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CUTTER SUCTION DREDGER TESTING PROTOCOL

Dredger Name: ECO 200 Project No.: S318
Date: 14-MARCH-2018 Inspector Name: BJORN FEJER / RONAK PADHIYAR

General Done Remarks
1.1 Check all fasteners for tightness before sending in testing site:
 Cutter front parts fasteners.
 Inspection piece and suction mouth fasteners.
 Dredge Pump area fasteners.
 Side tumblers fasteners.
 Rubber hose fasteners.
 Gantry part fasteners.
 Pipe line flange fasteners.
 Pontoon link fasteners.
 Winch foundation fasteners.
 Railing fasteners.
 Man hole cover fasteners.
 Cabin foundation fasteners.
 Ladder turning point fasteners.
 HPU foundation fasteners.
 Generator mounting fasteners.
 Spud bowl fasteners.
 Propellers fasteners.
1.2 Check if the followings parts are greased:
 Tumbler shaft and sheave.
 Cutter ladder hoisting sheave.
 Gantry sheave.
 Turning point.
 Winch & wire ropes.
 Spud cylinder bearing.
 Spud cylinder sheave head.
1.3 Disassemble the spuds before sending in testing site.
1.4 Ensure that there is lifting chain or wire rope or Kevlar rope & mooring
rope available for lifting the dredger.
1.5 Check and ensure that cutter ladder is attached securely with sling wire
to the gantry (used for temporary hoisting the ladder) before sending in
testing site.
1.6 Check and ensure that the spud cylinder is securely tied with spud bowl
before transporting to testing site.
1.7 Lift the dredger using the crane and slowly put it on water.
 Use mooring ropes to add additional control while lifting the
dredger.
1.8 Assembly the spud on site (after putting the dredger on water):
 Remove all spud door lock pins (2 on each door).
 Open the spud door.
 Position the spud inside the spud door using the crane.

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Record the cutter system pressure gauge reading.  At least ½ of the reservoir capacity should be filled with oil.12 Check if there if the fuel generator tank is full of fuel. engine temperature & oil temperature in the HPU. tight and ensure all the 4 bolts in installed. engine temperature & oil temperature in the HPU. 1.24 Switch on cutter and check if cutter head is rotating.  Adjust the speed to 80% and check visually if it rotates.22 Check if hydraulic power pack is running and system is pressurizing. engine temperature & oil temperature in the HPU. 1. joystick and knobs in the control panel and bring them all to the zero/neutral/off position.9 Check if deck is clean and free from unnecessary things. run for 2 minutes.  Perform dredger trim balancing if necessary. run for 2 minutes. 1. Cutter Head 1. 1. 1.16 Turn the hydraulic suction valve from hydraulic tanks to the “OPEN” position.  Close the spud door and install the spud door lock pins (2 on each door).25 Adjust the cutter speed control and check cutter head if RPM is changing visually. 1.10 Measure and record free board from aft.  The level should be visible at least ½ above the visibility range of gauge. run for 2 minutes.21 Turn the ignition switch to “START” to start the engine running:  Check all gauges of ENGINE CONTROL PANEL if active.  Adjust the speed to 60% and check visually if it rotates. engine temperature & oil temperature in the HPU. 1.23 Wait for 10 minutes before removing the cutter ladder sling wire attached to the gantry (used for temporary hoisting the ladder).15 Check all the switches. 1.14 Check hydraulic oil level. Record the cutter system pressure gauge reading. engine temperature & oil temperature in the HPU.11 Check if the muffler is installed.  Install the sling plate.19 Close all doors of the of the HPU and ensure that it is properly locked. 1. 1. Record the cutter system pressure gauge reading. run for 2 minutes. 1. Record the cutter system pressure gauge reading. run for 2 minutes. Starting the Engine 1.  Adjust the speed to 40% and check visually if it rotates.17 Turn the battery isolator in the engine compartment to “ON” position.  Adjust the speed to 100% and check visually if it rotates. 1. 1.20 Check and ensure that “Emergency STOP” button is released. -2- . front and middle of pontoon (record on the provided form).13 Check if there is 80 liters of diesel in the fuel tank.  Adjust the speed to 20% and check visually if it rotates. Record the cutter system pressure gauge reading. 1. 1.  Secure the spuds by installing the spud hoisting stopper pin.18 Check the oil level in reservoir for propulsion.

