How To Build Greener Hopper Dredges - final

How To Build The Next Generation of Greener

Hopper Dredges

Vinton Bossert, P.E.Stephen WrightEthan Wiseman

Presentation for:IMarEST

New York, NY

November 2015

How To Build Greener Hopper Dredges

Dredging Efficiency (Hopper Dredge Design 101)►Least Cost vs. Maximum Production

YD3

How To Build Greener Hopper DredgesDredging Efficiency

►Least Cost• Most Efficient Hull• Most Efficient Propulsion System• Most Efficient Pumping System• Crew Size Matched to Automation• Least First Cost• Least Maintenance


Dredging Efficiency ►Maximum Production

• Largest Hopper• Most Maneuverable• Highest Density Excavation• Most Efficient Hopper Loading• Fastest Loaded Speed to Disposal Site• Fastest Unloading• Fastest Speed Returning Empty


Best Available Technologies (BAT) Today• Hull Technologies• Dredging Technologies• Machinery Technologies

How To Build Greener Hopper DredgesHull Technologies

• Minimum Lightship Weight• Maximize Hopper Size for Hull

Envelope • Reduced Freeboard Loadline• Hydrodynamic Improvements

Around Recessed Hopper Doors & Propulsion

• Balanced Trim Without Ballast• Better Maneuverability – Z-Drive

Propulsion

Maximize Hopper Size for Hull Envelope LtWt + Dwt = Disp

Every lb Steel = lb Sand Cannot Carry

Older

Newer

Maximize Hopper Size for Hull Envelope Less Sloping Plate Larger Hopper Doors

2012 Hopper Plan

How To Build Greener Hopper DredgesBetter Maneuverability – Z-Drive Propulsion

Drawing from Thrustmaster of Texas

How To Build Greener Hopper DredgesMachinery

• Least Weight, Lowest Cost• Tier IV Engines• CFD Analysis To Optimize Propulsion• Shared Power Systems• Environmentally Acceptable Fluids

How To Build Greener Hopper Dredges• CFD Analysis


• Shared Power Systems – Optimum Engine Loading

Diesel-Electric - PMS Flexible Arrangement – wt, trim, cargo Main Engine Powered Pumps &

Generators with CRPP Ease of Construction - modular DC Technology – Optimum BSFC Hybrid Energy Storage Systems Cold Ironing Dual Fuel – LNG/CNG

Diesel-Electric Plant


• DC Grid• No Synchronization of Generators• Minimize Harmonics• Gen RPM Matched to Load

How To Build Greener Hopper DredgesMachinery ►Power Management System:

• Optimize number of generators and feeds connected to the bus relative to fuel efficiency and provide a sufficient reserve capacity of power based on user defined presets.

• Provide proportional load sharing in a symmetrical & asymmetrical plant configurations.

• Automatically manage Large Loads• Automatically control Load Shedding.• Automatically Restart Engines Generator/or Storage to restore

power following a Black Out Condition.• Automatically provide Load Limiting integral to the CPP system.

How To Build Greener Hopper DredgesMachinery ► Dual Fuel – LNG/CNG:

• No Urea Injection, No Sulfer, No Particulates• U.S. Reserves are Huge• Significant Op Cost Savings - Increase as Oil Price Rises

Broader Applications for Hybrid Power System

• Permanent Magnet Motors: Smaller and Lighter compared to Induction Motors and Alternator.• Further Improves Efficiency Difference between DE and

Conventional system• Battery Banks: Battery banks provide Peak Shaving, so

Generator Power managed more efficiently.


