USER MANUAL

Dredge pump
BP45-1100
 Dredge pump BP45-1100

MANUFACTURER:
Damen Dredging Equipment
Edisonstraat 32
P.O. Box 1021
3860 BA Nijkerk
The Netherlands

T. +31(0)33 - 2474040
F. +31(0)33 - 2474060
E. info@damendredging.com

Revision no. Revision date Remark Responsible

0.0 2009-06 Initial issue LO

0.1 2009-10 Changed description seal LO

© 2009 DAMEN DREDGING EQUIPMENT

All rights reserved. No part of this book (nor attached / applicable drawings) may be
reproduced or transmitted in any form or by any means, electronic or mechanical, including
photocopying, recording or by any information storage or retrieval system, without prior
permission in writing from the copyright holder.

Damen Dredging Equipment is a member of the Damen Shipyards Group.

BP45-1100 II
 Dredge pump BP45-1100

EC-DECLARATION OF CONFORMITY FOR MACHINERY

(Directive 2006/42/EC, Annex II, sub A)

Damen Dredging Equipment

Edisonstraat 32, 3861 NE,
P.O. Box 1021, 3860 BA,
Nijkerk, The Netherlands

Herewith declares that:

Dredge pump BP 45-1100
is in compliance with the Machinery Directive 2006/42/EC

The following harmonised standards have been applied:

NEN-EN-ISO 12100-1 and 12100-2, NEN-EN-ISO 14121-1

Nijkerk, June 4th, 2010

Frank W.A.M. Bosman
Manager Engineering Department

BP45-1100 III
 Preface

Preface
This manual has been written for the benefit of those personnel involved in the
operation, maintenance and repair of the pump. It contains information, which
is essential for the proper running and care of the unit. It also offers important
guidance in the prevention of accidents, which might cause injury to personnel
and / or damage to the unit.
This manual must be read and thoroughly understood before the pump is first
put into service. Its instructions and warnings must be followed closely.
In the description is assumed that the pump is part of a suction dredger,
however the pump can be sold as such. The customer must realise that some
descriptions are relating to the dredger.
Any suggestions for improvements to this manual are most welcome.

AFTER-SALES SERVICE
Please contact Damen Dredging Equipment (at the address given on this
manual's inside cover) for technical assistance, spare part enquiries and
warranty claims. Always mention machine type, part number and order number
when ordering spare parts.

SYMBOL DESIGNATION

O This is to warn of potential equipment damage and/or injury to

personnel.

e This is to warn of potential equipment damage.

O This is to draw attention to a point. It is not necessarily a

warning.

HOW TO INTERPRET INSTRUCTION SEQUENCES

Instructions numbered 1, 2, 3, etc. must be followed in numerical order. When a
numbered instruction is followed by further sub-instructions prefaced with a
hyphen (-), these must be followed in the order they are written before
proceeding to the next numbered instruction.
Sometimes instructions are prefaced with a bullet (•). This is used solely to
differentiate one instruction from another and does not indicate any particular
order of execution.

ADDITIONAL DOCUMENTS AND APPENDICES

The additional documents and appendices are listed on page IX and page X
and may be found in the documents on CD-rom.

BP45-1100 IV
 Contents

Table of contents
Preface....................................................................................................... IV
Table of contents ........................................................................................ V
List of figures.............................................................................................. VI
List of tables.............................................................................................. VII
List of additional documents .................................................................... VIII
Conditions of liability .................................................................................. IX
Warranty ..................................................................................................... X
1 Introduction ........................................................................................12
1.1 Applications............................................................................... 12
1.2 Advantages ............................................................................... 12
2 Safety ................................................................................................13
3 Description.........................................................................................14
3.1 Construction .............................................................................. 14
3.2 Working principle....................................................................... 14
4 Installation .........................................................................................15
4.1 Post-delivery inspection ............................................................ 15
4.2 Dredge pump unit...................................................................... 15
4.3 Transportation and storage ....................................................... 16
4.3.1 Transportation .................................................................16
4.3.2 Storage............................................................................16
4.4 Tests and adjustments .............................................................. 17
5 Operation ...........................................................................................18
5.1 Start-up ..................................................................................... 18
5.2 Shutdown .................................................................................. 18
5.3 Points to watch when operating the dredge pump .................... 19
5.3.1 Discharge pipe control ....................................................19
5.3.2 Suction pipe control.........................................................19
6 Maintenance ......................................................................................20
6.1 General directions ..................................................................... 20
6.2 Periodical maintenance............................................................. 21
6.2.1 Dredge pump unit............................................................21
6.2.2 Wear................................................................................21
6.2.3 Shaft seal ........................................................................22
6.2.4 Bearing case ...................................................................23
7 Repair ................................................................................................25
7.1 Pump unit .................................................................................. 25
7.1.1 Disassembly....................................................................25
7.1.2 Re-assembly ...................................................................27
7.2 Mechanical seal ........................................................................ 28
7.2.1 General directions ...........................................................28
7.2.2 Disassembly mechanical seal .........................................29
7.2.3 Re-assembly ...................................................................31
8 Disposal.............................................................................................33
Technical data............................................................................................ 34
Transportation data.................................................................................... 35
Maintenance and lubrication ...................................................................... 36
Troubleshooting ......................................................................................... 37
Tightening torques ..................................................................................... 38
Index .......................................................................................................... 39

BP45-1100 V
 List of figures

List of figures
Figure 1 Turning the wear plates ......................................................21
Figure 2 Oil piping mechanical seal ..................................................22
Figure 3 Oil piping bearing case .......................................................23
Figure 4 Section mechanical seal .....................................................28
Figure 5 Turning the grease connection ...........................................29
Figure 6 Assembly clamps mechanical seal .....................................30
Figure 7 Removing mechanical seal from shaft ................................31
Figure 8 Three-parted ring ................................................................32

