“backacter 1100” world’s strongest · pdf fileyard “de donge”...

“BACKACTER 1100”

World’s strongest dredge

“Donge Flushing Yard”, Portugalweg 3, 4455 TZ Nieuwdorp, The Netherlands, Tel. +31.113.613100, Email; [email protected], www.shipyarddedonge.nl

Changes without notice, reference to all pages, September 2015 Pages 2 of 10

Introduction

Yard “De Donge” designed and build the strongest type of dredger; the Backacter 1100. The

first very large dedicated marine dipperdredger excavator in the world and the biggest of the

BA series.

Why did we do this:

• The “Classic” approach of an (adapted land) excavator on a dipperdredger had too

many compromises.

• Higher lifting and penetration forces where demanded.

• Functional desire to put the engines in the hull, cooling, no fuel stop, reduced oil

spills, etc.

• Free choice of dimensions and components.

• Stronger dredging equipment.

• Improved design with regard to maritime environment.

General Features Gravity filling of the H-pumps.

A top-class marine dredger with all drive unit power packs in spaces under deck.

Big buckets at a deep dredging depth with highest penetration forces.

No fuel stops required anymore, less fuel consumption than a “classic” excavator.

High and extended dumping reach, unloading in even high barges is always possible.

Low turbidity dredging machine.

Shock-absorbing elastic foundation, integrated in the dredger’s deck.

All spud and spudcarrier operations from the Backacter’s cabin.

One hydraulic powerpack system for the Backacter, thrusters and spudsystem.

Water cooled diesels and water cooled hydraulic system.

For working in ambient temperatures till -25OC.

No “banana” shaped boom, but an almost straight one.



Technical Highlights

PONTOON:

Water-cooled diesels, hydraulic pump sets under deck in a well maintainable spacious

environment.

Easy to observe / check / maintain slewing motors.

Marine electric system.

Illumination for 24 hours working.

Air-conditioning and heating in the cabin.

Stainless steel hydraulic lines on the stick and boom (option).

All bearings of the dredging equipment centrally greased, via stainless steel lines.

By-pass float mode for the dredging equipment during spudcarrier moving.

Bucket cylinder rods are protected by sliding steel structure.

Triple greasing system.

Spacious cabin for dredging and spud operation.

Dredging instrumentation fitted in the cabin.



General Characteristics of the dredge pontoon

Below the main characteristics are given for the BA1100 mounted on a S-type pontoon.

BA 1100 mounted on flexible pedestal.

“IACS” classification, Deep Sea, unrestricted towage (high bow).

Capable to dredge in max. 2.5-m wave height.

Dimensions: 65.00 x 20.00 x 4.30 M.

Spud length: 34 m. basic length (or longer).

Stabilising spuds:1800 x 1800-mm, square built of special steel.

Tilting spuds together with their spudcasing and spudcarrier, through vertically mounted

hydraulic cylinders.

10-m. stroke spud carrier.

Dredging instrumentation with integrated automatic draft levelling

Auxiliary engine room at Stb. under high bow deck

Accommodation

Backacter’s diesels at aft with water-cooling and noise friendly

Auxiliary crane near “backacter”. DSF600 crane, 60 tons capacity at 19 M. depth.

Painting system (with impressed current system for corrosion protection).

Options:

- Self-propelled: assisted power

- Special fendersystem

- Additional auxiliary crane,

type DSF 600 with 60 tons cap.

See picture.

Note: The “Backacter 1100” can be mounted on a dipperbarge as well.

Such dredge has abundant deckspace for the loading of whatever materials.

Even combinations with heavy lifting cranes on deck are possible.



Dredging Equipment

The BA1100 can be executed with the

following boom – stick combinations:

First equipment:

Boom : 18.00 metres.

Stick : 6.50 metres.

Bucket : 25.00 m³ SAE

(15.00 m3 SAE rockbucket).

Max. working depth : 18.00 metres.

Penetration capacity on max depth : approx.185 tons (approx. 205 tons

with 15m3 rockbucket)

Second equipment:



Bucket : 20.00-m³ SAE (15.00 m3 SAE

rockbucket)


Penetration capacity on max depth : 150 tons approx.

(approx. 160 tons with 15.00 m3

bucket)

Third equipment:



Bucket : 20.00-m³ SAE


Penetration capacity on max depth : approx. 150 tons (restricted due to

fatique)

Fourth equipment



Bucket : 15.00 m³ SAE.


