BACKACTER 1100 World s strongest dredge

BACKACTER 1100 World s strongest dredge

Introduction Yard De Donge designed and build the strongest type of dredger; the Backacter 1100. The first very large dedicated marine dipperdredger excavator in the world and the biggest of the BA series. Why did we do this: The Classic approach of an (adapted land) excavator on a dipperdredger had too many compromises. Higher lifting and penetration forces where demanded. Functional desire to put the engines in the hull, cooling, no fuel stop, reduced oil spills, etc. Free choice of dimensions and components. Stronger dredging equipment. Improved design with regard to maritime environment. General Features Gravity filling of the H-pumps. A top-class marine dredger with all drive unit power packs in spaces under deck. Big buckets at a deep dredging depth with highest penetration forces. No fuel stops required anymore, less fuel consumption than a classic excavator. High and extended dumping reach, unloading in even high barges is always possible. Low turbidity dredging machine. Shock-absorbing elastic foundation, integrated in the dredger s deck. All spud and spudcarrier operations from the Backacter s cabin. One hydraulic powerpack system for the Backacter, thrusters and spudsystem. Water cooled diesels and water cooled hydraulic system. For working in ambient temperatures till -25 O C. No banana shaped boom, but an almost straight one. Changes without notice, reference to all pages, September 2015 Pages 2 of 10

Technical Highlights PONTOON: Water-cooled diesels, hydraulic pump sets under deck in a well maintainable spacious environment. Easy to observe / check / maintain slewing motors. Marine electric system. Illumination for 24 hours working. Air-conditioning and heating in the cabin. Stainless steel hydraulic lines on the stick and boom (option). All bearings of the dredging equipment centrally greased, via stainless steel lines. By-pass float mode for the dredging equipment during spudcarrier moving. Bucket cylinder rods are protected by sliding steel structure. Triple greasing system. Spacious cabin for dredging and spud operation. Dredging instrumentation fitted in the cabin. Changes without notice, reference to all pages, September 2015 Pages 3 of 10

General Characteristics of the dredge pontoon Below the main characteristics are given for the BA1100 mounted on a S-type pontoon. BA 1100 mounted on flexible pedestal. IACS classification, Deep Sea, unrestricted towage (high bow). Capable to dredge in max. 2.5-m wave height. Dimensions: 65.00 x 20.00 x 4.30 M. Spud length: 34 m. basic length (or longer). Stabilising spuds:1800 x 1800-mm, square built of special steel. Tilting spuds together with their spudcasing and spudcarrier, through vertically mounted hydraulic cylinders. 10-m. stroke spud carrier. Dredging instrumentation with integrated automatic draft levelling Auxiliary engine room at Stb. under high bow deck Accommodation Backacter s diesels at aft with water-cooling and noise friendly Auxiliary crane near backacter. DSF600 crane, 60 tons capacity at 19 M. depth. Painting system (with impressed current system for corrosion protection). Options: - Self-propelled: assisted power - Special fendersystem - Additional auxiliary crane, type DSF 600 with 60 tons cap. See picture. Note: The Backacter 1100 can be mounted on a dipperbarge as well. Such dredge has abundant deckspace for the loading of whatever materials. Even combinations with heavy lifting cranes on deck are possible. Changes without notice, reference to all pages, September 2015 Pages 4 of 10

Dredging Equipment The BA1100 can be executed with the following boom stick combinations: First equipment: Boom : 18.00 metres. Stick : 6.50 metres. Bucket : 25.00 m³ SAE (15.00 m 3 SAE rockbucket). Max. working depth : 18.00 metres. Penetration capacity on max depth : approx.185 tons (approx. 205 tons with 15m 3 rockbucket) Second equipment: Boom : 18.00 metres. Stick : 10.50 metres. Bucket : 20.00-m³ SAE (15.00 m 3 SAE rockbucket) Max. working depth : 22.00 metres. Penetration capacity on max depth : 150 tons approx. (approx. 160 tons with 15.00 m 3 bucket) Third equipment: Boom : 23.80 metres. Stick : 6.50 metres. Bucket : 20.00-m³ SAE Max. working depth : 22.00 metres. Penetration capacity on max depth : approx. 150 tons (restricted due to fatique) Fourth equipment Boom : 23.80 metres. Stick : 10.50 metres. Bucket : 15.00 m³ SAE. Max. working depth : 26.00 metres. On max. depth, 27.00 M : approx. 110 tons (fully stretched). Penetration capacity on max depth : approx. 150 tons (till -24 metres). Fifth equipment Boom Stick : Bucket Max. working depth Penetration capacity at max depth : 23.80 metres. 17.80 metres. : 7.00-m³ SAE : 33.00 metres. : approx. 80 tons Changes without notice, reference to all pages, September 2015 Pages 5 of 10

