Designing Dredging Equipment

OE4671/WB3408

Prof.ir. W.J.Vlasblm

12 September 2006

Section Dredging engineering

Purpose of the lecture

To design a particular type of dredger on basis of
(simple) dredging processes.
Such a method can be used for many design
problems!

September 12, 2006

Course development
Introduction lecture in the 5th quarter
Assignment for one or two persons can be done the
whole year around.
Total 4 credits (ECT)

September 12, 2006

Assignments for hydraulic dredgers

Trailing Suction Hopper Dredger (TSHD) for large
reclamation works
Multi Purpose TSHD for maintenance and beach
nourishments
Gravel Trailing Suction Hopper Dredgers
Cutter Suction Dredger
Environmental Dredger
Plain Suction Dredger
Dustpan Dredger
September 12, 2006

Assignments for mechanical dredgers

The backhoe dredger
The grab dredger
Bucket ladder dredger

September 12, 2006

Trailing Suction Hopper Dredger

September 12, 2006

Cutter Dredger

September 12, 2006

Plain Suction Dredger

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Plain Suction Dredger

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Dustpan Dredger

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10

The Environmental Dredger

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11

The Backhoe Dredger

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12

The Grab or
Clamshell Dredger

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Bucket Ladder Dredger

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Work Load
The assignment for
the TSHD, CSD are for 2 students
The other ones are for 1 student

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15

Designing Dredging
Equipment
Productions
Dredging installation
Propulsion (optional)

Prime movers (main engines)

General layout
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16

Design productions
Yearly production

Working hours

Soil type

Delays
Effficeincy
Excavating production

Losses
Transport production
Deposing
Losses
Situ production
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Design basis = yearly output in m3

(production)
To be translated to the significant design parameters.
Depends on the scale (or cycle) of the process.
Large scales
Hopper dredger volume and load per trip
Barge unloader dredger Barge volume
Backhoe dredger the volume per cycle
Continuous operating dredgers or equipment m3/week
or m3/month
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Design Basis (2)

Small scale:
Wall speed of a breach
Pump
Cutter head
Bucket ladder dredger
Backhoe dredger
Grab dredger
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mm/s
output in m3/s
Excavated output in
m3/s
Buckets/min
Bucket volume/cycle
Grab volume/cycle
19

Problems during translation

Change of volumes
In many cases the contractor is paid in volumes
removed, but many processes are based on mass.
Working hours per week (168 or 84 or 40)
Down time
Overhaul & Maintenance
Bunkering, crew changes, etc
Delays due to weather conditions
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20

Concentration (1/3)
By volume

Us
Volume sand
=
Cv =
Mixture volume U m

By weight

sU s
s
Sand mass
=
=
Cw =
Cv
Mixture mass mU m m

Delivered

U s / time Qs
Cvd =
=
U m / time Qm

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21

Concentrations (2/3)

Ratio between Cvd & Cv follows from:

Qs vs ACv
Cvd vs
Cvd =
=

=
Qm
vm A
Cv vm

Ratio between Cw & Cv

s
Cw s
=
Cw =
Cv
Cv m
m

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Concentrations (2/3)

Cvd vs
=
Cv vm
In horizontal transport vs < vm slip
In vertical transport vs vm the difference is the
settling velocity

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Mixture
Densities

Volumetric
Concentration

Massmixture=massliquid+masssolids

Us
mU m = f U f + sU s with Cv =
Um

m = f (1 Cv ) + s Cv
m f
Cv =
s f
September 12, 2006

" Note U is volume"

24

Volume changes
When removing soil the insitu density will change;
mostly from a dense to a loose state
Increase in porosity; f.I. From 40 to 50%
Porosity n is ratio pore volume over total volume
Condition: V1(1-n1)=V2(1-n2)
Examples:
Sand; n1=0.4 and n2=.5 gives V2/ V1=0.6/0.5=1.2
Rock; n1=0 and n2=.4 gives V2/ V1=1/0.6=1.7
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Losses
Every dredging process can have losses, called spillage
More excavated than picked up by the flow or bucket
Non removed loads in TSHDs, particular when the
loads is pumped ashore or rainbowed.
Unstable slopes after dredging (plain suction dredgers)
In accurate placing of material
Losses due to current and waves