BP45-1100 VI
 List of tables

List of tables
Table 1 Technical data BP45-1100 ................................................. 34
Table 2 Transportation data............................................................. 35
Table 3 Maintenance schedule........................................................ 36
Table 4 Recommended oils ............................................................. 36
Table 5 Troubleshooting mechanical system .................................. 37
Table 6 Tightening torques .............................................................. 38

BP45-1100 VII
 List of additional documents

List of additional documents

1. Pumpcurve
2. Drawings
• Arrangement dredgepump BP45-1100-00.015
• Dimension sketch BP45-1100.05.001
3. Subsupplier manuals
• Bloksma cooler
• IFM temperature sensor
• Woerner pump
4. Product information recommended oils
• Klüberoil GEM1-68
• Mobil DTE-16M

BP45-1100 VIII
 Conditions of liability

Conditions of liability
• Damen Dredging Equipment takes no responsibility if the installation is
used in a way other than that described in the user manual.
• The manufacturer has the right to alter its equipment with no liability to
make the same changes to equipment that already has been delivered.
• The manufacturer cannot be held liable if the client makes unauthorised
changes to the installation.
• Use only original Damen Dredging Equipment parts for safe and efficient
functioning of the system. The correct tools must be used. Warranty
expires if non-genuine parts are used.
• Local rules regarding accident prevention, safety, traffic and transport
must be followed.
• Only properly trained personnel who are aware of the potential danger
are permitted to operate or maintenance this installation.
• Damen Dredging Equipment has made this manual with the utmost care.
Nevertheless Damen Dredging Equipment cannot be held liable for
possible errors in this user manual.

e Failure to adhere to the instructions in this manual will be

considered negligence. Damen Dredging Equipment will not be
liable for any consequence resulting from negligence; the user
will bear full responsibility.

BP45-1100 IX
 Warranty

Warranty
The CONTRACTOR and/or seller warrants the satisfactory performance of
work contracted in respect of construction, material and treatment, which
implies that:
• It shall deliver free of charge new parts for all those parts that during a
term of twelve (12) months after operation date become defective due to
inadequate construction and/or defective materials.
• A maximum of eighteen (18) months after delivery date shall apply for the
period of time referred to in the first paragraph. Delivery date shall be
deemed to be the date stated on the "consignment note" and/or "bill of
lading".
• Defects that have arisen due to normal wear, incompetent treatment or
operation, incompetent or incorrect maintenance, insufficient lubrication
and lubrication with defective material are not covered by the warranty.
• Defects that have arisen after adaptations and/or repairs carried by and/
or on behalf of the CUSTOMER and/or the purchaser, or by third parties,
are not covered by the warranty.
• No warranty is given for parts, machinery, instruments, equipment,
installations or assembly that have not been installed by the
CONTRACTOR and/or the seller, or for those parts, machinery,
instruments, equipment, installations or assembly that have been
installed but not delivered by it.
• The warranty only applies if the CUSTOMER and/or purchaser have
complied with all its obligations financial or otherwise to the
CONTRACTOR and/or seller.
• In no event does the warranty cover more than the delivery and
installation of new parts. In no event the CONTRACTOR and/or the seller
are liable for any other damage incurred by the CUSTOMER and/or the
purchaser.
• Contrary to the aforementioned machinery, motors, instruments, the
warranty provisions laid down by the manufacturer shall cover equipment
or articles delivered with a manufacturer's warranty. If the manufacturer
does not provide warranty or provides a shorter warranty period then the
CONTRACTOR and/or the seller shall likewise provide no warranty or a
shorter warranty period.
• Unless otherwise agreed, no warranty is given for machinery motors
instruments equipment or articles delivered that were not new at the time
of delivery.
• A survey report, drawn up by an independent international claims
assessor or assessment agency, is required for warranty claims that
exceed a total amount of € 3,500.00.
• The CUSTOMER and/or purchaser shall submit in writing any warranty
claim to the CONTRACTOR and/or the seller within seven (7) days,
failing which the claim will lapse.

BP45-1100 X
 Warranty

• Disassembly and/or installation costs of those parts that are covered by

the warranty shall only be borne by the CONTRACTOR and/or seller if its
own workforce can carry this out during the normal working hours within
the Netherlands borders. Additional costs such as crane assistance,
internal transport assistance from an external workforce etc. shall not be
borne by the CONTRACTOR and/or seller. If installation and/or
disassembly must be carried out outside the Netherlands borders, all
related costs shall be borne by the CUSTOMER.

BP45-1100 XI
 Introduction

1 Introduction
This manual describes the basic configuration of the dredge pump BP45-1100
supplied with a mechanical seal and as if it were used onboard of a dredger.

This highly efficient dredge pump has wear plates, an impeller and a pump
shell of 30Mn5 cast iron and wear plates of NiHard4 cast iron, however the
wear resistant materials can vary to meet the local dredging circumstances.

1.1 APPLICATIONS
• Sand and gravel production on board of hoppers and cutter suction
dredgers.
• Used in boosterstations.

1.2 ADVANTAGES
• Heavy duty robust design.
• Continuous operation design.

BP45-1100 12
 Safety

2 Safety
Most injuries that occur during operation and maintenance of equipment are
due to failure to observe basic safety rules and take adequate precautions.
Personnel must be trained to recognise and avoid potential hazards and to
perform their work using appropriate methods and tools.
The dredge pump must be operated only by personnel that is familiar with and
fully understands the information given in the user manual.

e Always read the user's manual entirely and follow the

instructions before starting-up the engine for the first time!

e Before installing using or maintaining any separate machine or

parts of the overall installation, first read the specific
instructions for these parts. These instructions can be found in
the appendix supplied with the user manual.

