MEXICAN NAVY

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 Cutter Suction Dredger

Module I – Damen csd 500

The cutter suction dredger was developed at the end of the 19th century. The name of the equipment indicates that we are dealing with a
suction dredger with a cutter. The development of the cutter suction dredger followed from the need for equipment capable of cutting more
cohesive types of soil and subsequently transporting this hydraulically to a place on shore. Moreover, this type of dredging equipment makes it
possible to deliver the required dredge profile.
The suction dredger excavates the soil using the cutter head and transports it by means of centrifugal pumps. The excavation process requires
careful positioning of the cutter head in relation to the bottom and the anchoring has to lead the excavating forces through to the bottom.
The ladder carries the cutter system and suction pipeline. The ladder enables the correct depth setting to be made. The side wires also run via
the ladder. This gives the ladder the role of transferring the digging forces to the pontoon. The aft end of the ladder is hinged to the hull to the
rear of the well. At the other end, the ladder hangs in the ladder hoisting gear. The ladder wire runs over a number of pulleys in the lower ladder
end then of the ladder, reeved several times to create a greater hoisting force. The lowest pulley block is located behind the cutter. These
pulleys come too much in contact with the loosened mixture. The height of the ladder cables must be such that the cutter can be hoisted to a
certain level above the water for repairs and cleaning.
The side wires run along sheaves located on the fore end of the ladder to the anchors. Because the height of the anchor in relation to the ladder
can vary, swing sheaves are used. For a proper distribution of forces, these sheaves must be located behind the cutter. To prevent wear due to
contact with the ground, they are nevertheless placed not to close to the cutters. If, for example, dredging is taking place close to an quay wall,
it may be necessary to run the side wire through a sheave on deck.

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CUTTER SYSTEM
The cutter is driven hydraulically and the drive system is mounted on the ladder. A hydraulic drive usually consists of several low-speed hydro
motors fitted to a gearbox and mounted close behind the cutter on the ladder.

Figure 1 Hydraulic cutter system

The motors and gearbox are pressure-water tight and can be completely
immersed during dredging. Because the system has a short shaft, the
lower end of the ladder can also be constructed with a wedge. This
helps the cutter to have a better position during shallow dredging and
keep the ladder from dragging.

A special bearing or thrust bearing is placed in front of the gearbox

to absorb the axial forces on the cutter shaft. The transverse forces
are absorbed by the cutter end bearing directly behind the cutter.
This bearing is of extra heavy construction

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Ladder winch
For hoisting and lowering the ladder one hydraulically driven winch is mounted in front of
the operating cabin.
Pull : 12 tons on first layer
Speed : 0-15 m/min (controllable)
Drive : By a hydraulic motor
Reduction gear : Planetary type
Drum capacity : Sufficient to lower the ladder to the given depth

The ladder winch is equipped with a hydraulically controlled multi-disc brake, and is
controlled from the cabin. The ladder winch is mounted on the main deck as per GA Plan.
The ladder winch is provided with a hand operated locking pin.

Side wire winches

For swinging the dredger two hydraulically driven side wire winches are mounted in front of the
operating cabin. The side wires are guided over the guiding sheaves on top of the ladder, through the
balanced wire blocks near the cutter unit to the anchors.

Number : 2
Pull : 10,5 tons on first layer
Speed : 0 - 25 m/min (controllable)
Drive : By a hydraulic motor
Reduction gear : Planetary type
Drum capacity : 150 m

The two side winches are equipped with an adjustable hydraulic brake valve enabling the run-out wire
to be kept tight (CT), making cutter operation possible with one winch controller. The side wire
winches are mounted on the main deck as per GA-plan. The side winches are provided with a hand
operated locking pin.

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Spuds

Outside diameter approx. : 610 mm

Wall thickness : 17.5 / 20 mm
Total length of each spud : 19 m
Weight of each spud : 5.6 ton

The spuds have heavy points at the lower-end and holes at 2.25 m intervals for the locking pin.
The lowest locking pin points are turned 90 degrees to provide a visual warning that the spuds
have been lifted to the safest highest point.

The two spuds are lifted through steel wires, by hydraulic spud cylinders:

Type : Each one single acting cylinder

Mounting : Ball-hinged Stroke : 1,500 mm
Rod : Stainless steel 431
Rod protection : 25 µm chromium layer
Sealing : Low friction type

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Spud carriage

In the well of the carriage pontoon the spud carriage is running on

heavy steel rail construction by means of a double acting hydraulic
cylinder. The carriage is made of a heavy steel plate assembly with
the necessary stiffeners and reinforcements.

Length : 2.00 m
Width : 1.26 m
Depth : 2.80 m
Plate thickness : 12 / 15 mm

Carriage provided with 4 main wheels made of steel and equipped

with D-glide bearings. All wheels are continuously provided with
grease. At both sides of the carriage sliding blocks are installed to
withstand the side forces. Moving of the carriage by a hydraulic
cylinder double acting stroke 4m. Cylinder housing is mounted in a
heavy steel framing with suitable shock absorbers. On the top of the
carriage hinge plates and supports in which the spud-hoisting
cylinder and spud sling are mounted.

The spud carriage is moved by a hydraulic spud carriage cylinder:

Type : Double acting cylinder

Mounting : Flanged at front Stroke : 4,000 mm
Rod : Stainless steel 431
Rod protection : 25 µm chromium layer
Sealing : Low friction type

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Anchors
For maneuvering of the dredger

Anchors for side winches : 2 Weight approx. : 750 kg each Type : High Holding Dredging

Deck Crane
To handle pump and spare parts etc. a deck crane is mounted on the P.S. aft side pontoon. The crane reach is such that the dredge pump,
main E.R. hatch, store hatch and the quay can be served.

Lifting capacity : 4.00 tons Maximum radius : 3.50 m Maximum rotation : 290 degrees Hoisting : Electric operated chain tackle Slewing and
travelling : Electric operated Security : Mechanical locking pin

Wires
The dredger is equipped with the following wires and ropes. Type of wire: 6x36 WS + Stainless steel core

Winch wires
The ladder winch is equipped with: Steel wire : 24 mm Length : Sufficient to lower to the given dredging depth
The two side winches are equipped with: Steel wire : 24 mm Length wire for each winch : 150 m

Gantry wires
The cutter ladder gantry is equipped with: 2 steel stay wires 2 ladder safety wires

Spud slings
The spuds each are lifted by means of a spud sling equipped with special shackle and split cable eyes.

Spud hoisting wires

For each spud a steel wire equipped with cable eyes.

Wire sheaves
Wire sheaves are made of stainless steel. Sheave diameter is minimal 20x wire diameter. The sheaves in top of the gantry are with
maintenance free roller bearings. All sheaves under water are made of D-glide bearing bushes on stainless steel shafts and are continuously
provided with grease. All sheaves above the waterline are with maintenance free synthetic bearing bushes on stainless steel shafts (with
exception of the sheaves in the gantry)

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Rio Tinto – Simulator training syllabus Page 12 van 73
 Cutter Suction Dredger

Module II

How to use the simulator (button course)

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 Cutter Suction Dredger

Module III

Cutting process cutter suction dredgers

(particular csd 500 Damen build)

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III.1 Introduction:

The cutter process starts with the cutter. The cutter rotates at the front of the suction mouth. It cuts the
material loose and mixes it with water, ready to be pumped by the dredge pump and then transported
hydraulically through a pipeline.

The cutter is an important part of the cutter suction dredger, which is why this type of dredger carries its
name. It is in fact a rotating piece of equipment. The function of the cutter is to loosen the material, ready
for it to be brought to the suction mouth.

The production depends on:

a. shape of the cutter

b. the number of revolutions
c. the cutting force

The above result in a specialized model.

- Cutters for sticky materials (K),
- Cutters for not sticky soft materials (Z),
- Cutters suitable for hard material, that exert great forces on the
cutter and wear it out. In these conditions it is important that the
cutter teeth and cutter head can be switched quickly (R).

Together, the cutter revolutions and the sideways movement form the cut width and the amount of soil cut
away. This shows that it must be possible to regulate the revolutions in accordance with the composition of
the soil and the way it changes.

This csd 500 goes from 0 to 30 revolutions per minute.