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Excavating production

Mechanically

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Hydraulically

27

Mechanical excavation
Specific Energy Concept (SPE)
Energy required to excavated 1m3 of soil
Dimension is Joule/m3
or per unit of time J/s/m3/s=W/m3/s,
That equals a power over production

power
SPE =
power = SPE production
production
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Mechanical Excavating

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Mechanical Excavating

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Mechanical Excavating

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Hydraulic excavation
Momentum of flow
A reasonable assumption is that the jet- production is
linear with the total momentum flux of the jet system
independent of the trail speed.

Qsand = (1 n ) Qdredged
M sand = Qsand sand = (1 n ) Qdredged sand

M sand = I = w Qu = w Q
September 12, 2006

2p

= 2 w

Ppower
p pressure
32

Excavation by dragheads is
hydraulically

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Water injection dredger

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Transport production

Mechanically
ship/barge conveyor

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Hydraulically
pipeline

35

Mechanical transport
Trailing suction hopper dredger
Barges
Be aware of the effective load, because the unloading
is not always 100%

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Transport by barges

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By Trailing Suction Hopper Dredgers

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38

Pressure [kPa]

Hydraulic transport
Pump-pipeline system
mixture
3
water

2
4
mixture

water

Flow [m3/s]
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Hydraulic transport

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40

Methods of deposing (1/2)

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Methods of deposing (2/2)

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disposing

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Rainbowing

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Mechanical Assistance

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Design examples

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TSHD

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Example 1
Design a Trailing Suction Hopper Dredger that can
dredge yearly 5 Mm3 coarse sand & gravel at 75
nautical miles from a port.
The dredger works 5 days at 24 hours
Bunkers will be taken in the weekend
Overhaul 2 weeks
Weather delays 3 weeks
Workability 95%
Christmas 1 week
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Designing TSHD
Main dimensions

Dredging installation
Propulsion

General layout
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Main dimensions
Yearly production

Working hours

Soil type

Delays

Overflow losses

Effficeincy

Hopper capacity and Payload

Dead weight
Displacement
Bock coefficient
Main dimensions ship LxBxT
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Cycle time
First estimate of dredge cycle:
Sailing to the dredging area: 75/15=3.0 hr
Loading
=1.5
Sailing to the unloading area:
=3.0
Unloading
=1.5
Total
=9.0 hr

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51

Required load/trip
Available hours: (52-6)x5x24=5520
Effective hours: 0.95x 5520=5244
Number of trips per year: 5244/9= 582
Required volume per trip: 5,000,000/582=8591 m3
In coarse sand & gravel max.filling hopper is 90%
Required hopper volume: 8591/.9=9546 10000 m3
Density of sand & gravel in hopper 2000 kg/m3
PayLoad is: 8600x2=17200 ton
Hopper density: load/volume=1.72 t/m3.
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Deadweight & lightweight

Crew and their possessions, consumer goods, spare
parts, and ballast water and payload.
Deadweight=1.05 x payload
Light weight as function of deadweight

Light weight [t]

25,000
20,000
15,000

y = -3E-06x 2 + 0.5586x
R2 = 0.9607

10,000
5,000
0
0

10,000

20,000 30,000 40,000 50,000

60,000 70,000

Deadweight [t[
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Displacement
70,000
60,000

y = 0.6827x
R2 = 0.9929

Weight [t]

50,000
40,000

G Light weight

30,000

Dead weight

20,000

y = 0.3173x
R2 = 0.9622

10,000
0
0

20,000 40,000 60,000 80,000 100,000

Displacement [t]

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Block coefficient

T
L

Cb =
LBT
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Ship Numbers

L/B, B/H, B/T

Ships Numbers
8
7
6
5
4
3
2
1
0
1965

L/B
B/H
B/T

1970

1975

1980

1985

1990

1995

2000

Year of Construction

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Dredging installation
Cvd
Required pump capacity

Overflow losses

No
Main Dimensions

Overflow
losses equal as assumed?