• The dredge pump may only be used to transfer water suspended

mixtures of mud, sand and gravel or similar solids.
• The dredge pump must never be run without being connected to a
suitable discharge hose or pipe.
• The pump may be used only when it is mounted on a rigid suction frame.
• Retighten all bolts after the pump has been used for the first time. In
particular pay attention to the mounting bolts of the wear plates.
• Ensure sufficient filling of the dredge pump before starting-up as the
pump is not self-priming. It is advised to position the pump’s centreline at
or below the waterline.
• The pump and its subassemblies and components should only be lifted
using certified lifting equipment, which is in good condition.
• Before opening the pump or the inspection piece lift the suction mouth
above water level and close, if installed, the hull valve.
• Check the condition of the wear plates regularly as well as the level of the
oil in bearing case. (Refer to Table 4 on page 29).
• The acronims between brackets and in the illustrations refer to the items
on drawing BP45-1100-00.015.
• Safety helmets, boots and goggles must be worn when operating or
performing maintenance on the pump.
• Observe national and local safety regulations relating to the pump’
operation and environment as well as any specific instruction given in this
manual.

BP45-1100 13
 Description

3 Description
3.1 CONSTRUCTION
The dredge pump is a sturdy dredging tool designed for operating onboard
dredgers and as the pump of a booster station.
The pump must be mounted to a rigid frame to withstand the forces caused by
start-up.
The basic dredge pump can be equipped with an inspection piece for easy
access to the impeller when obstructions block the proper functioning of the
pump.
The high production capacity allows a discharge distance according to the
production graphs listed in additional documents 1.
The changeable wear parts made of high resistant material and a large
spherical passage make the dredge pump a tool that can be utilised at many
production sites, even in areas with contaminated soil.
The pumps are available in different sizes to suit the client’s requirements.
The pump motor is to be driven using a tooth and an elastic coupling. Also
driving by belt from the diesel engine shaft or E-motor driven applications are
within our scope.

3.2 WORKING PRINCIPLE

The dredge pump is of the non-self priming, single-stage centrifugal type.
The pump can only be used to transfer water-suspended mixtures of mud,
sand and gravel or similar solids.
It will not function properly at start-up above the water line, unless the pressure
at suction side is positive, e.g. priming with a vacuum pump or gland pump if
present. To ensure sufficient filling of the dredge pump make sure to continue
priming till water will spill from the suction mouth of the pump.

BP45-1100 14
 Installation

4 Installation
4.1 POST-DELIVERY INSPECTION
1. Examine the exterior of the dredge pump unit for loose fasteners, oil
leaks and damage.
2. Inspect castings and weld areas for cracks and dents. DDE must be
contacted immediately if any such damage is discovered. The pump must
not then be operated until DDE have given their approval.
3. Check that there are no rags or packaging materials obstructing the
pump’s inlet or outlet.
4. Check that the flange’s faces of the discharge and suction pipe are in
good condition.
5. Most pumps are delivered from the factory already filled with the
necessary lubricants. As a precaution the presence, condition and levels
of these fluids must be checked before attempting to operate the pump.
- Filling and checking the fluid level in the bearing case are described
in section 6.2.4.
6. The correction of most of the foregoing potential faults must be well within
the capabilities of a competent service mechanic. The customer is
encouraged to contact DDE at the first instance if he feels unsure of how
any such tasks must be undertaken.

4.2 DREDGE PUMP UNIT

The mounting frame or bed used to support the pump must be sufficiently
strong to withstand the static/dynamic loads generated and sufficiently rigid to
maintain correct alignment between the pump and the motor or gearbox driving
it. Refer to Dwg BP45-1100-00.015.
Typically the pump is mounted to a fabricated steel bed. The bed is deliberately
built about 25 mm lower than would be necessary to achieve the correct
vertical shaft alignment between the pump and its driver. This "gap" is filled at
installation time with a steel plate, which has been machined to the necessary
thickness. Alternatively an epoxy-based machinery-bedding compound can be
cast between the pump and bed.
The top of the foundation and the bottom of the pump support must be cleaned
before the dredge pump is installed.
The typical procedure for installing the pump on a steel mounting bed is as
follows:
1. Inspect the mating surfaces of the pump and mounting bed and carefully
remove any projections, weld spatter etc.
2. Lower the pump onto the bed and align it in the horizontal plane with the
motor/gearbox drive shaft. Alignment tolerances are to be found in the
literature supplied with the coupling for the pump to motor/gearbox
connection.
3. Mark the centres of the holes, for the pump hold down bolts, in the top of
the mounting bed and record the vertical distance between the
centrelines of pump and motor/gearbox shafts.
BP45-1100 15
 Installation

4. Lift the pump clear of the bed before drilling clearance holes in it for the
pump hold down bolts. If a steel gap plate is to be used then steps 5 to 7
follow next. If an epoxy-bedding compound is to be used then steps 8 to
11 are to be followed instead.
5. Machine the steel gap plate to the correct size / thickness and drill
clearance holes for the hold down bolts.
6. Lay the finished plate on the mounting bed followed by the pump. Insert
the hold down bolts and tighten them lightly.
7. Realign the pump with the motor/gearbox before fully tightening the bolts
and installing the coupling.
8. Lightly oil the underside of the pump's mounting face before lowering it
onto the bed. Use shims or jacking screws to hold the pump at
approximately the correct height above the bed. Insert the hold down
bolts (lightly coated with oil) and lightly tighten them.
9. Re-align the pump with the motor/gearbox. Vertical alignment is achieved
by adding/removing shims or adjusting the jacking screws as necessary.
10. Build a watertight dam around the bottom of the pump and pour in the
epoxy-bedding compound.
11. Once the bedding compound has completely set, fully tighten the hold
down bolts and install the coupling.