III.2 Cutter unit

The cutter unit is constructed from heavy steel plates and the necessary braces and reinforcements, to
form a rigid frame in which the cutter shaft bearing assembly is incorporated.
The cutter shaft, made of steel 42CrMo4 and supported by radial and axial roller bearings, rotates in an oil
filled heavy gauge steel pipe casing. A small header tank that is placed approx. 1,5 meter above water level
insures a positive oil pressure in the casing.
The cutter is mounted on the cutter shaft by means of screw thread. Between cutter hub and bearing house
a steel hawser and flame-cutting ring is mounted for easy removal of cutter.
The cutter is driven by a hydraulic motor:
Power : 180 kW (245 Hp)
Rotation speed : Continuously variable from 0-30 rpm

The hydraulic motor is directly mounted to the cutter shaft bearing housing.
The front end of the cutter unit is provided with a front plate and a dismountable special shaped suction
mouth with a nominal surface area of approx. 125% of the suction pipe surface. The wall thickness of the
suction mouth is 15 mm, and is provided with a stone grid with a passing slightly smaller as the spherical
passage of the pump. A dismountable suction pipe is also mounted to the cutter unit.

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Heavy duty cutter
Make : Damen Dredging Equipment
Model : Crown
Number of blades : 5
Diameter approx. : 1.625 mm
Teeth : Pick points (changeable)

III.3. Cutter characteristic

The accompanying page shows a cutter characteristic with the properties of the drive. You can use this to
assess how the cutting process will go and whether cutting is normative for production. The production
limits are:

a. Cutter power
b. Collecting cutter/side winch combination
c. Creating a mixture cutter/suction pump
d. Discharge limits of the discharge pump(s)

A cutter characteristic shows the maximum limits at a certain power:

a. Cutter revolutions (cutting speed)

b. Cutter torque (cutting force)

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III.4. Torque

To be perfectly clear, we will examine torque in more depth.

What is torque: Torque = force x arm in K Nm

The drawing shows a cutter head with 6 and 7 cutting teeth (as the
csd 500) respectively on the blades, shown as K1 through K6.

Each tooth is at a certain distance from the centre of the cutter,

shown as a through f. In fact it is a radius that stands perpendicular
to the tangent lines of the cutter.

Example: If the cutter has been pushed to the front by the spud
carrier so that the teeth K6 through K3 are in contact with the
ground, the torque exerted on the cutter is as stated below:

Torque = (K3 x c) + (K4 x d) + (K5 x e) + (K6 x f).

Cutting force
If more cutting force is demanded to cut a particular soil type, in
other words, all the working “K” forces increase. However, the
radius remains the same for each force as dictated by the cutter
construction. That means that the torque increases.

Generally cutters with a larger diameter are used for non-cohesive

soil types; the radius increases correspondingly. We can convert
the torque formula into a formula for cutting force:

Torque = Cutting force * Radius

Cutting force = Torque / Radius

Example:

Suppose the torque = 900 KNm. The average cutter cutting diameter is 2.50 m. In that case, the cutting
force of the cutter

K = Cutting force = Torque / Radius =

900 / (2,5/2) = 72 Ton

Divided over teeth K3 through K6 = 4 teeth,

then the average cutting force per tooth 72 / 4 = 18 ton
If only one arm is in contact with the soil.

Cutter power

Now, on the basis of the available cutter power:

N = power in KW (HP / 1,34)

n = cutter speed in revolutions per minute
K = Torque

Torque = Power / (0.105 x nc)

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Example:

Cutter power: 3,000 Kw = 4020 hp

Cutter rpm: 40 rpm

Torque = P / 0.105 x nc = 3,000 / (0.105 x 40) = 714,3 KNm or 71,4 Tonm

Average cutter cutting radius is 1.25 m

Cutting force = 71,4 / 1.25 = 57,12 ton

Example:

Now based on the available torque = 714,3 KNm nc = 40 rpm

Cutter power = 0.105 x nc x T = 0.105 x 40 x 714,3 = 3,000 KW or 4020 HP.

III.5 Sideways swinging

For swinging the dredger two hydraulically driven side wire winches are mounted in front of the operating
cabin. The side wires are guided over the guiding sheaves on top of the ladder, through the balanced wire
blocks near the cutter unit to the anchors.

Number : 2
Pull : 10,5 tons on first layer
Speed : 0 - 25 m/min (controllable)
Drive : By a hydraulic motor
Reduction gear : Planetary type
Drum capacity : 150 m

The two side winches are equipped with an adjustable hydraulic brake valve enabling the run-out wire to be
kept tight, making cutter operation possible with one winch controller. The side wire winches are mounted
on the main deck as per GA-plan. The side winches are provided with a hand operated locking pin.

Introduction The winches are hydraulically driven. As with the cutter characteristic, it must be possible to
control this accurately to achieve a variable sideways movement in proportion to the cutter load and the
composition of the soil and the way it changes, during the dredging process.

The side winches must take care of:

a. Optimum cutter load

b. Optimum mixture creation
c. Optimum collection of the dredge soil to avoid spillage
d. Optimum loading of the discharge pipeline, with the concentration having the correct standard without
any deposit formation occurring.

The side winch speed and tensile force influence the production process to a large degree.

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III.5.1. Hauling and slackening winch

The hauling winch pulls the cutter against the soil to be cut, especially if the material is being undercut
(undercutting cutter); this happens to a lesser degree if the material is being overcut. The slackening winch
develops a braking force to keep the hauling speed under control; also called braking winch. The aim is
also to keep the side wire taut so it won’t get into the cutter with all the negative consequences.

The hauling winch must be able to resist the following forces:

a. Cutting force of the cutter

b. Braking force of the slackening winch
c. Friction of ship and ladder through the water
d. Current, wind and waves
e. Forces from the floating pipeline
f. Bulldozer effect of the ladder as a result of
spillage
g. Position of the anchor. (see next page)

III.5.2. Varying side winch forces and anchor positions

The side winch wires go via the ladder side wire blocks to the side anchors. The maximum tensile force on
the side winch must be the same as the holding force of the anchors of course, and that depends in turn on
the weight and type of anchor and the soil type. The position of the anchor flukes in the soil also plays an
important part. The forces working on the side winches are not always the same as the cutting force of the
cutter. They are only the same if the side wire is at an angle of 90 degrees with the central axis of the ship.
In general, the hauled angle is as stated above, greater or smaller than 90 degrees, as the cutter suction
dredger is continually swinging from port to starboard and back again. In other words, the side wires will
always be pulled harder if the forces are exerted by the cutter, as mentioned in chapter 1.3.1, a through f.

The anchor can have such an unfavorable position that only a part of the tensile force comes to the benefit
of the cutting force of the cutter.

If the anchors are too far back, this causes the cutter suction dredger to have trouble coming out of the cut
corners, and the load on the spud increases greatly, shifting the dredger backwards. It is important that the
anchors are placed as far away as possible to avoid frequent shifting of the anchors; this is also beneficial
to the play of forces on the cutter process.

Because the dredger keeps moving forward during dredging, the anchors will stay behind more and more.
At some point the anchors will be too far behind. Particularly in the position where the dredger has to come
out of the corner, the resolution of the tensile force of the winch has become too small to swing the dredger.
This is shown in Figure 3.7 B. In that case the anchors must be placed forward, but not too far to prevent
the dredger being pulled forward in the corner and the side wire getting into the cutter (See page 27)

As indicated above, the direction of the side wire used for pulling is important. If the anchors are too close
to the cut, the anchor must be shifted. If possible, the anchors should be positioned further away from the
dredge to keep them longer in a favorable position. However, in that case it is important that the wire
continues running from the swing sheave towards the anchor. Especially with larger cut heights, the wire
can easily be caught in the sideways breach. In that case the skipper will have to hoist the ladder a little
and pull the wires free. Sometimes pontoons are laid underneath the side wires to keep the wire free from
the side breach.

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The afore mentioned also shows that with the dredger operating at great swing angles, the anchors are
positioned more backwards. The cut width can never become smaller than the minimum cut width required
for the dredge to keep itself free. (

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 Anchor for side winches: 2
Weight approx: 750 kg each
Type: High Holding Dredging (Delta Flipper)

Each anchor delivered with pick-up bouy,

hoisting wire (pennant) and shackles

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III.5.3 Side winch characteristic.

A side winch characteristic is a graph that shows the relation between the
hauling speed and tensile force of the winch. The graph shows the limitation of
the side winch clearly.

