|
Specifications and Features Of The 8
Inch Dredge Norma Lee
1) Designed And Built By Dredging
Specialists In 1979. Has completed over 150 projects in 22 states.
2) Rebuilt In 2007: New main
pontoons, new side pontoons, new ladder, new ladder mounting, new A
frame, new hoist winch, all four hydraulic pumps were rebuilt, new swing
winch proportional speed control valve with electronic potentiometer
speed control, new bearings in swing winches, rear winch and forward
winch, new bearings and seals in hydraulic pump drive gear box, gears
were like new. All new hydraulic hoses. New hydraulic pipes
and tubing on the ladder. Completely rewired the dredge. New flow
meter for dredge pump discharge. New hydraulic valve and new micro
switches for digging head flip-flop. Replaced one digging head
hydraulic cylinder.
3) Stretched To Dig 26 Feet Deep:
In 2007, thirteen foot long extension pontoons were built and bolted on
the front of the main and side pontoons to provide the flotation needed
to extend the digging depth from 17 feet to 26 feet. The new ladder has
3 sections. The front and rear sections are bolted together to dig 17
feet deep. To dig 26 feet deep, a center section is bolted between the
front and rear sections.
4) Construction. A fabricated
backbone made from 3/4 inch and 1/2 inch plate, is 8 feet wide, 2 feet
high and 1.5 feet front to rear, and provides a strong structure to
mount:
a) The ladder trunnions.
b) The main pontoons, which are welded to
the front of the backbone.
c) The bilge which, is made from 3/16
thick plate and is welded to the rear of the backbone.
The engine and hydraulic system are
mounted in the bilge.
The pontoons are built from 11 gauge plate with baffles every 5 feet,
which provide separate water tight compartments. The internal
reinforcing structure is made from 2 by 2 and 4 by 4 square tubing.
5) Length: In the long
configuration, the dredge is 49 feet long. In the short configuration,
the dredge is 36 feet long.
6) Draft and Freeboard: Pontoons
are 27 inches deep, which provides 9 inches of freeboard and 18 inches
of draft.
7) Side Pontoons Fold Up: The side
pontoons are hinged to the main pontoons and fold up and make the dredge
8 feet wide for trucking and fold down to make the dredge 13-1/2 feet
wide in the water. A crane that is needed to set the dredge from the
trailer into the water is used to fold the side pontoons down.
8) The Weight Of The Dredge is
33,000 pounds in the short configuration and 38,000 pounds in the long
configuration. In the short configuration, the dredge can be hauled on
a step deck trailer and is legal in all respects. In the long
configuration, the dredge is hauled on a double step deck trailer that
has a sliding extendable frame. In the long configuration, an over
length permit is required.
9) Fuel Capacity: Two 155 gallon
tanks, one in each main pontoon. Total capacity 310 gallons, will run
the dredge 6 to 7 days.
10) Engine: Deutz F8L-413-V8, air
cooled diesel engine, rated 220 horsepower.
Advantages of Air Cooled Diesel Engines: Forty percent of all problems
with liquid cooled diesel engines are caused by the cooling system.
Radiators leak, water pumps fail, hoses fail, overheat from loss of
coolant, heads crack, antifreeze gets in the oil, must check and change
the antifreeze, With Deutz air cooled diesels, you have none of these
problems. Without a radiator sticking out in front of the engine, air
cooled engines require less space.
The engine rebuilt in 2002 and has 2,274 hours since rebuilt. Summery
of rebuild:
New Parts: Cylinders, pistons, piston rings, wrist pins, wrist pin
bushings, rod bearings, main bearings, camshaft, camshaft bushings,
valve lifters, exhaust valve guides, exhaust valves, oil pump, bushings
on fuel injector pump drive, all seals and gaskets.
Parts that were checked and found to be in serviceable condition: Intake
valves, intake valve guides, valve springs, valve seats, ball bearings
on the fuel injector and blower drives, rocker arms, rocker arm pivot
pins, push rods, injectors.
Reconditioned Parts: Grind valve seats, grind intake valves, grind
rocker arms where they pivot on the valves.