4.3 TRANSPORTATION AND STORAGE

4.3.1 Transportation
The dredge pump must be transported and stored in a horizontal position with
sufficient supports and/or chocks to prevent it from moving.
Transportation data are given in Table 2 on page 28.

4.3.2 Storage
When the pump is to be taken out of service for more than two (2) months the
following precautions should be taken as a minimum:
• Flush any remaining solids out of the dredge pump and its suction /
discharge pipes.
• Remove all water from the pump’ impeller housing.
• Drain the bearing case and refill with a suitable preservative oil.

e Make sure that no traces of water remain in the bearing case,

especially when freezing temperatures are common in the area
the pump is stored.

• When storing the impeller and nut, the nut has to be grease at both the
outside surface, that will be in contact with the impeller, and the screw
thread. This will prevent corrosion at the interface of the impeller and nut.

e When the impeller is stored please store the impeller and it’s
nut together. Do not separate them or exchange with other
specimens.

BP45-1100 16
 Installation

When the pump is taken into operation after a prolonged storage period the
bearing case has to be drained and filled with the appropiate oil refer to Table 5
on page 29.

e Any routine service tasks that were due before the unit was put
into storage should also be performed.

4.4 TESTS AND ADJUSTMENTS

The dredge pump is thoroughly tested at the manufacturers test site. Any
required adjustments have been made at the factory.

BP45-1100 17
 Operation

5 Operation
The operator of the dredge pump must be thoroughly familiar with all the
features and operating instructions before putting the pump into operation.

5.1 START-UP
Before starting-up the dredge pump perform the daily checks and maintenance
procedures listed in section 6.2 page 21.
1. Start-up the diesel engine and allow it to warm up for a few minutes at
idle speed. Refer to the operating manual of the diesel engine.
2. Observe the engine’s gauges and indicators and ensure that they are all
functioning correctly and displaying the required reading. (Refer to the
engine’s operating manual for descriptions of each gauge's purpose and
how to interpret the values it displays).
3.

e The gland water pump must be started before the dredge pump
will be engaged.

e Regularly check that the water pressure of the glant water

system exceeds the drege pump’s discharge pressure by 1 bar.

4.

e The dredge pump should only be started when sufficiently filled

with water. As the pump is not self priming, an insufficiently
filled pump shell could cause serious damage.

5. Ensure that the pump is filled with water and the suction mouth is below
the waterline. Refer to section 3.2 on page 14.
6. Ensure that discharge of the pump is securely anchored at the desired
location for depositing the pumped material.
7. Adjust the speed of the diesel engine powering the dredge pump to a low
setting then engage the clutch to start the pump turning.
8. Once the dredge pump's discharge pressure has reached the required
level its speed may be gradually increased to the normal operation level.

5.2 SHUTDOWN
At the end of the dredging session the dredge should be shutdown as follows:
1. Raise the suction mouth above the river-bed or ocean-floor and allow the
clear water there to flush the remaining solids out of the dredge pump
and its discharge line up to the deposition site. This process may take
several minutes.
2. Gradually reduce the speed of the dredge pump's diesel engine to idle
speed.
3. Disengage the drive to the dredge pump.
4. Have the engine ran at idle speed for the recommended time before
switching it off. Refer to the operation manual of the diesel engine.

BP45-1100 18
 Operation

5. Raise the suction mouth above the water level.

6. Close any valve in the suction and discharge pipes of the dredge pump
and the gland water supply line.

5.3 POINTS TO WATCH WHEN OPERATING THE DREDGE PUMP

5.3.1 Discharge pipe control

Always ensure that sufficient water is present in the dredge pump's discharge
line to prevent clogging. An obstruction in the pipeline will often be indicated by
an abrupt increase in the pressure gauge reading for the pump discharge and a
similar drop in the vacuum reading at its inlet.
Common causes of real and apparent discharge pipeline obstruction are the
following:
• Large rocks or pieces of wood wedged in the pipe
• Severe kink in (floating) discharge hose
• Excessive length of discharge pipeline
• A valve at the discharge end of the pipeline may have been inadvertently
closed or partially closed

5.3.2 Suction pipe control

A solid obstruction in the dredge's suction mouth will tend to cause the vacuum
at the dredge pump's inlet to increase and its discharge pressure to decrease.
An obstruction which becomes lodged in the vanes of the dredge pump's
impeller will tend to upset the impeller's balance resulting in increased vibration
levels and large, rapid fluctuations in the vacuum and pressure values
measured in the pumps suction and discharge lines. Continuing to operate the
pump under these conditions will result in damage to its seals and bearings.
Prior to shutting down the dredge pump to remove an obstruction, the suction
mouth should be raised above the material being dredged and the pump
allowed to draw in clear water to flush the smaller solids out of the system.
We advise a short and easily removable section of suction pipe just prior to the
dredge pump to be installed. The section contains an inspection plate which
can be quickly unbolted to enable visual inspection of the pump’s impeller and
to remove small obstructions.

BP45-1100 19
 Maintenance

6 Maintenance
6.1 GENERAL DIRECTIONS

O Read this chapter carefully and ensure to fully understand it

before performing maintenance and/or repair on this product.

O The power supply to the dredge pump and its ancillaries must
be locked in the off position before any inspection maintenance
or repair work is attempted.

