1. Introduction:
The production of cutter suction dredger greatly affects the profitability of the dredging project and ultimately the profitability of the company. As cutter suction dredgers are expensive to operate, a slight increase in production yields a decent profit boost
However, we found that in many cases, the cutter suction dredger did not begin to function until it reached its full capacity. This means more output can be obtained at the same cost.
The reason why cutter suction dredgers are underused is usually due to a lack of knowledge about the operation of the operator combined with a fear of trying something unusual. If operators are unaware of the possibilities and methods of increasing production, there is almost certainly room for improvement.
In this article, we’re going to change that. We give you some simple ways to increase your production. These methods can be executed without significant modification costs, and most of them can be executed from the beginning. These methods are not entirely new, they have been around for a long time.
2. 6 ways to Improve Cutter Suction Dredge Production:
2.1 Locate bottlenecks in the system and identify remaining capacity
If you can identify the bottlenecks that are holding you back from dredging, you can increase your productivity. In the dredging process, there is always one link that is the slowest, and as the dredging progresses, this link may change. These bottlenecks continually slow down dredging. Identifying these bottlenecks will lead to significant performance improvements.
2.2 Use the control system
Through the use of automation, operators can greatly increase productivity and improve the quality of life of workers. Unlike human operators, the control system is not fatigued by physical exertion. Each dredging operation is carried out with machine-like precision for hours on end. Using a control system helps ensure that production targets are met every hour of the day and that the desired level of dredging is achieved.
2.3 Change the cutter teeth regularly
Every operator knows that after a while teeth need to be replaced. Teeth wear down due to contact with soil. If not replaced the adapters and cutter head will start to wear out, which is a more expensive repair.
But when is the best time to replace the cutter teeth? The answer has two options, the first is when they are completely worn out. This means the cutter teeth are worn down to the point where the adapter is almost exposed. Remember, the cutter teeth don’t just cut, they also protect the adapter and cutter head, so before replacing the cutter tooth, it is worn until the adapter.
Therefore, you need to replace the cutter teeth before they wear out completely to keep them sharp. A sign of when to do this is when you see a drop in production and/or swing speed. Replacing teeth obviously requires downtime, so you have to find a balance between replacing and continuing, specific to your project.
2.4 Regular Planned Maintenance
For us, regular means once a week. So there is a planned 12-hour maintenance every week, called a maintenance day. Having so much regularly scheduled maintenance may seem time consuming at first glance, but it will save a lot of money and time in the long run.
The best thing to do is to plan the maintenance period so that you can be prepared for it. Spare parts can be stocked, suppliers can be scheduled for the same day, bunker ships can be scheduled, and so on. This allows repairs to be performed very efficiently. It also prevents corresponding damage.
Consequential damage is damage that occurs due to another fault not repaired in time. A hydraulic oil system is a good example. If a gear inside the transmission fails, metal fragments can enter the hydraulic system. So first the gears need to be repaired and the oil needs to be refreshed. Metal fragments can damage other gears in transmissions, oil filters, oil pumps, hydraulic cylinders, etc. if not done quickly. All damage to other equipment that is not directly related to the first damage is called secondary damage. So the sooner it is repaired the more damage can be prevented. As you can imagine, repairing a transmission is much more expensive than repairing just one gear. And it takes a lot more time.
2.5 Reduce the speed of pump
This may be one of the most controversial methods of increasing production. The idea that high pump speeds lead to high output is very stubborn. It’s also very counterintuitive, which is probably why it’s so often misunderstood and such a stubborn problem. We’ve seen this happen on many occasions.
Let’s get this right first: “Higher pump RPM doesn’t automatically lead to higher production!”
In fact, higher pump RPM tend to result in lower production. The pumping process is a complex process with many variables and interactions between the pump, drive and piping.
Production through the pipeline is a combination of flow rate, volume and density of the mix (the amount of soil in the mix). The number of revolutions of the pump only affects the flow rate, not the output. So if only the flow is increased and nothing else, the density will automatically drop. This means the same output, but higher fuel consumption and wear rates.
The problem is even more serious when the suction process is a limit process, that is, when the vacuum degree is high. The effect of velocity on vacuum is quadratic. Also, the more vacuum you have for speed, the less space you have available for density. A 10% increase in speed will result in a 20% decrease in attainable density. This means that production will drop by 10%.
As mentioned earlier, the whole pumping process is more complicated, but in general, the slower the better.
You need to keep the speed of the mixture slightly above the critical speed. Just above the speed at which the mixture starts to settle.
2.6 Reduce Discharge Resistance
Almost all cutter suction dredger is discharged through pipelines. Almost everyone understands that the longer the pipeline, the lower the output.
But in reality, this understanding doesn’t always apply. Are you always thinking about how to reduce drag?
There are several ways to reduce drag. The most obvious is the shortening of the pipes. This means a more direct route to the reclamation area. It also means using as few floating pipes as possible. This also means adjusting the connection point on shore if required.
Another issue that is often found is the number of elbows, Y-pieces and valves. All of these also increase the discharge resistance and should be eliminated as much as possible. This also applies to floating lines, try to keep them straight, and if you need to bend them, try to make them smooth. Smooth elbows not only reduce drag, but also reduce wear on the elbow and the pipe behind the elbow. Also limit the use of net spreaders and the limitations of pipe ends. If high flow is the problem, refer to the previous chapter and reduce the pump RPM.
Finally, make sure the reclamation area is not building fountains, but keep the pipes as low as possible. Unobstructed horizontal outlet above reclamation level for minimum resistance and maximum yield.
When you reduce distance, you either increase production or reduce fuel consumption. Both of these are good results you can achieve.
3. Conclusion:
Optimizing cutter suction dredge production is vital for enhancing project profitability and overall operational efficiency. By implementing the six strategies discussed in this article, operators can overcome common challenges and significantly improve production rates. Identifying bottlenecks, utilizing control systems, prioritizing regular maintenance, timely replacement of cutter teeth, optimizing pump speed, and reducing discharge resistance all contribute to increased productivity. Operators must stay informed, embrace new techniques, and strive for continuous improvement to achieve optimal results in dredging projects. With a proactive approach and a focus on efficiency, operators can unlock the full potential of cutter suction dredgers and maximize the success of their dredging projects.
Contact with us for more details:
Sally Peng
Tel /WhatsApp /Wechat :+86 18554212226 +86 13793808065
Email: oceanpump2@tsbeng.com, sales@sanddredgers.com