Engine Automatic Shut Down Protection: The engine will stop if it
overheats for any reason. The engine will stop if more than five
gallons of hydraulic oil is lost from the hydraulic reservoir. This
limits pollution and saves hydraulic oil.
11) Underwater Dredge Pump:
Designed and built by Dredging Specialists. Has a 21 inch, three vane
impeller, with twisted vanes. 12 inch inlet and 8 inch outlet. RPM
1100.
Flow rate, 2,200 gallons per minute, at 120 feet of head. Has a
mechanical face type seal and a service water pump that provides clean
water that flushes the seal for extended life. Will pass a
6 inch spherical solid. Has a 3 inch diameter shaft with Timken tapered
bearings. We have never broken the pump shaft. Has two 5 feet long
walkways that fold down, one on each side of the dredge pump. The
walkways permit servicing the digging head and dredge pump without
getting in a boat.
On a recent project for the City of Philadelphia, PA, we dredged 300,000
cubic yards of river mud. We averaged 204 cubic yards per pumping hour
on a 1,500 foot pipeline. We averaged 29.3% insitu solids.
Why an Underwater Dredge Pump? Decomposing organic material
causes gas to form in most industrial and municipal sludge as well as
river and lake mud. When an above water dredge pump is used, the high
vacuum needed to move the material up the suction pipe will cause the
gas bubbles to expand, fill the pump with air and the pump will stop
pumping. This is called cavitation. When an underwater pump is used,
there is no suction pipe and the head of fluid above the pump provides
.4 pounds of supercharge pressure per foot of submergence. Thus, less
vacuum is needed to get the material into the pump. Thus, the gas
bubbles do not expand as much and there is much less cavitation. With
an underwater pump, you do not have to prime it as you do with an above
water pump.
12) Digging Head: Dredging
Specialists Design 8 head. Click
here to see a picture.
Provides a cut that is 3 feet wide by 1.5 feet high. Cutting force is
greater than a loader bucket on a Case backhoe loader tractor. Two
hydraulic cylinders flip-flop the head for left or right cuts. The
ladder has a four bar linkage which keeps the cutting edge of the
digging head, flat on the bottom, regardless of the depth at which the
dredge is digging.
13) Sampler Valve: Hydraulically
opened and closed from the cab. Permits the operator to see what he is
pumping and recover samples.
14) Dredging Specialists Exclusive 4
Cable Positioning And Swing System: It is common knowledge in the
marine industry, that to hold a vessel in a fixed position, at least
three anchors are required. An analogue is a chair. To be stable, a
chair must have at least three legs. Four legs work well and are
commonly used. A chair with two legs is unstable and only a fool would
make a chair with two legs. However, the folks that make auger dredges,
only use two anchor points on the dredge. This is like a chair with two
legs. An auger dredge is easily pushed out of the cut by the wind, and
also when there is material on one side and water on the other side of
the dredge. When these forces push an auger dredge out of the cut, it
pumps water and there is no means on the dredge to get it back in the
cut. The only solution is to move the dredge where there will be
material on both sides of the cut at all depths. This leaves a ridge of
material between each cut.
The dredge, Norma Lee, uses a four cable system which is like a chair
with four legs. Click
here
to see a drawing of the four cable system. The dredge is
accurately positioned to keep the dredge pump suction in the material.
The dredge is accurately and continuously moved by the swing winches,
explained below, which maintain the pump suction in material. The Norma
Lee is the only dredge of its size, which will swing a continuous arc of
350 feet. This means less water is pumped because there are fewer stops
and changes in direction. This means greater production. With the
winches on the dredge, the Norma Lee can be placed anywhere in a
rectangle 350 feet by 130 feet. It can be easily and quickly backed up
to make cleanup cuts. It can be quickly moved to shore for fuel or
repairs.
When you come to our shop to see the dredge, I will demonstrate our four
cable system and you will clearly see the advantages it has over an
auger dredge or a 3 cable system.