The dredge pump operator and maintenance personnel are strongly advised to
adopt a regular routine of inspection and preventive maintenance on the unit. It
is often found that a "don't repair it until it breaks down" philosophy results in
lower and less predictable availability of the machine along with higher repair
costs.
Always disengage the pump’s drive before performing any inspection,
maintenance or repair to the unit or its components.
The maintenance schedule in section 6.2.1 on page 21 lists the minimum
maintenance requirements for the dredge pump. Local operating conditions
may require changes to the content and frequency of some maintenance tasks.
Item numbers given in the sections that follow refer to the general arrangement
drawing for the BP45-1100 dredge pump. (Additional documents 2.) Extracts
from the drawing are included in this manual to aid the reader's understanding.
Section 7 concerns the dismantling and reassembly of the dredge pump in
order to repair or replace parts. They are written assuming that the pump to be
repaired is installed in a dredge.

e Be aware of the following safety precautions.

• Most accidents involving production operation, maintenance and repair

are caused by failure observing the basic safety rules or taking
precautions.
• Accidents often can be avoided by recognizing potentially hazardous
situations.
• People must be alert to possible hazards and need to have the necessary
training skills and tools to perform their functions properly
• Read this manual before taking this product in operation or have it
maintained.
• NEVER work at the pump while it is in operation. ALWAYS shutdown the
drive and secure the engine from being operated.

BP45-1100 20
 Maintenance

6.2 PERIODICAL MAINTENANCE

6.2.1 Dredge pump unit

The unit must be visually inspected every day before starting operations. Look
in particular for:
• Water and lubricant leaks
• Loose or damaged fasteners
• Worn, cracked or split pipes
• The oil level in the bearing case (BC) (Refer to section 6.2.4)
• The contents of the lubrication tank and fill up if necessary.

e These defects must be repaired immediately.

Regularly check the inside of the pump for wear. (Refer to section 6.2.2)
For periodical maintenance refer to appendices on page 29.

6.2.2 Wear
The wear of pump shell, impeller and wear plates depends on:
• its discharge pressure
• the material being pumped
• the amount of cavitation
Check the internal wear parts weekly when the pump starts work on a new
project. The interval between checks can be evaluated and adjusted,
depending on the new operating conditions.
6.2.2.1 Wear plates
Wear plates tend to wear specifically near the discharge of the pump. When a
suction cover wear plate is worn, it must be repositioned by 120 degrees
around the pump’s shell as shown in Figure 1 (the dark segments represent
areas of severe wear). This way a wear plate can be repositioned 2 times,
before it must be replaced

Figure 1 Turning the wear plates

BP45-1100 21
 Maintenance

When a gulley that is soon expected to become a hole the wear parts have to
repositioned or replaced. We advise to reposition or replace the wear plates
when ¾ of the material is worn-off.
6.2.2.2 Welded repairs
Adding layers of wear-resistant material by welding can repair the worn
surfaces of steel and cast-steel wear-parts. However, Ni-hard 4 castings cannot
be repaired in this manner.
The dredge pump's impeller is carefully balanced at the factory. Do not repair
the impeller by welding. This can cause imbalance, resulting in major damage
to the mechanical seal, the bearings and the impeller shaft. The warranty does
not cover pump damage caused by welded repairs to the impeller.

6.2.3 Shaft seal

A mechanical seal in good condition always allows a small amount of water
leaking. Any water leaking into the lubricating system tends to settle at its base.
This water must be drawn off daily using the oil drain line located at the base of
the piping (Figure 2, DP).
Over time some water will become truly mixed with the oil. Once the oil’s water
content reaches 0,1% by volume, the oil must be changed. Sample of the oil
must be regularly analysed for this and other contamination. These samples
can be drawn using the oil-drain line. When the oil has to be replaced the
header tank must be drained and refilled with fresh oil of the appropriate type.

Figure 2 Oil piping mechanical seal

BP45-1100 22
 Maintenance

The shaft seal must be lubricated continuously with oil. To supply sufficient lub
oil a supply container (4 litres) has been mounted to the dredge pump. Due to
the gravity force the oil will lubricate the shaft at the mechanical seal. Check the
contents and the proper operating of the lubricating oil tank daily.
For lubricating specifications we refer to Table 5 on page 29.

6.2.4 Bearing case

6.2.4.1 Filling and checking oil level
The oil level in the dredge pump’s bearing case must be checked daily. The
procedure is as follows:
1. Clean the areas surrounding the air vent (Figure 3 on page 23 and Figure
3, AV) and oil filler plugs (FP/DS).
2. Remove the air vent plug (AV) for correct measurement.
3. Remove the oil filler plug, which is provided with a dipstick (DS).
4. Check the oil level.
5. At low-level fill up the bearing case with the required oil up to the required
level, refer to Table 5 on page 29.
6.2.4.2 Changing oil
The oil of the bearing case has to be changed after 1200 working hours or each
year, which ever comes first.

Figure 3 Oil piping bearing case

BP45-1100 23
 Maintenance

1. Clean the areas surrounding the air vent (Figure 3 on page 23 and Figure
3, AV) and oil filler plugs (FP/DS).
2. Remove the air vent plug (AV) for correct measurement.
3. Remove the oil filler plug, which is provided with a dipstick (DS).

e Correct reading of the oil level is obtained only when the

dipstick has been screwed in its fitting completely.

4. Check the oil level.

5. Remove the drain plug (DP).
6. Drain the used oil into a suitable receptable.
7. Remount the drain plug.
8. Add extra oil of the correct grade as necessary using the oil filler plug on
top of the bearing case. For recommended oils refer to Table 5 on
page 29.
9. Clean the air vent (AV) and oil filler plugs (FP) before reinstalling them.

BP45-1100 24
 Repair

7 Repair
7.1 PUMP UNIT

7.1.1 Disassembly

O Mind the siphon action of the pump. If the suction mouth is still
under water there is free flow of water between the sea and the
interior of the ship. When the pump is opened now seawater
will enter the engine room with large quantities at high speed.