Introduction
The principles are the same in broad lines as those discussed in chapter 1.2.2
for cutter characteristic. However, the big difference is that the slackening
winch must develop a braking force.

III.6. Interaction between cutter and side winch

There is continuous interaction between cutter load and side winch speed. For instance, if the cutter is
overloaded and the revolutions start decreasing, whereby the cutting force increases (tries to cut free), the
side winch speed should also decrease so the cutting crust thickness is not enlarged by the lower cutter
revolutions at equal hauling speed. Cut thickness = Vs / (nc * Cutter blades) (Damen 30 rpm and 5 blades)

Conversely, if the side winch becomes overloaded and the hauling speed decreases, the cutter cuts
smaller slices with the same constant revolutions. Check if this is correct!

In general the side winches must be strong enough not to get overloaded, so that the automatic hauling
speed works better.

III.6.1 Influence of side winch speed depends on cutter load

The cutter power consumption is normative for the hauling speed and the tensile force of the side winches.

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III.7 Spud carrier system

Introduction The spuds keep the cutter suction dredger in position. The spuds are the pivot/anchoring teeth
of the dredger that is hauled sideways over the dredging cut. Once the swinging movement has been
completed to satisfaction and left behind a reasonable profile, the dredger can be shifted forwards by
means of the spud carrier .

III.7.1. Spuds

The spuds are made of heavy gauge pipe S355JO.

Outside diameter approx. : 610 mm

Wall thickness : 17.5 / 20 mm
Total length of each spud : 19 m
Weight of each spud : 5.6 ton

The spuds have heavy points at the lower-end and holes at 2.25 m intervals for the locking pin. The lowest
locking pin points are turned 90 degrees to provide a visual warning that the spuds have been lifted to the
safest highest point.

Spud hoisting equipment

The spuds are lifted by steel wires and single acting hydraulic cylinders. These cylinders are hinged
mounted on a base at the aft deck. The top of each cylinder is equipped with a wire sheave and guide.

Stroke of the spud cylinder : 1,500 mm

Stroke of the spud pole, approx. : 2,250 mm

The cylinders are equipped with free-falling valves and slow fall operation, both controlled from the cabin.
Manual lowering is also possible near the spud poles.

The function of the spuds includes:

a. Creating a fixed pivot point and providing a stable position.

b. Creating the possibility of moving the dredger forwards.
c. Absorbing reactive forces of the cutter, side winch, floating pipeline, current, waves and wind, for
instance.

Of course the strength and the weight are determined by the forces and working depths. The length
depends on the working depth and penetration into the bottom. The diameter and weight can go up to 140
m length and 120 ton respectively. The spud can best resist the forces exerted on it by:

a. If the soil resistance properties are high, making penetration difficult, this is a reason for the spud to drop
several times.

b. If the soil resistance properties are low, the spud must drop carefully.

c. A sharp point is located on the end of the spud. It often has four fins for loose soil types. The wall
thickness of the spud varies greatly; at the pointed end it is 16 mm, halfway 25 mm, the top part under
the ship is 38 mm. The above values are calculated on the basis of moments exerted on the spud: in
shallow work there will be low moments, and at great depths there will be substantial moments.

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III.7.2. Spud carrier

In the well of the carriage pontoon the spud carriage is running on heavy steel rail construction by means of
a double acting hydraulic cylinder. The carriage is made of a heavy steel plate assembly with the necessary
stiffeners and reinforcements.

Length : 2.00 m Width : 1.26 m Depth : 2.80 m Plate thickness : 12 / 15 mm

Carriage provided with 4 main wheels made of steel and equipped with D-glide bearings.
All wheels are continuously provided with grease. At both sides of the carriage sliding blocks are installed
to withstand the side forces. Moving of the carriage by a hydraulic cylinder double acting stroke 4m.
Cylinder housing is mounted in a heavy steel framing with suitable shock absorbers. On the top of the
carriage hinge plates and supports in which the spud-hoisting cylinder and spud sling are mounted.

III.7.3 Stepping

Introduction The stepping distance depends to a great extent on the soil properties to be dredged; they
influence the cutting process. Important criteria are:

a. Soil properties
b. Cutting force of the cutter
c. Cutter length and diameter
d. Hauling speed and force
e. Spillage being left behind
f. Dropping or rising water levels

III.7.4. Spud carrier cycle

The spud carrier cycle consists of the following steps to move the cutter suction dredger forwards:

a. Starting position in the central axis of the cut

b. Haul to port or starboard (half a cut
width)
c. At the end of the cut (in the corner),
stop hauling and push the dredger as
desired forwards
d. Haul to starboard or port from the cut
corner
e. Repeat this procedure until the full
length of the spud carrier has been
shifted to the back
f. Haul to the central axis of the cut
g. Drop the auxiliary spud and hoist the
operating spud
h. Shift the spud carrier to the fore part
of the ship
i. Drop the operating spud
j. Hoist the auxiliary spud
k. The spud carrier is now in its starting
position and a new spud cycle can
be started as described above.

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III.7.5 Concentric cutting circles

When hauling, the cutter moves as part of the segment of a circle with the spud pole as the centre of
rotation.

When the dredger is pushed forwards, the radius of the circle increases gradually, that is, the radius differs
by 4.0 metres between the spud carrier in starting position and in final position, if the travel of the spud
carrier cylinder is 4 metres.

The result of the above is that with every step forwards, concentric circles are described. The
accompanying drawing shows the effect.

You get an overlap with production losses as shown below. As an example we will take a distance of spud
to cutter of 100 metres. The losses through overlap in cubic metres are:

Swing in degrees Cut width Loss

45/50 80 m 3%
45/50 100 m 5%
45/50 120 m 8%

Cut width carriage 1

Cut width carriage 2

First cut present carriage 2

First cut previous carriage 1

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III.8 Loosening the ground

Introduction Loosening, cutting and creating a mixture are closely related. The cutter cuts and mixes the
soil at the same time with water, ready for hydraulic transport;

In theory there are three types of cutters.

A. Clay cutters
- The clay cutter has a large opening between the five blades to create as large a passage
as possible for clay and clayey soil types.

B. Rock cutters
- The rock cutter is much more compact and has a heavier construction with 6 blades to be
able to exert great cutting force. The opening between the blades is smaller than the
opening of the pump impeller entrance.

C. Multipurpose cutters (clay and sand)

- The multipurpose cutter is designed for different material types like sand and clay.
The diameter is larger than the rock cutter and it has 5 blades.

III.8.1.
Cutting elements

Cutters can be equipped with different teeth for cutting, all depends on the soil to be cut, also the adaptors
on which the teeth are mounted, they form the connection between the cutter arms and the teeth and to
guide the cutting forces to the cutterladder. Adaptors have different connection systems for teeth.

III.8.2. Cutting angle of teeth

A great deal of research has been done to obtain the

ideal cutting angle for the cutting element in the
different soil types. Knowledge gained from
experience has caused the angle to change
considerably: from 35 to 45 and 60 degrees.

- Sand and clay cutters The cutting angle as

illustrated is for sand and clay points more inwards
than for rock cutters; the angle is 45 degrees.

- Rock cutters Here the angle points more to the

outside than for sand and clay cutters. The angle is
60 degrees.

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III.8.3. Cutting soil with cutters

Introduction The movement of the cutter determines how much soil is dug up, depending on the cutting
force and the sideways movement. The correct number of blades of the cutter and the helical design of the
blade will ensure that the cutting forces are exerted as equally as possible.

The sideways movement of the cutter, called hauling, makes the rotating movement deviate from that of a
circle, increasingly so as the relation of the hauling speed with the cutting speed becomes greater.

This ratio determines the actual shape of the size cut off and of the cutting surface. In soil types that are not
too hard, cutting is possible in both hauling directions, starboard and port.

This is not possible in hard soil types like rock, because the cutter tends to climb the slope and perform little
productive work. There is also a danger that the cutter will dance up and down, resulting in a great many
broken teeth.

Sometimes it is advisable to keep the central axis of the cutter 30-50 cm below the surface to be cut, so the
cutter will not be inclined to climb on top of it.

III.8.4. Cutting power

The cutting power is indicated on the accompanying diagram by the symbol K, which is resolved in the
force P perpendicular to the cutting surface. This is called the penetration force. This force must make sure
that the blade/tooth does not go out of the cut and must realize the necessary penetration into the material
to be cut. This force depends on the shape of the blade, the tooth and the circular properties.