Yes
Pumps and pipelines
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Pump capacities
10000 m3 in 90 min=1.85 m3/s including pores or
1.85x0.6=1.11 m3/s excluding pores
Assume Cvd=0.2 capacity Q=1.11/0.25=5.55 m3/s
or per suction tube 2.8 m3/s
Critical velocity for course sand is 5 m/s, so pipe
diameter is 0.85 m 0.85 m
In coarse sand and gravel there are no overflow losses
to account for.
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Excavation process

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59

Calculated the required jet pressure

Sand mass follows from production

Qsand = (1 n ) Qdredged
M sand = Qsand sand = (1 n ) Qdredged sand
Momentum follows from:
M sand = I
With =0.1

I = w Q jet u = w Q
September 12, 2006

2p

= 2w

Ppower
p pressure
60

Relation between Qmix, Qjet and Qerosion

1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0

0.1

0.2

0.3

0.4

0.5

Qjet / Qmixture

September 12, 2006

0.6

0.7

0.8

0.9

Cvd/(1-n)=0
Cvd/(1-n)=0.2
Cvd/(1-n)=0.4
Cvd/(1-n)=0.6
Cvd/(1-n)=0.8

61

Pumps and pipelines

Determine jet capacity

and pressure

Submerged pump required?

No
Yes
Depth of submerged pump
Determine headlosses
and power(s)
Choose pump(s)
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Submerged pump required?

k
H
water

mixture
hs

Non cohesive material

1
1
2
water gH + Vac = mixture ghz + mixture v = mixture g( H k ) + mixture v 2
2
2
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Hydraulic transport
From seabed into the hopper
From hopper to the shore
Mostly empirical relations (Matousek)

For gravel dredgers this is

mostly be mechanically

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Pump characteristics

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Propulsion
For dredging & sailing

Bow trust power

Total Installed

Power balance

General layout
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Propulsion power

25000
y = 0.4641x - 510.11
2

Pp [kW]

20000

R = 0.8741

15000
10000
5000
0
0

10000

20000

30000

40000

50000

Displacement [t]

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Bow trust power

Bow trust power

Bow trust power [k

3,500
3,000

y = 0.1758x - 19.495

2,500

R2 = 0.8036

2,000
1,500
1,000
500
0
0

2,000

4,000 6,000 8,000 10,000 12,000 14,000 16,000

Propulsion power during trailing [kW]

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General Arrangement

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General Arrangement of gravel

dredger

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Simple general arrangment

A

C D E

Tship
=
13,2

Hs

ho
pp
er

=
1
3

hip

See figure
B7.1

Bh
op
per

=
2
5
m

=
1
4,
7

Bs
hip

=
3
3

Lhopper = 62 m
Lship= 165 m
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The Cutter Suction Dredger

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72

Example 2
Design a cutter dredger that can dredge dredge yearly
5 Mm3 rock with a unconfined compressive strength of
5 MPa. The tensile strength is 1 Mpa
The dredgers have to work 168 hrs a week.
Yearly overhaul 4 weeks
Christmas leave 1 week
General delays 10%
Dredging delays 20
SPE~qu
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Required cut production

Available hours (52-5)x168=7896
Non dredging hours:0.3x7896=2369
Dredging hours 7896-2369=5527
Estimated spillage 25%
Required hourly output: 1.25x5000000/5527=1130 m3.
Qdredged=1130/3600=0.314 m3/s
Time losses due to stepping, spud changes 15%
Qcut=0.31/0.85=0.37 m3/s
SPE=5MJ/m3.
Required mean cutter power 0.37x5=1.85 MW
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Cutter head productions c.q. Spillage

The rotational speed of the cutter head causes spillage.
The productivity c.q. spillage depends on the ratio:
For sand the productivity is:

Pr 2.5

Q pump
3
Rcutter

For rock the productivity is much lower

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Cutter head productions c.q. Spillage

RELATIVE PRODUCTION
Gravel 10 mm

Gravel 15 mm

Ladder 25 deg.