1. Remove the suction-side cover as follows:

- Disconnect and remove the inspection piece prior to the pump.
- Fasten a hoisting cable to the hoisting eye of the pump cover
suction side (Figure 4, PC) using a shackle and take up any slack.

e Do not drop the pump’s components!

Hardned cast steel can easely break on impact.

- Remove bolts (HB1) at the cover’s periphery to the pump casing

(PC) complete with wearing plate suction side (WP), suction mouth
(SM) and O-ring (OR3) and lift it clear.
• Lay the cover down on a flat surface and choke it to prevent any
unwanted movement.

2. If the wear plate (WP) needs replacement or has to be repositioned,

dismount the wear plate (WP) from the pump cover (PC) by removing the
three bolts (HB), rings (SLW/CR) and O-rings (OR1, OR2).
3. Mount the assembly clamps (AC) to consolidate the mechanical seal
(MS) if this has not been done before, using the provided screwthreads.
(Refer to Figure 6 on page 30).
4. Remove the impeller as follows:

e Check whether the assembly clampshas been mounted to the

mechanical seal before removing the 3-parted ring (3PR). Refer
to section 7.2!

• Remove the bolts (HB, HN) of the 3-parted ring (3PR) to release
the tension of the impeller on the shaft.
- Remove each ring segment by striking the tab beside the bolthole
using a mallet and long drift.

e Do not force a chisel between the mating surfaces of the

adjacent segments in an effort to pry them apart.

• Support the weight of the impeller (Figure 5, I), using a suitable

hoisting tool, which can be provided by DDE. Refer to Table 2 on

BP45-1100 25
 Repair

page 28 for weights and dimensions of the pump parts.

e Do not separate the nut from the impeller.

They are delivered as a set.
Do not mount a used nut in a new impeller.

O When hoisting the impeller horizontaly make sure the nut is at

the upside to prevent it from dropping out.

- Turn the shaft (IS) to remove the impeller (I) and the impeller nut
(IN) from the shaft using the turning device (TD) (Left-handed
thread). Take special care when the impeller is almost disengaged
from the shaft not to damage the thread of the shaft or the impeller
nut.
5. Remove the shaft-side wear plate as follows:

O When the pump shell will also be removed, this can be done
first. However, there is no need to.

- Support the weight of the wear plate (•, WP).

- Remove the bolts (HB) complete with closing ring (CR), spring lock
washer (SLW) and O-rings, (OR, OR1) that connect the shaft-side
wear plate (WP) to the shaft-side cover (PC).
• Remove the shaft-side wear plate using a suitable hoisting tool.

6. Remove the pump shell as follows:

- Support the weight of the pump shell (Figure 7, PS), using a
hoisting sling or a suitable hoisting tool. Refer to Table 2 on
page 28 for weights.
- Remove the mounting bolts, nuts and washers (HB) from the pump
shell (PS).
- Separate the pump shell (PS) from the pump cover (PC) shaft side.
• Inspect the O-ring (OR) and replace if necessary.

BP45-1100 26
 Repair

7.1.2 Re-assembly

1. Check the shaft-side wear plates for wear at the indicated location
(Figure 1). Mount the shaft-side wear plate and pump shell as follows:
- Level the shaft-side wear plate (Figure 6 on page 17, WP) with the
shaft-side cover (PC).
- Check the condition of the O-rings (Figure 6, OR, OR1). Replace if
necessary.
- Insert and tighten the mounting bolts (HB) complete with spring lock
washer (SLW), O-rings (OR2, OR3) and closing ring (CR). Apply a
suitable anti-seize compount (e.g. Copaslip).
- Position the pump shell (Figure 7, PS) against the pump cover
(PC). Be careful not to damage the O-ring.
- Insert and tighten the connection bolts (HB), applying anti-seize
compount (e.g. Copaslip).
2. Mount the 3-parted ring onto the impeller shaft as follows:

e Make sure that the 3-parted ring (3PR) is mounted with play on
the shaft so the impeller can be tightened properly.

- Mount the 3-parted ring (3PR) on the impeller shaft between the
pump’s bearing casing and the shaft bushing.
- Notice that the chamfered side is facing the engine and the
numbered parts are corresponding with each other (1-1, 2-2, 3-3).
Refer to Figure 8 on page 32
- Tighten the bolts (HB, HN) of the 3-parted ring.
3. Mount the hoisting tool to the impeller and mount it onto the shaft

O Be careful not damaging the thread (left-handed thread) of the

impeller nut (IN) or shaft engaging the first few turns.

- Grease shaft and nut with anit-seize compound.

- Carefully mount the impeller complete with nut (I, IN).
• Ensure free rotation of the impeller.
• Remove the assembly clamps (AC) and remount the screw
coulpings (SC).
4. Mount the suction-side’s wear plate and pump cover as follows:
- Inspect and clean the mating faces of the pump cover (Figure 4,
PC), suction mouth (SM) and pump shell (PS). Apply anti-seize
compound.
- Check the condition of the O-rings (OR, OR3) for damage and
replace if necessary.
- Level the suction-side wear plate (WP) with the suction-side cover
(PC).
- Insert and tighten the mounting bolts (HB, CR, SLW) and O-rings
(OR1, OR2).
- Position the suction-side cover (PC), complete with wear plate
(WP) against the pump shell (PS), using a suitable hoisting tool.
- Insert and tighten the mounting bolts (HB, SLW).

BP45-1100 27
 Repair

- Ensure the free rotation of the impeller (I). Any rubbing or binding
must be corrected before proceeding.

e Make sure that the assembly clamps (AC) have been removed.

5. Finaly remount the lubricating lines and the suction and discharge piping.

7.2 MECHANICAL SEAL

7.2.1 General directions

The seal prevents the leackage of water, sand, mud etc.
The seal is fitted as a cartridge assembly comprising a stationary section
(MSS) and a rotating section (MSR) (refer to Figure 4).