The cutting force is expressed by the symbol S, tangent to the cutting surface. The cutting force must also
cancel out the friction force which results from tooth wear. A worn tooth has a wearing edge that runs
parallel to the tangent to the cutter; the clearance angle of the worn tooth with the bottom is in that case
almost nil. As the teeth wear, the wear surface increases and more force is needed to keep the tooth in the
ground.

Penetration force This force P must make sure that the cutting edge of the tooth penetrates sufficiently into
the compact soil. The P force will cause tensions that make the desired shape change or shatter the
surface.

Cutting force This force S must overcome the shear resistance (clay) or tensile resistance (rock) of the
pieces that are broken away, as well as the frictional resistance between the soil and the inside/front of the
tooth.

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III.8.5. Crust thickness and fragmentation

In the cutting process, cutting the soil loose underwater plays an important role with the following normative
factors:

a. Cutting speed
b. Height of the cutting element
c. Cutting depth
d. Cutting angle

We know that the required forces for cutting or fragmenting are mainly determined by the properties of the
soil to be cut. Two deformation processes have an important part in cutting:

a. The shearing of material on top of material at the place of the shear plane.
b. Shifting the material to be dredged over the steel to the location of the cutting
element.

The following forces work on the slice of ground in front of the blade:

P1 = force on the blade surface as a result of under pressure in interstitial water.

P2 = force on the shear plane as a result of under pressure in interstitial water.
P3 = force exerted by grains of sand on the blade surface.
P4 = force on the shear plane between the grains of sand.

Desired cut thickness

So, if we want to dig a certain amount of soil it is better if we do this by utilizing the length of the cutter head
as much as possible and if necessary, by settling for a smaller cut thickness.

This throws up a different advantage that we certainly must not disregard. The cutter blades and cutting
edges actually cover the jacket of the cutter head in such a way that when you dig with the full cutter head
length, you cut over the full cut thickness. (in practice the maximum step length will be approx.. 70% of the
cutter diameter.

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Cutter torque

The cutting forces develop evenly, without gaps or impact loads. The required cutter torque (power of the
cutter engine) and tensile force in the hauling side wire (power of the side wire engine) are then more or
less constant at steady circumstances of soil properties, clearance angle, cutting angle and cut thickness.

Disadvantages of small ‘step length’

From the above we can see that we want to keep the distance between two concentric swings as large as
possible. This has the added advantage of not allowing the step length to become too small, so that fixing
the operating spud in consecutive positions improves. If the step length becomes too small, you get the risk
of the operating spud being pushed back into the previous spud hole.

The under pressures in the interstitial water have a dominant influence on the forces of the cutter. They are
generated by the volume increase that occurs, called dilatation.

The size of the under pressures at certain cutting speeds (cutter revolutions per minute) depends on the
water porosity. The following soil mechanical properties play a part in the cutting process:

a. Angle of internal friction

b. Volume increase (dilatation)
c. Friction angle between material and cutting elements
d. Water porosity

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Page 36 van 73
The influence of the cutting speed on the cutting resistance or slide is mainly important in sand types. As
fine types of sand are usually compact, when they shift the grains will have to go further apart from each
other and the pore space will increase.

In water-saturated soil this means the increased pore space will have to be filled with water; this needs
time, given the limited permeability of the soil.

As long as this has not happened, the interstitial water will be under tension, resulting in an increase of the
grain tension and the shear resistance.

At high speeds you get cavitation. In this case the undertensions (under pressures) occurring in the
interstitial water become greater in proportion to the permeability of the sand.

In the shear plane area an increase in volume occurs and the water permeability will be greater than in
undisturbed water. This dominates the cutting process. The following influence the cavitation that occurs:

a. Cutter and side winch speeds

b. The shape and size of the cutter
c. The soil mechanical properties

When a piece is slid off, the shear

pressure along the shear plane will
not occur everywhere at the same
time. This is called progressive
failure.

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III.8.6. Influence of distance between teeth

The accompanying graph shows the influence of the distances between the teeth on the cutter blade. If this
distance is too large, the fracture areas will not influence each other, teeth 1 and 2. With teeth 3 you dig in
the middle between this path and they overlap each other. Staggering the cutter teeth between the two
consecutive blades can influence the length of the fracture areas positively as well as the amount of cut
ground. The cutter power is also utilized better as the production increases per Kw unit.

All teeth in the same position

fracture area is 1 through 6

Staggered teeth
fracture area is 1 through 3

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III.8.7. Collecting process

Introduction Once the material to be dredged has been cut loose by the cutter, it must be collected to make
it suitable for hydraulic transport. The output of this process depends entirely on the soil type.

We call this a hydraulic process, seeing as the dredged material has to be mixed with water. The suction
force of the water sucks the material into the suction mouth.

With cutter suction dredgers loosening and collecting are one continuous process.

Unfortunately some of the material is not pumped up by the suction mouth. We call it spillage. The volume
of the freed soil can be considerably larger than the collected volume. In practice this comes to about 30%
of the face height. Only 70% of the soil is pumped up. (pending cutter rpm, swing speed, step length)

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III.8.8. Collecting production

When the sediment has been broken up by the cutter, the material is pumped up as much as possible by
the suction mouth to be transported hydraulically via two or three pumps through the floating pipeline to the
dump site. In order to achieve the above, the cutter and the suction mouth are moved along the cut width
by means of the side winches. The cutting and suction process depends entirely on the method of the
cutter ladder angle and shifting along the face.

The face/cutting height, the progress of the cutter (horizontal depth) and the sideways swinging speed are
related to the composition of the material. If free-running materials like sand and silt can be dredged, the
face/cutting height can be increased substantially, and along with that, the progress.

Overcutting Undercutting

III.8.9. Creating a mixture

Creating a mixture can take place in two ways:

a. as a result of post-caving of the slope;

b. during the cutting processing, especially with an undercutting cutter.

With hard, compact soil types it depends to a great extent on the method and shape in which the separate
fracture areas occur, which in turn is connected to the presence of the stratification or shear planes, the
variation in tensile resistance and shear resistance, and:

a. presence of stratification and cleavage planes

b. the variation in tensile or shear resistance
c. the shape of the tooth
d. the cutting angle of the tooth.

The drawing below shows different fracture patterns. You can see that the size of the penetration force is
closely connected to the position of the fracture area. The stratification in the soil is extremely important to
the cutter output. Sedimentary rocks or old clay soils have fracture areas that the cutter can process better
in one particular direction than in the other.

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Post-caving
With high faces and low cutter hauling speed, the face (particularly with non-compact or cohesive soil
types) needs sufficient time for post-caving. The angle of the slope and the position of the cutter ladder
have an important part in this.

Post-caving can occur through:

a. landslide shifts
b. sand flowing along the slope.

The cutter cuts the soil and mixes it with water. This is
called creating a mixture.

There is always some cut soil that does not get

pumped up by the suction mouth.

This is the main cause of excessive cut soil or of the

cutter flinging it away through its centrifugal force.

As mentioned previously, the ratio of loosened soil

and pumped-up soil is about 100% to 70%,
depending on the face height and the material to be
cut.
Also quite often with non-cohesive soil types the face
crumbles (is not cut) and is pumped up by the suction
mouth.

We can make a distinction between cutting process

and discharge production. The difference is SPILLAGE.

III.8.10. Spillage

What is the cause of spillage? As described previously on page 24 about cutters, the blades of the cutter
have a helical shape that scoops the material into the suction mouth. It works like a kind of pump. But the
suction mouth, for reasons of construction, is placed at the bottom of the end of the ladder. Because of this
position it cannot suck up all the loosened material. (Some have mouth turned in direction of cutteturn)

The end of the ladder forms a shield that pokes in a cone shape in the cutter. The scooping effect of the
cutter blades also throws material over the shield; this material is not pumped up and lies loosely on the
bottom in the dredged area.

Another cause is that the centrifugal force of the cutter flings away some of the material; this of course
increases if the cutter speed is increased.

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III.9 Influence of overcutting cutter

Introduction Overcutting cutter means: If the direction of rotation of the cutter is such that the teeth move
from the top in the material to be dredged to the bottom, this is called overcutting. (see page 41)

The overcutting cutter shows that the hauling direction works together with the direction of rotation of the
cutter. This has a bad influence on the creation of a mixture and causes considerable spillage. (page 41)

III.9.1. Creating a mixture process

As touched upon earlier in this chapter, there are problems in creating a mixture. The cutter processes the
material so that when mixed with water it follows the direction of rotation of the cutter blades and falls or
flows by gravity downwards towards the suction mouth.