1.33 Lift the cutter ladder and set it to the home position using the joystick. both winch should rotate at opposite direction.30 Switch on the dredge pump. Winches 1.  Adjust the speed to 60% and check if there is water flow discharge from the orifice. Run for 5 minutes. 1. 1. Dredge Pump 1. 1. engine temperature & oil temperature in the HPU. 1. 1. check if the ladder hoisting winch is working. Spuds 1. Record dredge pump pressure gauge reading.31 Adjust the dredge pump speed using the dredge pump speed control. then:  Lower the cutter ladder until maximum dredging depth (if possible. if not at least 2 meters) before switching on the dredge pump.28 Switch off the cutter.29 Ensure that there is orifice installed at the end of discharge pipe and the cutter ladder is at maximum depth (if possible. Record dredge pump pressure gauge reading.32 Switch off the dredge pump.  Perform dredger trim balancing if necessary.  Adjust the speed to 20% and check if there is water flow discharge from the orifice. Run for 5 minutes. Record dredge pump pressure gauge reading.37 Check and ensure that the spud pins are installed. 1.27 Measure and record free board from aft. engine temperature & oil temperature in the HPU.38 Remove the connection between the spud cylinder and spud by removing the shackles attached to the spud wire rope (for both spuds). Record dredge pump pressure gauge reading. Run for 10 minutes.26 While the cutter head is rotating.  Adjust the speed to 80% and check if there is water flow discharge from the orifice.35 Check port side winch if working by switching the pay in – pay out control. Run for 5 minutes. 1. 1. Run for 5 minutes. if not. Record dredge pump pressure gauge reading.34 Check starboard side winch if working by switching the pay in – pay out control. engine temperature & oil temperature in the HPU. engine temperature & oil temperature in the HPU.  Adjust the speed to 100% and check if there is water flow discharge from the orifice.  Adjust the speed to 40% and check if there is water flow discharge from the orifice. front and middle of pontoon (record on the provided form). using the joystick move it up and down.39 Check if starboard side spud cylinder is working by operating the control switch: -3- .36 Check if the swing joystick is working by toggling left and right. 1. engine temperature & oil temperature in the HPU.Cutter Ladder 1. at least 2 meters).

the dredger should move reverse.  Move the joystick to right. check cylinder retraction. 1.  Remove the connection between spud cylinder and spud.  On second spud hole from top.50 Ensure that cutter ladder is attached securely with sling wire to the gantry (used for temporary hoisting the ladder).41 Set both cylinder to fully retracted position.  Extend the cylinder to the maximum.  Exterior lights. return the spud to original position.  Ensure that the hydraulic cylinder is not blocking the tilting path of spud.42 After checking the spud tilting feature. 1.  Lift the spud a little until you can remove easily the spud hoist stopper pin.  Remove the spud tilting support upper block. joystick and knobs in the control panel to zero/neutral/off position.47 Check and rate electrical cable management and rate from 1 to 10.46 Check if air-conditioning system is working. Cabin 1.49 Check if the ventilation fan is working.  Pull the spud.44 Check all lights are working. 1.52 Reduce the engine RPM to idle.40 Check if port side spud cylinder is working by operating the control switch:  Extend the cylinder to the maximum. 1. -4- .  Interior lights.  Move the joystick to left.  Remove the sling wire and spud hoisting wires. until it reaches and rest to the spud tilting support on pontoon. 1.45 Check the cabin seat.  Lift the spud until the tilting hole (hole in spud with color) matches the spud tilting support position.48 Check if the wiper is working.43 Check if the propeller is working:  Move the joystick to forward. 1. Propulsion 1.  Adjust up and down.51 Bring all switches.  Press spud free fall button. Stopping the Engine 1. the dredger should turn right. 1.  Move the joystick to reverse.  Secure the spud by wire rope by tying it on the spud tilting support on pontoon.  Install the spud tilting pin and reinstall the spud tilting support upper block.  Connect the spud cylinder and spud by connecting the spud cylinder shackles and spud wire rope. 1. connect a chain/wire rope.  Press spud free fall button. 1.. the dredger should turn left. 1. the dredger should move forward.  Lower a little the spuds until its weight is fully supported by the spud tilting support. check cylinder retraction.

 Winch foundation fasteners.  Spud bowl fasteners. 2.3 Check all fasteners for tightness.  Rubber hose fasteners.56 Disassemble the spuds before transportation.  Pontoon link fasteners.  Railing fasteners.7 Apply touch up paint. 1.2 Apply antirust protection on all exposed metal.4 Remove the orifice at end of the discharge pipe. 2. 2. 2.1.1 Wash the dredger with normal water to remove the remaining salt water especially suction and discharge pipe inside diameter.  Inspection piece and suction mouth fasteners.  Dredge Pump area fasteners.  Side tumblers fasteners. 1.53 Turn the ignition switch to “OFF” position.  HPU foundation fasteners.  Pipe line flange fasteners. 2. (applicable for stock dredger only). -5- .  Ladder turning point fasteners.  Propellers fasteners. especially for stock dredger.  Generator mounting fasteners. 2.55 Bring the suction valves of hydraulic lines to “CLOSE” position. if there is any scratch happened after testing of the dredger. 2.8 Cover the dredger to avoid deterioration of some parts due to sunlight exposure.  Gantry part fasteners. 1. Post testing protocol Done Remarks 2.54 Turn “OFF” the battery isolator switch.  Cabin foundation fasteners.  Man hole cover fasteners.  Cutter front parts fasteners.6 Remove the engine battery connection and store in secure place.