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Cutter Suction Dredger M15

BORAMTEC Bohr & Rammtechnik Berlin GmbHKöpenicker Allee 123-135 // 10318 Berlin / GERMANY

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M 15

Content

General Arrangement Plan ................................................................................................... 3

Cutter Suction Dredger M15 ................................................................................................. 4

General ................................................................................................................................. 5

Shipbuilding ......................................................................................................................... 6

Machinery, Hydraulic, Electric ............................................................................................ 7

Machinery...................................................................................................................... 7

Hydraulicsystem .......................................................................................................... 9

Electricsystem ............................................................................................................ 10

Dredging Equipment .......................................................................................................... 11

Cutter Drive ................................................................................................................. 11

Spud Equipment .......................................................................................................... 12

Plain Suction Equipment ............................................................................................. 13

Dredge Pump System ........................................................................................................ 13

Winch System .................................................................................................................... 14

Dredge Master House ........................................................................................................ 15

Appendix 1: GL Survey ....................................................................................................... 16

Appendix 2: Output of Dredge System ............................................................................... 18


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M 15

General Arrangement Plan


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M 15

Cutter Suction Dredger M15Name M 15 MachineryType Cutter CAT 3516 1176 KWOwner Boramtec GmbH CAT 3508 Power

Suplly + Hydraulic588 KW

Build O & K, Lübeck Atlas Copco QAS 48 48 KWTotal inst. Power 1812 KW

Rebuild 2001Class SBG Cutter 300 KWDimensions Dredge pump 1051 KWLength overall 58,81 mLength Pontoon 41,40 m WinchesBreadth 8,0 / 9,15 aft m Ladder hoisting 15 tMoulded Depth 2,77 m Side 2 x 15 tDraught 2,00 mStructural weight 370 t Measurement

SystemsDredging Depth 12 Cutter(18) m DGPS Position xDredging Depth 16 Suction m Dredge Depth Indic. xDischarge Pipe 600 mmSpudcarriage 4 m Production System xSpuds 16 m


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M 15

GeneralThe M15 has been constructed according to the rules of Germanischer Lloyd , but without acceptance, on the yard Orenstein & Koppel AG, Lübeck, Germany. The rules of german authority SBG are accepted.First owner was the Phillip Holzmann AG, later on owned by Möbius AG in Hamburg.The first concept of construction was to dredge in channels and rivers with hard soil.After several jobs on a number of sites, for example as cutter suction dredger in the Dortmund-Ems-Kanal, the dredger has been reconstructed in the year 2001 to be able to dredge down to -12m. Also reconstruction of some parts of the pontoon was necessary.A complete measuring system is installed for the control of dredging in an economical way.After its last hard jobs in Barcelona, Spain and Poland, the dredger has been dismounted and transported to Hamburg, where it has been reassembled and is laying idle ever since.

M15 production at project Dortmund-Ems-Kanal


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M 15

ShipbuildingThe yard Orenstein & Koppel AG built the M15 as Ship-No. 772 like a mono-pontoon with double hull and without propulsion device. The design and construction of the dredge is according to Germanischer Lloyd with the class name GL + 100 A 5 “I” (Binnenschiff) Bagger, but without survey by GL.The dredger is built also according to the rules of Seeberufsgenossenschaft (SBG).Originally the main dimensions of the pontoon had been L x B x H = 24, 7 x 8, 0 x 2, 35 m and had been divided as follows:

Beam 0 – Beam 15 = spud slide areaBeam 15 – Beam 33 = machinery roomBeam 33 – Beam 44 = dredge pump room

To get more buoyancy for the longer cutter ladder part, in the year 2000 the pontoon has been lengthened at Kölner Schiffswerft for about 10m and two flexifloat pontoons are now at the aft side of the dredger. The pontoon has been reconstructed to the following main dimensions

Length Pontoon = 41, 40 mBreadth Pontoon = 9, 14/ 8, 0 mHeight Pontoon = 2, 35 m

Aft section M15, spudslide area (design O&K)


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M 15

The GAP given in Appendix 1 is showing the details of the dredge in general. All stability criteria according to GL and SBG are strictly confirmed.Above the engine room a container is located to be used as a dayroom and kitchen for the crew and another container to be used as store.Above the deck the dredge master house is located for the best view around.