This does not allow much time for creating a mixture. As a result only some of the loosened material is
pumped into the suction mouth and a large amount passes under the suction mouth and ends up lying in
the dredged area as spillage.

After all, with an overcutting cutter gravity works together with the speed of the blade and the direction of
the water, this has a negative effect on the creation of a mixture and therefore on production.

1. Loose material partly flooding towards the suction mouth and partly spill.

2. Spillage due to centrifugal force of cutter.

3. Sucked up for hydraulic transport.

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III.9.2. Influence on side winches with respect to tensile and braking force

The cutting force of the cutter is used to penetrate into the soil and to cancel out the frictional resistance, as
we learned from page 41 and onwards.

When the soil is being overcut an upward reactive force occurs, as a result of the downwards cutting force.
In hard soil types the cutter tends to lift out with the following adverse results:

a. The cutter starts to cut less deeply.

b. The cutter tends to walk over the cut.
c. The cutter starts dancing, and as a consequence the cutter teeth and adapters on the
bottom break off.
d. The cutter increases the swing speed, so that the hauling winch does not have to pull as
hard.
e. The slackening winch often has to brake the swinging speed.

III.9.3. Influence on production

Breaking loose and cutting in a downward movement makes it difficult to fragment the soil. That is one
reason why the cut thickness and the pieces do not have a controlled size. Due to their weight they fall to
the bottom and are difficult to mix with water (creating a mixture). They pass beneath the suction mouth
and remain lying on the bottom: spillage. A great deal of energy and money is spent on tooth wear, and yet
the suction mouth is not capable of sucking up all the material.

Experience has shown that spillage can rise up to 40 to 50%; with an overcutting and undercutting cutter
operation you have to count on an average of about 30%. You can decrease the cutter revolutions per
minute and increase the hauling speed to limit the spillage to a certain degree and increase the production.
However, as a result of lower cutter speeds and increased swinging speed the cut pieces become larger,
which increases the power consumption on cutter and winch.

III.9.4. Clean-up swing

If work is being performed in hard soil types like rock, the cutter must always rotate at a higher speed (35-
40 rpm) for the following reasons:

a. to fragment the rock more finely

b. lower power consumption
c. keep the side winch tensile force within limits.

But the high revolutions per minute mean the centrifugal force increases, so that the material is flung
outwards and the spillage increases.

You cannot work any longer with the overcutting cutter because the work becomes too turbulent and the
cutter tends to climb up the slope. As a result, with overcutting cutter you are forced to swing back with an
empty (not working) swing, which is not productive.

This empty swing is frequently used to clean up the cut made with an undercutting cutter, without stepping
forward. Best practice would be to make the overcutting a larger step length than the undercutting swing
(clean up)

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III.10 Influence of undercutting cutter

Introduction Undercutting cutter means: If the direction of rotation of the cutter is such that the teeth move
from the bottom in the material to be dredged to the top, this is called undercutting.

The undercutting cutter shows that the hauling direction works against the direction of rotation of the cutter.
This has a favourable influence on creating a mixture, so that the spillage is limited considerably because
the direction of rotation and suction influence work against each other. Hard soil types are attacked and
disintegrated only with the undercutting cutter, ready for hydraulic transport.

III.10.1. Creating a mixture process

As mentioned earlier in this chapter, the creation of a mixture is affected positively so that there is only
limited spillage. The cut slices/pieces are pushed upwards against gravity by the speed of the blade, so that
the material breaks out upwards, causing a lower breaking-out force.

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Page 46 van 73
This reduces the speed of the material, so that water has sufficient time to mix with the medium; this is also
called creating a mixture.

When the mixture comes down as a result of gravity, the suction mouth has sufficient time to suck up the
mixture and transport it hydraulically; see page 47.

With an undercutting cutter gravity works together with the speed of the blade and the speed of the water,
so that there is sufficient time available for creating a mixture; this has a positive production result and less
spillage as a result.

III.10.2. Influence on side winches with respect to tensile forces

During the cutting process the reactive forces of the cutter push downwards, increasing a frictional force
between the teeth and the soil. The downward reactive force tends to make the cutter cut more deeply. The
hauling side winch must push the cutter against the slope.

III.10.3. Influence on production

Loosening/cutting in an upward movement makes the breaking-out process and the fragmentation of the
medium easier. Page 35 we already discussed the influence of stratification. It has a great influence on the
breaking-out forces, in other words, on the cutter power.

The revolutions of the cutter determine to a great extent the slice thickness/fragmentation suitable for
hydraulic transport without any blockage occurring in the pumps. (Cut slice = Vz /(nc*Cutter blades)

As mentioned in the above chapter, the spillage is restricted with undercutting cutters, with the subsequent
positive influence on production. Experience shows that spillage only accounts for 10-15% of the cut
material, which is 15-20% lower than normal with the cutting process (average 30%).

III.10.4. Power loss of cutter and side winches

The soil is undercut in an upward direction. This breaks the material out as it were, so that mixture creation
is improved, the water fills the pores and hollow spaces and dilatation (volume increase) occurs.

The above results in the cutting forces being kept within limits, so that less cutter power is required. On the
other hand, the side winch requires a lot of power as the cutter has to be pushed against the slope so the
cutter can cut into it. The cutting forces increase considerably when cohesive clays are being cut, even up
to the maximum, as the adhesive has a strong effect on the frictional influence.

III.10.5. Cleaning up

Clean-up swings are rarely made with an undercutting cutter; they are reserved for the overcutting cutter. If
you clean up with an undercutting cutter, there is a danger that you get the football effect. The large pieces
of rock in particular are pushed or rolled to the cut side, creating a berm between two cuts. It is self-evident
that in cleaning up the cutter must work at a lower speed to reduce the centrifugal flinging-off effect.

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III.11 Summarize overcutting and undercutting

Introduction
The previous chapters III.8.8 - III.10 introduced us to the influences of overcutting and undercutting cutting
methods. The purpose of this chapter is to compare both cutter directions of rotation with each other and
come to a conclusion. In summary:

a. The direction of cutting of the overcutting cutter is from top to bottom.

b. The direction of cutting of the undercutting cutter is from bottom to top; hauling works against the
direction of rotation.

III.11.1. Creating a mixture

a. Overcutting cutter: the force of gravity of the material works together with the blade direction of cutting of
the cutter and the pumped-in water speed direction. Bad creation of a mixture and a lot of spillage.

b. Undercutting cutter: the force of gravity of the material works opposite to the blade direction of cutting
and the water speed direction. Good creation of a mixture and little spillage.

III.11.2. Influence on side winch tensile force

a. Overcutting cutter: the hauling winch has to exert only little force as the cutter is helping. The slackening
winch usually works as a brake to keep the process under control.

b. Undercutting cutter: the hauling winch must press the cutter against the slope, causing great tensile
forces to arise.

III.11.3. Influence on production

a. Overcutting cutter: the bad creation of a mixture means that relatively little material gets pumped up in
the suction mouth. The result is low production as a consequence of about 40 to 50% spillage.

b. Undercutting cutter: the cutting process proceeds at an optimum. As a result of good mixture formation, a
relatively large amount of material gets pumped up in the suction mouth. The result is much greater
production (3 to 3.5 times greater) than with the overcutting cutter, with about 10 to 15% spillage.

Note: The spillage percentage for overcutting and undercutting cutters is an average of 30%, depending on
the face height.

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Page 49 van 73
III.11.4. Power loss of cutter and side winches

a. Overcutting cutter

- Cutter power is considerably greater due to the downward cutting direction. - Hauling winch power is
limited as the cutter works together. - Slackening winch usually has to work as a brake to keep the
process under control.

b. Undercutting cutter

- Cutter power can be kept within limits and is less than with an overcutting cutter.
- Hauling winch requires a lot of power to keep the cutter against the slope.
- Slackening winch only has to keep the side wire taut.

III.11.5. Clean-up swing

a. Overcutting cutter

- For rock: with lower cutter revolutions and without cut depth and increase in height, clean up the spillage
from the undercutting cutter.
- For soft soil types the overcutting cutter works totally with the production process.

b. Undercutting cutter

- Cleaning up is rarely performed. If positive, the cutter revolutions must be decreased to combat the
football effect.