Sand

80
70

Pr [%]

60
50
40
30
20
10
0
0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

Flow number [-]

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Cutter head production process

in rock or gravel

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Cutter head dimensions for rock

with 25 % spillage

Cutter head speed [rpm]

120

Vm=5 m/s
12

cutter head speeds

100

10

Capacities

80

60

40

20

0
0.0

September 12, 2006

Vm=3.5 m/s

0.5

1.0

1.5
2.0
2.5
Cutter diameter [m]

3.0

3.5

Pump capacity [m3/s]

Vm=2.67 m/s

4.0

78

Pump capacity and concentrations

Qdredged=0.314 m3/s
Qmixture=3.5 m3/s

Qdredged (1 n )
Qsand
Cvd =
=
Qmixture
Qmixture

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Pumping distances and installed

pump power
Knowledge of hydraulic losses can be found in the
lecture notes of Matousek c.q. Talmon
Knowledge of dredge pump can be found on our
website and is downloadable.

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Lightweight of pontoon

Light weight [t]

10,000
y = 0.3485x

8,000

R = 0.925

6,000
4,000
2,000
0
0

5,000

10,000

15,000

20,000

25,000

Total installed power [kW]

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Pontoon dimensions (1/2)

L/B

B/T

12.00

L/B & B/T

10.00
8.00
6.00
4.00
2.00
0.00
0

1000

2000

3000

4000

5000

6000

7000

8000

9000

Light weight [t]

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Pontoon dimensions (2/2)

10,000
y = 0.4664x
R 2 = 0.9597

9,000

Light weight [t]

8,000
7,000
6,000
5,000
4,000
3,000
2,000
1,000
0
0

5,000

10,000

15,000

20,000

25,000

BLD [m 3]

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Simple Plan

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Backhoe dredger

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Example 3
A backhoe dredger have to dredge 500 m3/in fine sand
with a SPE of .7MJ/m3.
Calculated the Bucket size and cylinder forces

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Fill Degree & Bulk factor

Soil type
Soft clay
Hard clay
Sand & Gravel
Rock; well blasted
Rock, unblasted

September 12, 2006

Filling degree
1.5
1.1
1
0.7
0.5

Bulking factor
1.1
1.3
1.05
1.5
1.7

87

Dredge Cycle
Cycle times of the bucket depends on the dredging
depth and soil type, but are in the order between 20
and 40 seconds.
The cycle consists of:

Digging

Lifting and swinging

Dumping

Swinging and lowering

Positioning.
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Crane weight versus bucket size for

soft soil
30
2

y = -7E-06x + 0.0494x + 1.5486

Bucket size [m3]

25

R = 0.9778
20
15

bucket2

10
5
0
0

100

200

300

400

500

600

Crane weight [ton]

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Required power
Liebherr Excavators
2500

Power [kW]

2000
1500
y = 4.4679x
R2 = 0.9936

1000
500
0
0

100

200

300

400

500

600

Crane weight [tons]

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Relation for existing dredgers

1200.00
Rock buckets

Installed power [kW]

1000.00
800.00
600.00
400.00
200.00
0.00
0.00

5.00

10.00

15.00

20.00

Bucket size [m3]

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Light weight pontoon

1800
1600
Light weight [t]

1400
1200
1000
800
600
400
200
0
0

250

500

750

1,000

1,250

Total installed power [kW]

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Pontoon volume

1800
1600

y = 0.4713x

Light weight [t]

1400

R = 0.6122

1200
1000
800
600
400
200
0
0

500

1000

1500

2000

2500

3000

LBD [m3]

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Ships numbers for BHD

L/B & B/t

L/B

B/T

9.00
8.00
7.00
6.00
5.00
4.00
3.00
2.00
1.00
0.00
0

200

400

600

800

1,000

1,200

1,400

1,600

1,800

Light weight [t]

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Simple Plan

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Newer ideas can be discussed

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The shallow draught TSHD

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