Figure 4 Section mechanical seal

O Take careful notice of the directions below.

- The mechanical seal should not be removed from the pump unless
it has suffered damage or its integrity is in question.
- The mechanical seal must only be removed or replaced on the
dredge pump as a complete cartridge using the assembly clamps
(Figure 5, AC) provided to hold the stationary and rotating sections
together. The assembly clamps provided are mounted to the pump
frame. DDE will not accept any warranty claims for mechanical

BP45-1100 28
 Repair

seals, which are submitted for repair having been disassembled or

transported without their assembly clamps in place.
- When re-assembling a dredge pump never fit a used mechanical
seal or one in which the stationary and rotary sections have been
allowed to separate. Always fit a new mechanical seal or one,
which has been reconditioned by DDE.
- The mechanical seal is a delicate assembly, which requires that its
removal from a pump be undertaken with great care. Never employ
hammers or other impact tools to aid removal.
- The manufacturer can refurbish a mechanical seal assembly up to
three times.
- Assemblies returned to the manufacturer for refurbishment should
be packaged carefully to avoid damage in transit.

7.2.2 Disassembly mechanical seal

1. Drain the oil from the lubritating container serving the mechanical seal.
2. Disconnect the lubricating oil lines and turn the grease nipples (SC) 90
degrees towards the shaft.

Figure 5 Turning the grease connection

3. Secure the stationairy and rotating sections of the seal using the
assembly clamps (AC) if this has not been done previously.

BP45-1100 29
 Repair

Figure 6 Assembly clamps mechanical seal

4. Disconnect the bolts of the 3-parted ring (3PR) and remove the ring.
5. Remove the impeller (I). (Refer to section 7.1.1 item 4.).
6. Thoroughly clean the area around the mechanical seal with clean water
(do not use high-pressure cleaning equipment).
7. Remove the bolts (Figure 6, HB) that hold the mechanical seal in place.

BP45-1100 30
 Repair

Figure 7 Removing mechanical seal from shaft

8. Screw four M8 bolts (minimum thread length 45 mm) (JB) (refer to Figure
7) into the tapped holes located around the seal's mounting flange.
Gradually tighten each bolt against the annulus (MSH) behind the
mounting flange to pull the seal out of its housing and off the pump shaft.

7.2.3 Re-assembly

e A new or DDE reconditioned mechanical seal is delivered as a

cartridge held together with three assembly clamps. These
clamps must not be removed until the cartridge has been
installed on the pump.

e It is vital that this work be performed using clean components,

tools, etc.

1. Clean the end of the impeller shaft (IS), the seal housing in the shaft-side
pump cover (PC) and the surrounding area. Check mating surfaces for
damage and correct as necessary.
2. Grease the shaft with anti-seize compound.
3. Mount the 3-parted ring (3PR) on the impeller shaft. Notice that the
chamfered side is facing the engine and the numbered parts are
corresponding with each other (1-1, 2-2, 3-3). Refer to Figure 8.

BP45-1100 31
 Repair

Figure 8 Three-parted ring

4. Tighten the bolts of the three-parted ring (3PR).

5. Check the condition of the seal cartridge's outside O-rings (OR/OR1)
refer to Figure 4 on page 28, and replace if necessary.
6. Insert the mechanical seal, as a complete cartridge, into the housing in
the pump cover against the bushing (B) refer to Figure 4. The bore of the
seal cartridge can be coated with anti-seize compound to aid it slide onto
the pump shaft.
7. Than remount and tighten the mounting bolts (Figure 8 on page 32, HB)
equally in a diagonal sequence.
8. Mount the impeller according to 7.1.2 on page 27.
9. Remove the seal cartridge's assembly clamps (Figure 6, AC).
10. Reconnect the lubricating oil lines.
11. Mount the pump ‘s cover according to 7.1.2 on page 27.

BP45-1100 32
 Disposal

8 Disposal
Damen Dredging Equipment aims at manufacturing environment-friendly
products. To extend the pump’s life the spare parts are for sale during 10 years.
When the pump is written off, it can be converted into scrap.
When a dredge pump or parts of it are dismantled, waste materials should be
separated as follows:
• Tap the oil from the pump drain(s) and submit it as chemical waste to a
local chemical waste collector / depot.
• Plastics should be submitted to a local chemical waste collector / depot.
• Steel (alloys) should be submitted to a local collection depot.
• DDE recommends to submit wear parts (cast steel and cast iron) to our
foundry (address details can be obtained from DDE), due to the higher
scrap value compared to structural steel.
• All other metals (copper and aluminum alloys) should be submitted
separately to a local collection depot.

BP45-1100 33
 Technical data

Technical data

Technical data Dredge Pump

General Manufacturer Damen Dredging

Equipment
Type BP45-1100
Pump dimensions Diameter suction mouth 450 mm
Diameter discharge 400 mm
Spherical passage 200 mm
Number of impeller blades 4
Direction of rotation Clockwise
(seen from suction side looking towards pump)
Wear material Pump house Ni-hard 4
Impeller Bainitic Nodular
Wear plates Ni-hard 4
Suction mouth Ni-hard 4
These materials can be changed on clients request.
Shaft seal Type Mechanical seal
Pump performance Mixture capacity Refer to Addotional
documents 1.
Pump speed (max.) 480 rpm
Shaft lubrication Oil container
Contents 4200 cc
Total oil contents 5700 cc
Table 1 Technical data BP45-1100

BP45-1100 34
 Transportation data

Transportation data

Dimensions and weights

UNIT Lenght Width/ Height Weight

[mm] Diameter [mm] [mm]
[mm]
Complete dredge pump 2025 1095 1625 5500
assembly
Pump shell 927 1095 1625 1440
Pump cover - Ø 1315 253 500
Impeller incl. nut - Ø 1060 487 670
Wearing plate suction side / - Ø 1063 75 185
Suction mouth
Wearing plate shaft side - Ø 1063 75 180
Suction mouth - Ø 780 265 175
All dimensions and weights are approximations
Table 2 Transportation data