III.11.6. Conclusions

a. Overcutting cutter
- Suitable for soft and stiff clay, all types of sand
- Not possible for hard materials like rock and sometimes coral
- High spillage percentages, so low production.

b. Undercutting cutter
- Suitable for all soil types
- Only one possible in hard materials
- Low spillage percentages, so high production.

The characteristics of overcutting and undercutting cutters are shown schematically below.

Cutter Cutting Spillage Production Cutter Side Soil type Soil type
direction power winch hard soft
of rotation power

Over Over Much Low High Low No Yes

cutting

Under Under Less High Low High Yes Yes

cutting

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The drawings of the work to be dredged show the horizontal and vertical dimensions of the dredging area.
The cutter dredger has to remove all the soil indicated by the drawing. To do this as efficient as possible,
the dredge master (and the dredging supervisor) prepare a cutting plan. They need all project survey
details to prepare this plan. These details include, in addition to the ordinary drawings, the sounding charts
(identifying all depth lines), information about current, swell and tide, and especially information about the
soil types involved. External conditions are also taken into account such as shipping and client
requirements. Other important considerations are the shore connections, of the floating pipeline and the
dredger’s maximum operating width and depth.

First, the dredger’s minimum and maximum cut width must be established. This width depends on the
swing angle from centerline and the swing radius (cutter radius) of the dredger. The maximum swing angle
is approximately 40°. For practical reasons, an angle of 30º or 35º is usually chosen, depending on the
forces required for hauling. Relevant factors include soil type, anchoring, current and wind. In case of a
smaller angle, the anchors may be positioned slightly more forward to make more efficient use of the force
of the fore side winches and to reduce anchor loads.

One should take into account that, with a given cut width, the greatest swing angle must be made with the
ladder in deepest position and the spud carriage in front most position. When the carriage is moved or the
ladder is hoisted, the cutter radius increases and therefore the swing angle decreases.

In planning the cut width, a certain extent of cut overlap must be taken into account. During dredging, soil
dropping from the edges—the quantity depending on soil type and cut height—will have to be cleared by
the next cut.

III.11.7 Cut Height

When dredging cohesive soil types, all soil has to be cut. This means that the cut height (or face height)
must always be less than the cutter diameter. If the ladder is lowered at a given swing, the forward slope
will always show a certain curvature. Non-cohesive soils such as sand do not have to be cut completely.
With a cut height greater than the cutter size, the sand on top will come banking down. In addition, the
forward slope will have a certain inclination, depending on the natural properties of the sand. There are a
number of drawbacks attached to dredging a high breach, however. Only small steps forward can be taken,
because the sand banking down after the swing of the cutter must be removed again at the next swing.
However, if the breach is too high, sand will drop behind the cutter where it stays until it is cleared
away later. This is why small steps forward are made and swinging at high speed in order to minimize the
spill behind the cutter.

When the various dredging levels have been determined for cohesive soil, a decision must be made as to
how to handle the underlying layers. Where a spud carriage is used, one step backward may be made after
each stroke so the underlying layers are treated as well for that particular spud position. However, this
method leaves a slope that is so steep it may collapse. Usually preference is given to dredging the topmost
layers for a number of spud carriage lengths and then to step backwards in order to get behind the breach.
Then the underlying layers are treated until one spud carriage length ahead of the top layer remains.
(Figure page 53) This method prevents too much soil remaining untouched. An alternative approach is to
do the top layers until work is done on the anchor position or the floating pipeline, step back and then do
the lowest layer in one or two strokes. The last swing is the cleaning stroke.

Proper planning also involves taking into account the time required for hauling and stepping backwards.
Once a dredging depth has been set, it should be maintained to achieve the objective of cutter dredging: to
obtain a dredging profile at the required depth. The bottom swing can be cut with over depth to take
account of a certain amount of spill and to obtain the depth required. If no over depth can be dredged an
extra finishing and non-productive swing must be made.

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III.11.8 Step size

Step size is defined as the distance between the forward movement at the end of a swing and the start of
the next swing. In principle, the step size should never exceed the size of the cutter head. When a smaller
step is used, only the front part of the cutter is used for cutting. Since the teeth at this part of the cutter are
not ideally aligned, the stepping distance must be accurately set, especially where hard soil is involved.
However, a slightly smaller step offers the benefit of the suction mouth passing the spill another time.
Dredgers equipped with a spud carriage allow step size adjustment during swinging.

III.11.9 Swing speed

At a given cut height and step size, the volume of dredged soil per time unit depends on the swing speed.
This is defined as “cutting production”. The skipper will always try to optimise production while adjusting the
swing speed. However, a high swing speed produces more spill. In case the side winches reach their
maximum load during swinging, the skipper will try to reduce the pulling force by adjusting the cutter speed
or step size.

Layer plan

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 Cutter Suction Dredger

Module IV

Cutter revolutions
(particular csd 500 Damen build)

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IV.1. The cutter revolutions

Introduction The preceding chapters mentioned the cutter revolutions frequently. This was to gain a better
understanding of the cutting process of the cutter. In practice you can divide the cutter revolutions into two
groups, whereby you work with a constant revolution speed:

a. For soft, non-cohesive soil types generally 18 to 22 rpm is used for working.

IV.2. Influence of cutting force In chapters before we acquired knowledge about the cutter characteristic
and loosening the ground respectively. Both are closely related to the cutting force of the cutter and mixture
formation. We learned that the revolutions can be controlled from 0 to 30 revolutions per minute.
The cutter drive on the csd 500 is hydraulic.

Torque = force x arm in K Nm

Lower cutter revolutions at equal hauling speed Higher side winch speed at equal cutter
revolutions

The results for the cutter are as follows: Results for the cutter:
a. Increase in cut thickness a. Greater forces on the cutter
b. Greater power generation on cutter b. Higher torque
c. Higher required torque c. Greater power.
d. Constant cutter power

For the side winch: For the side winch:

a. Greater tensile force required a. Increasing cut thickness
b. Higher required torque b. Greater tensile force
c. Greater power required c. Higher torque
d. Increases in power

Notes:
- Winch and cutter demand more power
- A larger area can be processed in the same time as a result of the increased side winch
speed
- More ground is cut loose per time unit, resulting in higher production.

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IV.3. Cutter revolutions and hauling speed as influence on cut thickness

Obviously cut thickness has a function that depends on cutter revolutions and hauling speed. From
chapters before “Sideways hauling” and “Side winch characteristics”, we learned that the hauling speed of
the side winch and its tensile force form a marriage for the production.

If the cut thickness becomes larger, this will require more torque/cutting force, as the demanded torque is
more or less proportional to the cut thickness. In other words, if the cut thickness doubles, the torque also
doubles.

Of course there are exceptions for different soil types, for example:
- In soils which easily cuts, the torque does not increase proportionally
- In clay the torque increases more than proportionally

The cut thickness increases in the situations below:

- If the cutter revolutions are decreased and the hauling speed remains constant.
- If the hauling speed is increased and the cutter revolutions remain constant.

hauling speed V swing

Cut thickness = cutter revolutions x number of cutter blades = n cutter * Cutter blades =

meters/min
rev/min * amount = meters

Example 1: V swing = 20 m/min n cutter = 23 rpm Cutter blades = 5

V swing 20
Cut thickness = n cutter * Cutter blades = 23 * 5 = 0,174 m = 17,4 cm this is an average thickness.

Example 2: V swing = 20 m/min n cutter = 40 rpm for rock, Cutter blades is 6.

V swing 20
Cut thickness = n cutter * Cutter blades = 40 * 6 = 0,085 m = 8,5 cm this is an average thickness.

Cut thickness = 20 = 0.085 m = 8.5 cm rock

40 x 6

The cut thickness above is average, as it goes from nothing to maximum; see the drawing below.

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Page 56 van 73
IV.4. Influence on side winch load

This subject was already treated in depth in chapters before respectively, "Loosening the ground" and
"Influences of overcutting and undercutting cutter”.
In summary: A higher cutter torque also requires more side winch torque (tensile force). After all, if the force
on the cutter doubles, the side winch tensile force must more or less double to push the cutter against the
bank.
The calculation example in chapter 4.4.6 shows a maximum cutting force of the cutter of 57 ton at 40
revolutions per minute. That means that the tensile force of the side winch also has to meet this value, only
if the side wire is at an angle of 90 degrees with the cutter ladder.
Increasing revolutions of the cutter always result in smaller side wire load.
As discussed before, the side winch tensile forces occurring are continually changing. Generally the angle
mentioned of 90 degrees is larger or smaller. This comes from the cutter suction dredger continually being
hauled from port to starboard and back again. In other words, the side wires always have to be pulled
harder than the forces that are exerted on the cutter.
As illustrated on page 26 with anchor positions and interaction of forces, it is of the utmost importance that
the anchors are shifted on time.