• Environmentally Acceptable Fluids Water Fluid Power Applications

Hopper Door Operators Hydraulically Operated Valves Draghead Davits/Swell

Compensators Draghead Visor Actuators CPP Servo System

Engine Coolants Lubricants

How To Build Greener Hopper DredgesDredging

• New Dredge Pumps• Over-The-Bow Pumpout Systems• Shallow Draft• Active Dragheads• Large Hopper Doors• Automated Dredging Process Control

VOSTA LMG Bow Coupling


Dredging • New Dredge Pumps

• High Efficiency > 87%• Better Wear Characteristics

• Hi Chrome White Iron• Diverter Technology

• Better Suction (NPSH) Characteristics (skewed vanes)


Dredging • New Dredge Pumps


• Active Dragheads More Pump NPSH is available for

Density Jet-assisted Excavating Teeth Adjustable Visor

IHC’s Wild Dragon® Draghead

VOSTA LMG Draghead


• Automated Dredging Process Control Free Up Officers to Optimize Operations Operate 24-7 Without Fatigue – One Man Bridge Algorithms Continuously Learn/Adjust/Improve -

Maximize Production without Plugging Pipeline Variable Hopper Fill Rate Reduces Overflow Losses Replacement Every 7-10 Years

Automation• Highest Efficiency Gains Optimize

Interrelationship of Propulsion, Draghead Visor, and Dredge Pump Speed

Water Hydraulic Systems

Water Hydraulic Technical Considerations

• Design Approach – Typically lapped spool type designs; Internal Leakage is part of design; rely on internal leakage for lubrication

• Practical Realities – Plunger floats; minimal metal to metal contact, no requirement for high strength/anti corrosive materials

• Physics – Oil allows for higher pressure drops and higher velocities, creating smaller components, but at a price of energy loss

• Economic Impact – Manufactured in volume, price points relatively low given large market size (several $Billion per year)

• Design Approach – Zero Leakage – internal leakage damages base materials; water is a cutting agent at high pressure and velocity. Avoidance of internal leakage is key to success

• Practical Realities – Given zero leak requirement, most valves use ‘soft’ packers; lack of lubricity and difficult application environment often requires high strength, more exotic materials such as stainless

• Physics – Water does not compress, makes it more efficient to pump; zero leakage makes it more energy efficient

• Economic Impact – Manufactured in low quantity, price points higher, much smaller market ($100 M)

Oil Hydraulics Water Hydraulics

Zero Leakage – Environmentally Friendly – Higher Efficiency – Lower Total Cost of Ownership

Water Hydraulic Fluid Additives

• Purpose - Many Biodegradable additives aid the use of water as a hydraulic fluid. Water is limited in its ability to lubricate (low viscosity). It also can be a media for biological growth, and it freezes at a relatively high temp.

• Corrosion Control – Synthetic additives bond to the internals of the system and prohibit or slow corrosion

• Algae Control – Algaecides mix with the fluid and prevent growth of biologics which can degrade system performance

• Lubricity Assistance – Other additives are design to add lubricity to the fluid making it slippery and enhancing life of components

• Freezing Control - Additives such as Propylene glycol (FDA approved food additive) lower the freezing temperature of the water

Additives Serve Many Purposes

Initial Cost - Water Hydraulics vs Oil Hydraulics

Fluid Cost - Water Hydraulics vs Oil Hydraulics

Description Tank Volume

EAL Cost WH Cost

Reservoir 350 Gal $13,300 $350

Storage Tank 2000 Gal $76,000 $0

Fluid Makeup $38/Gal $1/gal

Fluid Contamination

350 Gal $13,300 $350

Notes:• Water Hydraulics is filled directly from potable water

system.• No clean up cost or fines associated with Water Hydraulics.• No storage or handling costs for Water Hydraulics.

Filling the Hopper

ViewVideo

View Video

Emptying the Hoppers

Dredge MURDEN’s Water Hydraulic System

How To Build Greener Hopper DredgesEliminate Inefficiency

• Wasted Fuel• Environmental Impacts • Personal Injuries• Unnecessary Exhaust Aftertreatments• Unnecessary Fines• Over-crewed Vessels• Antiquated Practices• Legacy Equipment

DISCUSSION & QUESTIONSContact Information:

Vinton BossertPresident – Bossert Dredge Consulting

[email protected](302) 740-1841

Stephen WrightPartner – SanSailTEC, LLC


Ethan WisemanNaval Architect & Marine Engineer


mailto:[email protected]



How To Build Greener Hopper Dredges - final

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