On max. depth, 27.00 M : approx. 110 tons (fully stretched).

Penetration capacity on max depth : approx. 150 tons (till -24 metres).

Fifth equipment



Bucket : 7.00-m³ SAE


Penetration capacity at max depth : approx. 80 tons



Penetration Diagram of 1st / shortest configuration



Estimated Standard Production

The Estimated standard production calculation for a type 1100 “Donge Backacter”:

At 20 meters depth with a 20-m³ SAE approx 810 m³/hr

At 17 meters depth with a 25-m³ SAE approx 1012 m³/hr

The above calculation is done with the following assumptions:

- Filling degree 90 %

- 45 min. effective production per hour

Variables are e.g. : when dredging layer thickness is limited

: resistance of bottom

: barge availability

: environmental (current, waves, etc.)

: operator, capability / experience, etc.

: profile dredging

- BA1100 dredging 850 m3 per hour in stiff heavy clay with a 20 m3 SAE bucket -



Technical Characteristics BA1100 Installed diesel power : 2 x 1730 kW (“Cummins”, type QSK60 DM)

Max. oil flow per minute : 11000 l/min

Estimated weight of “Backacter: 510 tons*

Hydraulic boom cylinders : 580-mm / 380-mm

Stick cylinders : 400-mm / 280-mm

Bucket cylinders : 360-mm / 240 mm

Forged connection eyes at rods will be applied (mono and stick)

All cylinders have hydraulic “damping”

Large operation cabin with build in dredging instrumentation

Automatic greasing on slewing ring and on the dredging equipment, except bucket

connections through 3 separate systems

Boom and stick can be switched in H-bypass (floating position)

Diameter slewing ring : 5200-mm (triple roller)

Slewing gears : 5

Slewing teeth height : 300 mm

Like all “Backacters”, the main hydraulic tank is non-pressurized, thus enhancing H-

pump and life-time and other components life-time (e.g. eliminating air bubbles)

Water cooled hydraulic system through closed loop, fresh water circuits and bun coolers

* weight is excluding powerpack, fuel and hydraulic oil tank, there is no counterweight, etc.



Hydraulic Installation

Specification of the main features of the Hydraulic installation of the “Backacter 1100”.

Main pumps: 8 double variable displacement, axial piston pumps (make : ‘’Rexroth’’)

Pressure : 320 bar

Capacity each : 1440 l/min

Total capacity : 11000 l/min

Reservoir capacity: 23000 litres.

Filtering: Full flow return line filtering at 10 mμ

Full flow leak oil filtering at 3 mμ

Full flow filters at 200 mμ in each pump discharge line

By-pass filtering at 1 mμ

Cooling: Plate type heat exchanger for sea water at 35°C

Swivel: Large capacity swivel with 8 pressure paths 1440 l/min at 320 bar

1 return line path 19000 l/min at 25 bar

1 through hole Ø63mm for e-cabling

Piping: Above deck: executed in high strength stainless steel or duplex

Below deck: executed in in carbon steel S355

Controls: Proportional electronic control of all valves and pump outputs

Alarms: Continuous monitoring of all filters, gearbox temperatures,

oil temperatures and levels, operating pressures and oil contamination

Notes:

- All pumps mounted on the gearbox behind the 2 x 1730 kW main diesels.

- The gearbox on which the H-pumps are fitted, is water-cooled, as well as the main

system.

- The hydraulic system is non-air pressurized, thus enhancing life-time of pumps.

- The H-oil reservoir is fitted above deck level, the powerpack is mounted under deck.



Some experiences from practice

With its huge penetration forces of about 200 tons, which is concentrated on a few cm2 of its bucketteeth, all sedimentary rock types can be dredged. The chance that the bucket is full is highest due to the power of this extreme machine, being world’s strongest dredge. The BA1100 is designed from tip to toe for one purpose only; dredging in a marine environment and is thus no adapted mining excavator.

Some dredging production data noted on a project dredging soft soil: - After 23 cycles, a 900 m3 splitbarge was filled. - Whatever heap there is in the 25 m3 SAE bucket, the BA1100 lifts it out. - A 600 m3 barge appeared too small, it was filled in 12 movements (12 min.), and loading had to be done with care, in order to protect the barge.

“backacter 1100” world’s strongest · pdf fileyard “de donge”...

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