Influence on spillage:

- Overcutting cutter causes a lot of spillage

- Undercutting cutter by contrast does not
- High rpm causes a lot of spillage
- Low rpm by contrast does not
- Mixture formation with an overcutting cutter is far from sufficient, causes a lot of spillage, 40-50%
- Mixture formation with undercutting cutter is close to optimum and causes little spillage, only 10-
15%
- By working with excessively high face heights

This will be discussed further in the chapter “Influence of the cutter cycle on production". This is one of the
most important aspects for reducing this. A lot of cutter power is exerted, with the necessary wear
especially in the harder soil types, with the negative result that about 30% spillage remains in the dredged
area. Note: On the basis of the chapter “Optimization” we will attempt to find a solution to this.

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 Cutter Suction Dredger

Module V

Basic Dredging Dredge pump and hydraulic transport

(particular csd 500 Damen build)

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 V. DREDGE PUMPS

V.1 INTRODUCTION

This part of the course deals with the theoretical aspects of determining the pump production and the
energy consumption for transportation of soil water mixtures. The units used in this course are in
accordance with the Système International (SI).

Common used SI units;

b: Width m
D d: Diameter m
F: Force Newton (N), kgm/s2
g: Gravity m/s2
h: Height m
l: Length m
m: Mass kg
p: Pressure kg/(ms2), N/m2, Pascal (Pa)
P: Power W
Q q: Flow m3/s
ρ (rho): Density kg/m3
u, v, w, c: Velocity m/s
T: Torque Nm
rpm: Pump/Motor speed revolutions per minute
V: Volume m3

Common used decimal prefix (SI);

µ (mu) micro 10-6
m milli 10-3
k kilo 10³
M mega 10 6
G giga 10 9

However the following units for pressure are often used in the dredging world and are calculated with the
gravity on earth (9.81 m/s2) ≈ 10 m/s2).
1 N/m2 = 1 Pa
1 bar = 9.8 ⋅ 1 104 = 98,000 ≈ 100 kPa
1 mwc (meter water column) = 9.8 kPa ≈ 10 kPa (clear water)
76 cm Hg (Mercury) column = 98 ≈ 100 kPa

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Centrifugal pumps are applied in the dredging industry for various purposes. Different types of pumps are
produced to perform these functions. For the sake of clarity, we will classify the pumps according to the
differences in:

- application
- construction

Application:

A dredge pump is used for the transport of a mixture of water and dredged materials.

The centrifugal dredge pump provides a large number of advantages, such as:

- Continuous fluid flow rate.

- A minimum of moving parts, which makes it possible to pump solid particles.
- They are relative cheap, compact and can pump large quantities

The major disadvantage is that they are not self-priming.

This means that the pump must always be filled with water and thus be placed.

The most important differences between the centrifugal water pump and the centrifugal dredge pump are:

- A larger flow cross-section, with no narrowing. The smallest flow cross-section is located at
the suction side.
- In connection with achieving as large a flow cross-section as possible, the number of vanes
is reduced to a minimum. This is despite the fact that many vanes are required for a good
pump efficiency.
- The pump housing has a wider passage.
- In view of wear, the components are easy to replace.
- Robust construction.

The selection of the type of dredge pump is extremely important, and is determined by the expected
working conditions.

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These conditions are:

- The type of medium that must be pumped

- The service life and wear resistance of the pump.
- The depth at which the material needs to be pumped.
- The pumping distance.
- The required efficiency.
- The production per hour.
- The allowable variation in production caused by variations in the mixture to be pumped and
the dredging depth.

A number of different types of dredge pumps are produced nowadays, largely as the result of improved
dredging techniques. These pumps are characterized by high efficiencies (80 –90%) at different flow rates,
a long service life and good wear resistance. The pumps have a wide range of applications and are
available with pressures of up to 1.4 MPa.

V.1 History:

Originally, dredge pumps were of riveted, plate-iron construction. The pump was built entirely from
rectangular plates and wear plates, to make it easy to replace the worn components. The open-type
impeller had a small number of vanes (3 - 4), which were furthermore flat. The efficiency of this pump was
extremely low.

Impellers with curved vanes were a later development, and this was followed by so-called closed impellers
with a front and rear shroud. Cast pump housings, covers, impellers and other components were
introduced during the same period. As a result of these developments, together with research,
measurements and improved production methods, the fluid mechanical design became much better. The
efficiency and other properties of the pump, such as the maximum delivery pressure and the normative
vacuum, also increased and the wear behavior improved.

These factors expanded the application range considerably.

The dredging depth became greater and greater and the pumping distance longer and longer. The pumps
were mounted on ladders and placed under water to dredge at even greater depths. The rubberized pump
housing and the plastic-coated pump housing then came into use for some time.

After this, the so-called “wear resist pumps” cast in high-alloyed steel came onto the market. These pumps
were overtaken by the more universal, double-walled pumps, in which wear housings of high-alloyed cast
iron can be placed.

Various types of pumps were produced with suction diameters of 200 - 1400 mm, in the following designs:

- Single-walled dredge pump.

- Double-walled dredge pump.
- Underwater pump.

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V.2 The single-walled dredge pump:

In a dredge pump, it is
important that the
construction allows a large
flow cross-section for the
dredged materials, as is the
case in the model above.
Another characteristic of the
single-walled pump is its
simplicity. The pumps are
accessible and easy to
disassemble for inspection
and maintenance.

This is shown in the above

assembly drawing of a Damen dredge pump.

Pump housing and bearing block

The pump housing is constructed from a

single-piece and is securely attached to
the pedestal at the shaft cover.

The pedestal is welded in the standard

construction. The pedestal contains the
pump shaft bearing, consisting of two
radial spherical roller bearings and one
spherical roller thrust bearing. A turning
device is also frequently installed here.

The cast pump housings can be

manufactured from any type of steel:
from low-alloyed Si.Mn. steel to
extremely hard, wear-resistant Maxidur
and Nihard cast-iron alloys.

The harder varieties of cast iron

possess less elasticity than the cast
steel, and there is therefore more risk of
cracks forming.
For this reason, the harder types of steel
are mainly applied for the internal pump
in double-walled pumps where the inner
housing does hot withstand any
pressure.

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In some cases, the pump housing is coated with rubber or plastic instead of cast steel or hard steel.
Rubber has a high wear resistance for clean sand mixtures but is easily damaged by scratches and cuts
when coarse material is pumped. Rubber has the further disadvantage that it causes more environmental
impact when it becomes necessary to dispose of the pump component.

V.3 Impellers

The impeller is of the closed type and is often fitted with 3 to 5 vanes. The
choice of the number of vanes depends on the material to be pumped and
the associated flow passage of the pump and the pump efficiency.

In the older and small types of dredge pumps, the impeller is often secured
to the pump shaft with a cone and key. In larger pumps, the impeller hub
has an internal trapezoidal thread and is screwed onto the pump shaft.

To improve the suction and flow properties, the vanes are sometimes
allowed to continue farther into the inlet opening and have double curvature
of the vanes. The disadvantage of this is that it limits the flow passage, and
the impeller becomes a kind of catcher for dirt and stones. In general, a
compromise must be reached between optimal vane design and maximum
flow passage. In the event of a limited flow passage, the continuous vanes
are sometimes cropped off. The part of the vane that lies horizontally on the
suction diameter and along the shaft shielding is usually cut away.

The same factors apply to the impeller material as to the pump housing material. But with regard to
impellers, fracture is a greater consideration. Rubberized impellers also occur, but only in the smaller types
of dredge pump.

On some impellers, the exterior of the shrouds are equipped with so-called contra vanes. These are fitted
to compensate for the backflow of the water/ sand mixture between shroud and pump house as the vanes
provide some pump action. Backflow is a major cause of wear in the pump’s impeller and cover. The gap
between the impeller shrouds and the pump’s suction and shaft covers must be as small as possible but
especially at suction side.