Machinery, Hydraulic, Electric

MachineryAs mentioned, there are three diesel engines built in to the M15, which are summarized in total to 1812 KW. Only CAT engines are used.This means maximum power supply, reliability and maintenance friendliness.In detail, following engines have been installed:

No. Type Power Application on M15 Remarks1 CAT 3516 1176 KW Dredge Pump Gearbox2 CAT 3508 588 KW Power supply and hydraulic3 Atlas Copco QAS 48 48 KW Supplement for power supply

On October 11th 2012 Germanischer Lloyd did a survey on board of the M15 (see Appendix) All engines are working according to GL rules and have passed a test on 12th of November by Caterpillar.

To use the power of diesel engines in an economical way, there are distribution gear boxes installed on both sides of the engine. Flywheel side for cutter drive and winches, front side for generator and flushing pump.

CAT 3508 power supply and hydraulicCAT 3516 dredge pump drive


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M 15

Motor for dredge pumpe drive

Motor for power supply

All auxiliary systems like

• Cooling water• Lubrication• Fuel• Ballast and drainage system• Heating• Jetwater and firefighting System• Cutter seal flushing• Dredge pump seal flushing

have been checked during test on 12th of November 2012 and passed.


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M 15

HydraulicsystemFollowing operation parts are driven by hydraulic systems:

• Cutter drive• Winches• Spud slide system• Spud hoisting system• Several valves in dredge piping

Mainly the hydraulic parts have been manufactured by Rexroth and were renewed partly during reconstruction in 2010. Cutter drive is of 4 Staffa hydraulic motors B 150. The side winches are driven by Staffa motor B 80-S and the ladder hoisting winch is driven by Rexroth motor A2FM 160/61. Spud slide and spud hoisting rams were manufactured by Hydrodyne. The hydraulic pumps drive is mainly controlled via the distribution box.

Cutter drive by staffa hydraulic motors

Distribution gearbox with hydraulic pumps


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M 15

ElectricsystemCAT 3508 DI-TAU diesel motor is driving at front side the Generator of 62, 5 KVA via a conical gear box for power supply of 380 V 50 Hz. At reconstruction time an additional generator set has been installed with power supply of 45 KVA, mainly for the measuring system.

During test phase on November 12th 2012, all electrical systems have been checked and no main parts were defect, but some had to be overhauled partly.Switch board and desks in the dredge master house were checked and the measuring system had to be partly renewed.

Generator for power supply 62,5 kVA Generator set QSA 48

Switchboard in engine room


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M 15

Dredging Equipment

Cutter DriveThe cutter drive has been constructed for a dredging depth of up to -12m and is, with its length of 9,2m, 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 300 KW could assembled to an another 5 m elongation part and with a new total length of 23, 4 m it will possible to reach a dredging depth of about – 18 m. Revolutions of cutter are 23 Rpm. The cutter head is a 6 - blade crown head with a diameter of about 2400 mm and with a teeth system of Type 34 D 95.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 lower part

Cutter 2400 with dredge teeth


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M 15

Spud EquipmentDuring 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 600 mm and a length of 14 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 slide. Working spud has the same dimensions as the holding spud. Spud slide has a stroke of about 4, 0 m, means three times of the height of the cutter head or just say three cuts. With a ram stroke of 2, 1 m and by using a loose pulley, the spud can be hoisted of 4, 2 m at one strokeBoth spuds are to be let down on deck during transport.