15) Hydraulic System And Winches:
All the functions of the dredge are hydraulic powered. Three hydraulic
pumps are mounted on a Funk three pad gear box that is mounted on the
engine flywheel housing. The reservoir holds 110 gallons of oil and is
3/4 submerged for cooling.
a) Dredge Pump Drive: Closed loop
hydrostatic transmission using a Denison P6P Cold Cup axial piston pump
and a Rexroth 15 cubic inch per revolution bent axis piston motor.
b) Hoist Winch. Bloom 1400 series,
hydraulic powered, worm drive, with a spring applied hydraulic released
brake. Denison vane pump. Maximum line pull 15,000 pounds. Will hoist
the ladder from 26 feet in less than 30 seconds. Has Dredging
Specialists exclusive Bird Nest Eliminator which prevents tangled
cable. Click
here to see an example
of a Bird Nest Eliminator.
c) Swing Winches: Has one for left
swing and one for right swing. Designed and built by Dredging
Specialists. Cessna, load sensing axial piston pump with Parker low
speed high torque motors. Eskridge spring applied hydraulic released
brakes on each winch. Drum holds 350 feet of 3/8 cable. Swing speed
variable from 0 to 150 feet per minute. Maximum line pull 3800 pounds.
Both winches have Dredging Specialists exclusive Bird Nest Eliminator,
which prevents tangled cable.
To swing left, move the left swing lever to the detent position, it will
lock in. The left swing winch will wind in and the cable on the right
swing winch will be pulled off with an adjustable tension. The swing
speed is adjusted with a potentiometer.
d) Forward Winch Called The Lock Winch:
Bloom hydraulic powered worm drive. Holds 130 feet of 3/8 cable. Line
speed up to 100 feet per minute. Line pull up to 8,000 pounds. Has a
dog clutch that permits free spooling.
In the cut being made, this winch is locked and the cable cannot wind
in or out. The swing winches cause the dredge to swing on the arc made
by the distance from the dredge to the forward anchor on the shore.
When the cut is completed, this winch is used to move the dredge
forward for the next cut, or back for cleanup. Has Dredging Specialists
exclusive encoder that permits the operator to see the distance he is
moving forward. Click
here to see a picture
of the encoder.
e) Rear Winch Called The Rubber Band
Winch: Built by Dredging Specialists. Has a Char-Lynn low speed
high torque motor, with hydraulic released spring applied brake. A dog
clutch provides free spooling.
This winch is always trying to wind in with an adjustable tension. When
the load on the cable is greater than the setting, the winch winds out.
When the tension on the cable is less than the tension setting, the
cable winds in. This permits the cable length, from the dredge to the
shore anchor, to change as the dredge swings. It provides a constant
tension on the rear cable and also the forward cable. With constant
tension on the forward and rear cables, as well as tension on both swing
cables, as explained in item 15-c, the cabling system holds the dredge
pump suction pipe in material, at all times, as the dredge swings.
16) Hydraulic System Filtration:
Three micron, full flow filters, with a Beta ratio greater then 200,
provides filtration to ISO 18-15-11. This provides double the life of
hydraulic components compared to other dredges. New oil is not clean
enough to be used in a hydraulic system. When adding oil, it is common
for sand and other debris to fall from the lip of a five gallon can into
the reservoir. To clean new oil and eliminate sand and other debris
from entering the reservoir, all oil entering the reservoir is pumped in
through a 3 micron filter. The hydraulic reservoir has a Greer clean
vent. The clean vent does not permit outside air to enter the reservoir
as it breathes, from the oil heating and cooling. This prevents
condensation in the reservoir, which leads to water in the oil, which
substantially shortens the life of the oil and the hydraulic
components. The combination of fine filtration, filtering all makeup
oil and the clean vent will more than triple the life of the oil and the
hydraulic components, compared to other dredges. Long oil and long
hydraulic component life will lower your repair expense, increase your
production and income by many thousands of dollars.
17) Fuel Efficiency: With the price
of diesel fuel today, fuel efficiency is a most important
consideration. By using a high efficiency piston pump and a piston
motor for the dredge pump drive, along with a load sensing piston pump
for the swing winches, fuel efficiency is better than dredges that use
open center gear pumps.
On a 300,000 yard project, pumping 1500 feet, production was 27 cubic
yards per gallon of diesel fuel. At a cost of $4.00 per gallon, the
cost per yard for fuel was $0.15.