V.4 The expansion piece or inspection piece

The smallest flow passage in the dredge pump is located at the

inlet side of the impeller. The pump is easily accessible here,
which makes it simple to remove dirt and other contaminants that
has caused a blockage. This is done by opening the inspection
cover of the expansion piece, which is located at the suction side
of the pump, in front of the suction cover. Nowadays, the
expansion piece is often of a construction that enables it to be
removed very quickly. The inspection cover is therefore only
used for quick inspections and the controlled emptying of the
pump and associated pipe section. It is necessary to remove
the entire expansion piece from the pipe to carry out other tasks,

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such as the removal of dirt, small welding repairs when welding
on wear spots in the volute of the pump housing or to the
impeller, and more detailed inspections. The purpose of the
expansion piece is to give space for the mounting and
dismounting of the suction cover, the impeller and the pump
housing.

The length of the expansion piece is determined by this

dismounting requirement.

The dismounting and mounting of the impeller usually requires

the most space, due to the impeller hub, which sticks out
towards the shaft side, and the impeller hook: the dismounting
tool that sticks out towards the suction side. There must be
sufficient space for the impeller to pass the pump housing.

This csd 500 is equipped with a suction line

under the expansion piece to remove remaining
water from the suction pipe in order to avoid
contact with contaminated water from the pit
when inspecting the pump.

V.5 The pump covers

The pump housing is closed off at both ends with covers. The cover at the suction side – known as the
suction or front cover – should be removed when performing an inspection or replacing the impeller, wear
rings or wear plates.

The so-called shaft or rear cover is located at the shaft side. The shaft cover is securely fastened to the
pedestal and acts primarily as a foundation for the pump housing.

The material from which the pump covers are manufactured is important. In the event of large pressure
changes, caused by e.g. water hammer or vacuum shocks, high forces will be exerted on the surface of the
covers. For this reason, the pump covers are made from a material with good elasticity .

Backflow of the sand / water mixture causes considerable wear. At the suction side, this leads to excessive
wear of the wear plates and rings in particular. It also results in a permanent loss of efficiency, due to the
connection between the suction and delivery sides. Sand mixture at the shaft side causes wear of the shaft
seal. The pump shaft seal then will start to leaking therefore it is of the utmost importance to inspect the oil
levels at tanks placed at the back of the dredge pump.

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V.6 Damen Dredge pump

The dredge pump is placed in the main pontoon. It is coupled by a gear coupling to a gearbox with clutch.
The gearbox is coupled with a flexible coupling to the dredge pump engine. The dredge pump is mounted
on an epoxy filling to the foundation.

Make : Damen Dredging Equipment

Type : BP5045
Suction diameter : 500 mm
Discharge diameter : 450 mm

Impeller diameter : 1175 mm

Width of the impeller : 270 mm
Number of blades : 4
Spherical passage : 230 mm

Wear parts material : CW280 (A49)

The impeller is of a closed, high efficiency type with double curved vanes and is secured on the impeller
shaft by means of screw thread. Mounting and dismounting can easily be done through the 3-piece ring
construction.

The impeller shaft made of forged steel 42CrMo4 is fitted with 2 radial and 1 axial oil bath spherical roller
bearing. The oil of the pump shaft bearing is cooled by means of an oil cooler.

The impeller shaft is sealed by means of a mechanical seal, so no gland water nor grease supply is
necessary.

The impeller shaft is provided with a hand operated turning device. All pump parts are replaceable. A
hoisting tool for easy and safely changing of wearing parts is delivered with the pump.

V.7 The pump seal

A countless number of constructions have been applied over the years to seal the pump shaft. This seal
must prevent the mixture from flowing along the shaft at the passage through the pump cover as a result of
the higher pressure in the pump housing. This flow causes excessive wear of the pump shaft and in the
gap between the impeller shroud and the shaft side wear plate.

Damen dredge pumps are equipped with a mechanical seal which consists of a rotor (a ring that rotates
with the shaft) and a stator (a stationary ring mounted in the housing).

The mechanical seal is lubricated with oil and also flushed

with water. A spring, mounted behind the rotor, minimizes
the axial play between both rings. The major advantage of
this type of seal is that it is extremely reliable. The shaft
movements do not affect the seal. Refer to the following
figure.

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V.8 Maintenance of a single-walled dredge pump:

This paragraph gives a brief overview of the maintenance to be performed on a dredge pump. The example
we have used is a single-walled dredge pump Other pump types may be different. Refer to the on-board
drawings and instructions. It is very important that the person who performs the maintenance is familiar with
the construction of the dredge pump and with the instructions for handling all parts. This is to avoid risks
and accidents.

V.9 PUMP DRIVE

Diesel engine: Engine

The most common power source on a cutter dredger is the
diesel engine. In addition to the diesel engine, the electric
motor and the hydraulic motor are used as well. The diesel
engine can be used to directly or indirectly drive the pumps of
the pump installation.

Direct drive:
Direct drive means that the pump is driven by the diesel
engine through a shaft.
To reach the desired rpm, a (in some cases controlled)
gearbox may be included.

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V.10 Pump system

Any dredging system working on the hydraulic principle, means that it uses water as a transport medium,
has an intake side and a discharge side. Both sides are connected with pipes and in-between there is the
dredge pump. The pump generates the driving power of the whole dredging system. It causes a flow of
water (with sediments in it) to enter the suction pipe and to pass through the suction pipe, the pump and the
discharge pipe into a floating pipeline.

The pump is the heart of the dredge and the:

 pumping process should be continuous; once the flow starts it must continue smoothly and within
the limits of the pump characteristic;

 suction capacity must be adequate to bring the required capacity up from the bottom into the pump;

 discharge capacity must also be adequate to bring this bottom material in the water flow from the
pump into the discharge pipe of the CSD;

For this process the centrifugal pump is the most suitable tool. Centrifugal-type dredge pumps are, in many
varieties and versions, almost exclusively applied in dredges. The word centrifugal is used to describe the
method in which the impeller in the pump transfers its driving force into the flow. The centrifugal force
causes a body of water rotating in the pump to be thrown away from that centre.

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V.11 IMPORTANT PROPERTIES OF FLUIDS

V.11.1 Density

The density of a fluid depends on the temperature and the salinity. Not considering the salinity, water has
its maximum density at a temperature of 4°C. Within the normal temperature range of soil water mixtures
the dredges are working (5° to 20° Celsius), it is safe to assume that the density of clear water is:
ρw = 1000 kg/m³
V.11.2 Compressibility

Compressibility of fluids under normal circumstances can be neglected and so variation of volume due to
compressibility can be ignored. This is the reason why it is safer to test a pipe system by filling it with water
and putting it under pressure rather than with air. The same phenomenon is reason for the damage that
water hammer can cause if sudden changes in flow velocity occur.

V.11.3 Pressure

The symbol for pressure indicating is p.

The unit for pressure is N/m² also called Pascal (Pa).
In the dredging world they are using “bar” and sometimes the unit “m.w.c.”(meters water column.
1 bar – 100.000 N/m² or 105 N/m².
The atmospheric pressure is about 1 bar.
In this paper the pressure is always the absolute pressure.
The manometer indicates an overpressure.
A manometer indicates zero when de atmospheric pressure is 1 bar.

Example 1
The atmospheric pressure is one bar. A manometer gives a reading of 0 bar.

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Example 2
If there is an absolute vacuum of 100 % , the absolute pressure is 0 bar and the manometer reading is –1
bar or 100 % vacuum.

V.11.3.1 Hydrostatic pressure

No frictional tension is exercised on dead water, only normal pressure is acting. This is called hydrostatic
pressure. The pressure at a certain depth in a reservoir depends on the weight of the mixture column
above that plane in the reservoir. The atmospheric pressure is normally disregarded so pressure is
indicated relative to the atmospheric pressure

Weight of the column of water on the plane dA is:

dG = ρw.* g * h * dA, (N)
G = m⋅g
h = water depth (m)
g is acceleration of gravity ( 9,81) (m/s²)
ρ is the density of the liquid
The water pressure at the level of A is:
dG
p = dA = ρw * g * h (Pa)

According to the model of Pascal in stationary water

only normal pressures act, this means that pressure in a
fluid is equally strong in all directions. An application is
the gauge-glass: the pressure at the connection point is
equal to the pressure in the fluid in the gauge.
The pressure due to the water column ha. is equal to the
pressure in point B

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