Holding spud with hydaulic hoisting systemSpud slide withe bearing

Spud system let down on deck M15


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M 15

Plain Suction EquipmentWhen dismounted the lower cutter piece the flange of the 5 m connection piece for connection of the suction pipe on the main ladder is given. Extra buoyancy parts for the suction pipe are to be constructed. The plain suction pipe is now located at the Möbius Yard in Eversween. Its length is of 11, 4 m and is equipped with jetwater pipe. The jetwater will be transported to one nozzle closed to the suction mouth and is loosening the soil to be dredged.In addition a jetwater pump would be necessary .This pump could be driven by hydraulic, due to the absence of the cutter drive. With a capacity of about 1000 m³/h and a head of about 6 bar the right dimensions are given.

Dredge Pump System On board dredger M 15 there is one dredge pump type Sürken 500/1400. This pump is driven by a CAT 3516 DI-TAU diesel motor via elastic coupling and gear box. The mixture capacity is about 5400 m³/h at a head of about 58 m WS.Suction and delivery pipe is of 600 mm diameter. Hydraulically driven valves are installed at suction and at delivery side for economically dredging.The output of the dredge system of M 15 is shown on Appendix 2. For example the output in soil will be about 1650 m³/h discharging on a pipe length of about 400 m.

Dredge pump in pump room


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M 15

Winch SystemOn dredge M 15 there are following winches to be installed:

• Ladder hoisting winch Type HW 150, pull of 15 t, hydraulic driven• 2 Side winches of 15 t at 24 m/min, hydraulically driven

Side winches Ladder hoisting winch

Densitiy transmitter has been removed


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M 15

Dredge Master HouseFor 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 DGPS- 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 15 had to show a so called “Umgangsgenehmigung” for this nuclear device. Only then the dredge can be used in an economical way.

Dredge master house

Desk in dredge master house


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M 15

Appendix 1: GL Survey


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M 15


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M 15

M 1

5 m

it Inboard

-Pum

pe

1,0

0

1,1

0

1,2

0

1,3

0

1,4

0

1,5

0

1,6

0

0100

200

300

400

500

600

700

800

900

1.0

00

dis

charg

e lenght [m

]

Cv in [t/m³]

M 1

5 m

it Inboard

-Pum

pe

Avg

. V

olu

me

co

nce

ntr

atio

n in

[t/m

³]

M 1

5 m

it Inboard

-Pum

pe

0

500

1.0

00

1.5

00

2.0

00

2.5

00

3.0

00

3.5

00

0100

200

300

400

500

600

700

800

900

1.0

00

dis

charg

e length

[m

]

output in

[m³/h]

M 1

5 m

it Inboard

-Pum

pe

pu

mp

ou

tpu

t in

m³

of so

lids p

er

effe

ctive

pu

mp

ing

ho

ur

Cu

tte

r S

uctio

n D

red

ge

r M

15

dre

dg

ing

de

pth

: 1

0 m

ge

od

ätic h

ea

d: 3

m

dis

ch

arg

e p

ipe

line

dia

me

ter

60

0 m

m

ma

teri

al: m

ed

ium

to

co

ars

e s

an

d

acco

rdin

g to

atta

ch

ed

gra

in s

ize

dis

trib

utio

n c

urv

e

Dis

charg

e length

: 400 m

Pum

p O

utp

ut of solid

s: 1 6

51 m

³/hour

Dis

charg

e o

f m

ixtu

re: 5 3

42 m

³/h

060905_F

ests

tofftr

ansport

_M

15.x

ls, Leis

tungskurv

e-1

Lott, 05.0

9.2

006, 1 v

on 1

Appendix 2: Output of Dredge System

Outp

ut D

redg

er M

15:

Mix

ture

: ca.

540

0m³/

h So

il: c

a. 1

650m

³/h

Pipe

leng

th: c

a. 4

00m

cutter suction dredger m15 - · pdf fileboramtec bohr & rammtechnik berlin gmbh...

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