 800 KW has not been used during job at JadeWeserPort and is

The cutter head is a 5- blade crown head with a diameter of 2500 mm and with a teeth system of Type SC 15.02.

11 Dredging Equipment Cutter Drive The cutter drive has been constructed for dredging depth up to 22, 5 m and is with its length of 7 m the lower part of the cutter ladder. Screws are to be used for the connection to the main ladder. The complete cutter part with hydraulic drive of about 800 KW has not been used during job at JadeWeserPort and is laying idle in Eversween, with defect cutter bearing and dismounted cutter. The cutter head is a 5- blade crown head with a diameter of 2500 mm and with a teeth system of Type SC Depending on the strength of soil to be cut, the cutter head easy to be replaced with its trapezoid thread by the crew onboard. Cutter 2500 with dredg teeth Cutter lower part 11

Spud Equipment During cutting the dredger will be moved about 45 to each side, portside and starboard. This will be done by the side winches with the working spud to be used as an anchor.

This holding spud will be used as anchor as well, but only when the working spud will be removed to another position by the spud carriage. Working spud has the same dimensions as the holding spud.

12 Spud Equipment During cutting the dredger will be moved about 45 to each side, portside and starboard. This will be done by the side winches with the working spud to be used as an anchor. The holding spud with a diameter of 800 mm and a length of 40 m has a fixed position in the pontoon and can just be hoisted and lowered by a hydraulic ram. This holding spud will be used as anchor as well, but only when the working spud will be removed to another position by the spud carriage. Working spud has the same dimensions as the holding spud. Spud carriage has a stroke of about 6 m, means three times of the height of the cutter head or just say three cuts. Both spuds are to be let down on deck during transport. The holding spud is still installed onboard, together with its hydraulic hoisting device. Spud carriage and working spud have to be overhauled. Spud carriage, weight about 72t Holding spud with hydraulic hoisting system 12

Plain Suction Equipment For the dredging job JadeWeserPort the dredge M 28 has been equipped with a new suction pipe for a dredging depth down to 44 m below NN, with an inclination of 55.

The plain suction pipe is now located at the Möbius Yard in Geesthacht. Three connection pieces of 10 m each together with the 6 m suction mouth are available.

13 Plain Suction Equipment For the dredging job JadeWeserPort the dredge M 28 has been equipped with a new suction pipe for a dredging depth down to 44 m below NN, with an inclination of 55. When dismounted the lower cutter piece the flange for connection of the suction pipe with a 5 m connection piece on the main ladder is given. The plain suction pipe is now located at the Möbius Yard in Geesthacht. Three connection pieces of 10 m each together with the 6 m suction mouth are available. The jetwaterpump will be used during plain suction. By disconnecting the cutter drive at the distribution gear box, the jet water pump is connected to the diesel engine CAT With a capacity of 1400 m³/h and a height of 6 bar the jet water will be used at the suction head for getting the soil absorbent. If necessary, the stone chest can be used. For the special job at JadeWeserPort an aft winch has been located in the area of the dismounted spud carriage. For using the cutting device again, this winch with its foundation has to be removed and the spud carriage will be mounted again. The guide sleeve for the aft wire has also to be removed. Aft winch in spud carriage space Traverse with wire shifting 13

Dredge Pump System There are three pump systems installed in dredge M 28: The Under Water Pump System The Booster Pump System The Inboard Pump System The Under Water Pump

This pump is located about 12 m under the water line and is driven by the CAT 3516 via a gear box combination.

14 Dredge Pump System There are three pump systems installed in dredge M 28: The Under Water Pump System The Booster Pump System The Inboard Pump System The Under Water Pump System: To reach a high mixture concentration, an under water dredge pump has been installed. This pump is located about 12 m under the water line and is driven by the CAT 3516 via a gear box combination. The rated capacity of the pump is about 7700 m³/h at a height of 55 m WC. The engine power will be about 1825 KW. Suction and delivery pipe have a diameter of 700 mm. In case of JadeWeserPort job the mixture is discharged to the booster pump, which delivers the mixture through the pipe to shore. Stone chest Under water dredge pump 14

Boosterpump As a land based booster station constructed, the M 7 has been installed on the aft side of the pontoon M 28.

Auxiliary engine CAT 3208 with a power of 138 KW will be used for flushing- and cooling water system.

2400 KW. This dredge pump had a capacity of 6480 m³/h together with a height of 6, 8 bar.

15 Boosterpump As a land based booster station constructed, the M 7 has been installed on the aft side of the pontoon M 28. As tandem diesel engine system of CAT 399 TAs together with CAT 398 TAs a total power of 1473 KW in total had been installed. Auxiliary engine CAT 3208 with a power of 138 KW will be used for flushing- and cooling water system. Inboard Dredge Pump Booster M7 In original M 28 was constructed with an inboard dredge pump, driven by a diesel engine MAN 12ASV 25/30 with an output of 2400 KW. This dredge pump had a capacity of 6480 m³/h together with a height of 6, 8 bar. For the JadeWeserPort job, this inboard pump was out of work and booster M 7 had been installed. To get the inboard pump system in function again, one should use a more modern dredge pump for a good cooperation with the under water pump system and the diesel engine should get overhauled. Invouard dredge pump O&K MAN Dieselmotor 12 ASV 25/30 15

winches to be installed: Ladder hoisting

8 t at 20 m/min, electrical driven 1 aft

16 Ladder hoisting winch Side winch Winch System On dredge M 28 there are following winches to be installed: Ladder hoisting winch of 32 t at 30 m/min, electrical driven 2 Side winches of 25 t at 26 m/min, hydraulically driven 4 Mooring winches each 8 t at 20 m/min, electrical driven 1 aft winch, new installed Mooring winch STb. aft Mooring winch Bb. fore 16

A density- and flow rate measuring system does the dredge master help to check the output of his dredge as well as the velocity of mixture in the delivery pipe.

17 Dredge Master House For a good view around, the dredge master house has been constructed at the highest point of the dredge. From this point the dredge will be handled by the dredge master, all necessary instruments and steering device are here installed. A density- and flow rate measuring system does the dredge master help to check the output of his dredge as well as the velocity of mixture in the delivery pipe. Measuring points for an ACC system are installed for a good evaluation. Due to the order of the Atomaufsichtsbehörde the transmitter for density- and flow meter had to be dismounted. To get it installed again on board, the next owner of the dredge M 28 had to show a so called Umgangsgenehmigung for this nuclear device. Only then the dredge can be used in an economical way. Elevated position of dredge master house Desk in dredge master house 17

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23 Appendix: GL Survey 23

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Cutter-/ suction dredger

Cutter-/ suction dredger PARTICULARS : Type Cutter suction dredger I Barge loading suction dredger. Name "Cornelis". Dimensions Minimum draught Length o.a. 61.80 m Length pontoon 47.02 m Width 9.93 m Depth 2.30 m 1.34 m Air draft