BP45-1100 35
 Maintenance and lubrication

Maintenance and lubrication

Maintenance schedule

Task Frequency
Visual inspection of pump exterior Daily
Check for oil & water leaks Daily
Check for loose fasteners Daily
Inspect pump wear parts and drain Weekly initially, then as warranted
the water from the lubricating by operating conditions
system of the mechanical seal
Check oil level in bearing case Daily (see marking on dipstick)
Check the contents of the lubricating Daily
oil container for the lubrication of the
seal
Change oil of bearing case and of After 1,200 operating hours or
the lubricating oil container of the annually, what ever comes first
mechanical seal
Table 4 Maintenance schedule

Recommended oils

Location Approximate Type

quantity
Oil in bearing case 3750 cc Mobil DTE 16M
Seal lubrication 4200 cc Klüberoil GEM1-68
Equivalent oil types may be used.
Never mix different types of oils.
Table 4 Recommended oils

BP45-1100 36

Troubleshooting
Mechanical system
Problem Cause
Bearing case runs 1 Worn bearing.
warm (above 70°C).
2 Oil level in bearing
case too low or too
high.
3 Oil cooler malfuctioning
(if installed)
Mechanical 1 Impeller off balance
vibrations in pump because of obstacle or
damage.
2 Impeller off balance
because of wrong
assembly.
3 Cavitation of pump on
board of dredger.
Lack of production. 1 Worn impeller or worn
wear plates.
Cracked pump shell. 1 Worn pump shell.
Table 5 Troubleshooting mechanical system
BP45-1100
Troubleshooting
Remedy Refer to
Bearing to be replaced
contact DDE,
Top up or lower oil level 6.2.4
in bearing case.
Check flow of cooling
water pump
Check regulating valve
Check if water inlet
strainer is clogged
Remove obstacle from 5.3.2
impeller. In case of
damage, contact DDE.
Disassemble impeller 7.1.1
check for damage and 7.1.2
re-assemble according
to instructions in user
manual.
Do not put the suction
mouth too deep into
soil. Lift the suction
mouth some what.
Remove any 5.3.2 &
obstruction in suction 7.1.1
line or mouth
Disassemble pump and 7.1.1
re-assemble with new 7.1.2
parts.
Disassemble pump and 7.1.1
re-assemble with new 7.1.2
parts.
37
 Tightening torques

Tightening torques

TIGHTENING TORQUE (Nm)

Re usable connection Permanent connection

(75% of max. torque) (90% of max. torque)
MATERIAL
SIZE
BOLT
Material nut Bolted in Material nut Bolted in
>= bolt class struct. steel >= bolt class struct. steel

8.8 8 5,5 9,5 6,5

M6
SS A4 70 5 3,5 6 4
8.8 19 13 23 16
M8
SS A4 70 11 8 14 10
8.8 40 30 45 30
M10
SS A4 70 25 20 30 20
8.8 65 45 75 55
M12
SS A4 70 40 30 45 30
8.8 160 110 195 135
M16
SS A4 70 95 65 115 80
8.8 310 215 370 260
M20
SS A4 70 185 130 220 155
8.8 535 375 640 450
M24
SS A4 70 300 210 360 250
8.8 790 555 945 660
M27
SS A4 70 440 310 525 370
8.8 1050 735 1260 880
M30
SS A4 70 600 420 720 505
8.8 1420 995 1700 1190
M33
SS A4 70 805 565 970 680
8.8 1830 1280 2195 1535
M36
SS A4 70 1045 730 1250 875
8.8 2365 1655 2835 1985
M39
SS A4 70 1350 945 1620 1135
Bolts are lubricated (µk=0,125)

Table 6 Tightening torques

BP45-1100 38
 Index

Index

A Wear ..............................................21
Wear plates ....................................21
Advantages ..........................................12
Welded repairs ................................22
Applications ..........................................12

B R
Bearing case ........................................23 Re-assembly
Changing oil ...................................23 Pump unit .......................................27
Filling and checking oil level .............23 Seal ...............................................31
Recommended oils ...............................36
Repair ..................................................25
C Pump unit .......................................25
Changing oil .........................................23 Re-assembly pump unit ...................27
Construction .........................................14 Seal ...............................................28

D S
Description ...........................................14 Safety ..................................................13
Disassembly Shaft seal .............................................28
Pump unit .......................................25 Shutdown .............................................18
Discharge pipe .....................................19 Start-up ................................................18
Disposal ...............................................33 Storage ................................................16
Suction pipe .........................................19

I
Installation ............................................15
Dredge pump unit ...........................15
Post-delivery inspection ...................15
Test and adjustment ........................17
Transportation and storage ..............16
Introduction ..........................................12
T
Technical data ......................................34
Dredge pump ..................................34
Tests and adjustments ...........................17
Transportation ......................................16
Transportation data ...............................35
Troubleshooting ....................................37

M
Maintenance .........................................20
W
Bearing case ..................................23 Wear
Changing oil ...................................23 Wear plates ....................................21
General directions ...........................20 Welded repairs ................................22
Periodical maintenance ...................21 Working principle ..................................14
Wear plates ....................................21
Welded repairs ...............................22
Maintenance schedule ...........................36

O
Operation .............................................18
Discharge pipe control .....................19
Shutdown .......................................18
Start-up ..........................................18
Suction pipe control .........................19

P
Periodical maintenance .........................21
Pump unit .......................................21
Shaft seal .......................................22

BP45-1100 39