Penetration Diagram of 1 st / shortest configuration Changes without notice, reference to all pages, September 2015 Pages 6 of 10

Estimated Standard Production The Estimated standard production calculation for a type 1100 Donge Backacter : At 20 meters depth with a 20-m³ SAE approx 810 m³/hr At 17 meters depth with a 25-m³ SAE approx 1012 m³/hr The above calculation is done with the following assumptions: - Filling degree 90 % - 45 min. effective production per hour Variables are e.g. : when dredging layer thickness is limited : resistance of bottom : barge availability : environmental (current, waves, etc.) : operator, capability / experience, etc. : profile dredging - BA1100 dredging 850 m3 per hour in stiff heavy clay with a 20 m3 SAE bucket - Changes without notice, reference to all pages, September 2015 Pages 7 of 10

Technical Characteristics BA1100 Installed diesel power : 2 x 1730 kw ( Cummins, type QSK60 DM) Max. oil flow per minute : 11000 l/min Estimated weight of Backacter: 510 tons* Hydraulic boom cylinders : 580-mm / 380-mm Stick cylinders : 400-mm / 280-mm Bucket cylinders : 360-mm / 240 mm Forged connection eyes at rods will be applied (mono and stick) All cylinders have hydraulic damping Large operation cabin with build in dredging instrumentation Automatic greasing on slewing ring and on the dredging equipment, except bucket connections through 3 separate systems Boom and stick can be switched in H-bypass (floating position) Diameter slewing ring : 5200-mm (triple roller) Slewing gears : 5 Slewing teeth height : 300 mm Like all Backacters, the main hydraulic tank is non-pressurized, thus enhancing H- pump and life-time and other components life-time (e.g. eliminating air bubbles) Water cooled hydraulic system through closed loop, fresh water circuits and bun coolers * weight is excluding powerpack, fuel and hydraulic oil tank, there is no counterweight, etc. Changes without notice, reference to all pages, September 2015 Pages 8 of 10

Hydraulic Installation Specification of the main features of the Hydraulic installation of the Backacter 1100. Main pumps: 8 double variable displacement, axial piston pumps (make : Rexroth ) Pressure : 320 bar Capacity each : 1440 l/min Total capacity : 11000 l/min Reservoir capacity: 23000 litres. Filtering: Full flow return line filtering at 10 mμ Full flow leak oil filtering at 3 mμ Full flow filters at 200 mμ in each pump discharge line By-pass filtering at 1 mμ Cooling: Plate type heat exchanger for sea water at 35 C Swivel: Large capacity swivel with 8 pressure paths 1440 l/min at 320 bar 1 return line path 19000 l/min at 25 bar 1 through hole Ø63mm for e-cabling Piping: Above deck: executed in high strength stainless steel or duplex Below deck: executed in in carbon steel S355 Controls: Proportional electronic control of all valves and pump outputs Alarms: Continuous monitoring of all filters, gearbox temperatures, oil temperatures and levels, operating pressures and oil contamination Notes: - All pumps mounted on the gearbox behind the 2 x 1730 kw main diesels. - The gearbox on which the H-pumps are fitted, is water-cooled, as well as the main system. - The hydraulic system is non-air pressurized, thus enhancing life-time of pumps. - The H-oil reservoir is fitted above deck level, the powerpack is mounted under deck. Changes without notice, reference to all pages, September 2015 Pages 9 of 10

Some experiences from practice Some dredging production data noted on a project dredging soft soil: - After 23 cycles, a 900 m 3 splitbarge was filled. - Whatever heap there is in the 25 m3 SAE bucket, the BA1100 lifts it out. - A 600 m 3 barge appeared too small, it was filled in 12 movements (12 min.), and loading had to be done with care, in order to protect the barge. With its huge penetration forces of about 200 tons, which is concentrated on a few cm 2 of its bucketteeth, all sedimentary rock types can be dredged. The chance that the bucket is full is highest due to the power of this extreme machine, being world s strongest dredge. The BA1100 is designed from tip to toe for one purpose only; dredging in a marine environment and is thus no adapted mining excavator. Changes without notice, reference to all pages, September 2015 Pages 10 of 10