18) Booster Pump and Barge: The
pump was designed and built by Dredging Specialists. 10 inch inlet and
10 inch outlet. 2000 gpm at 110 feet of head. Powered by a Deutz BF6L
913 six cylinder air cooled diesel engine rated 150 horsepower. Skid
mounted for ease of placement on the shore or on the barge.
a) Engine Overhauled in 2003. Hours
since overhaul 1,545. Overhaul summery:
New Parts: One new cylinder and piston, rings, rod bearings, main
bearings, exhaust valve guides. All other parts within specifications.
Ground valves and seats, honed cylinders, rebuilt belt tightener, and
rebuilt the injectors. Installed Donaldson 6 micron filter.
b) Rebuilt the Pump: June of 2008,
0 hours since rebuilt. Installed new wear plates in the suction inlet.
Hard faced the case as needed. Rebuilt and balanced the impeller.
Installed a new seal.
c) Booster Pump Barge: Main barge
is 16 feet long, 8 feet wide and 2 feet high. Made from 11 gauge plate
with internal reinforcement and baffles to support the booster pump.
Has three water tight compartments. The center compartment is a 500
gallon fuel tank. Side pontoons are 16 feet long, 2 feet wide and 2
feet high. Made from 11 gauge plate with internal reinforcement and a
baffle that makes two watertight compartments. Side pontoons bolt to
the main barge and are removed for trucking. Draft is 10 inches with 14
inches of freeboard.
The booster pump barge is attached to the dredge using pintle hooks, [Pintle
hooks are used to pull a trailer] and two steel tubing linkage bars.
This provides flexibility between the dredge and the booster barge. A
walkway permits walking from the dredge to the booster barge.
19) Handrail: Has Dredging
Specialists exclusive user friendly handrail on the dredge and booster
pump barge. Provides entry to the dredge or booster barge at any
location at any time. Click
here to see a picture
of the handrail. Once you use it, you will love it.
20) Equipment To Make A Complete
Dredging Plant.
a) 10 Inch Pipe: 4,800 feet of 10
inch aluminum pipe in 30 feet lengths.. Rated 200 psi. Floats that
will make 525 feet of floating pipeline. A 4 length of rubber hose
goes between each 30 foot floating pipe and provides a flexible floating
pipeline. Gaskets and quick coupling clamps, couple the pipe together.
Fourteen 90, 60, and 30 degree elbows.
b) 12 inch pipe: 1,525 feet of 12
inch aluminum pipe in 30 foot lengths. Rated 150 psi. Floats to make
600 feet of floating pipeline. A 6 length of rubber hose goes between
each 30 foot floating pipe and provides a flexible floating pipeline.
Victaulic clamps and gaskets are used to couple the pipes together and
make a leak free pipeline. Two 90 degree steel elbows, one steel tee,
one 90 degree aluminum elbow.
The Reasons We Use Aluminum Pipe: Lightweight, two men can easily carry
a 30 foot pipe. Easily and quickly laid out and coupled together using
common tools. Easily banded together for loading and shipping. 2,200
feet per truck load.
We have used aluminum pipe for over 30 years. We have 10 inch pipe that
is over 30 years old and still in service. We have 12 inch pipe that
has pumped 850,000 cubic yards of river mud that contained 42,000 yards
of sand, and 8,500 yards of gravel and rocks, up to 6 inches and the
wear was .013.
c) Cable: Comes with 5,000 feet of
new 3/8 inch cable. Comes with two Dredging Specialists exclusive cable
stands. These stands can be placed on sloping ground and the shaft, nor
the cable spool, will not slide to the side and dump the spool on the
ground. Stands will hold spools of up to 4,000 feet of 3/8 cable. 4
spool stands with crank handles for cable or rope. Click
here
to see cable stands.
Comes with 500 feet of 1/2 inch Poly rope and 1, 200 feet of 3/8 Poly
rope.
Comes with four Dredging Specialists exclusive cable clamps. These
clamps permit you to dredge a pond or lake, of any length, without
cutting or splicing the front or rear cables that go from the the dredge
to shore anchors.
d) Cable Floats: Comes with six
Dredging Specialists exclusive cable floats. These floats are made from
two 55 gallon drums with a steel frame that holds the cables 5 feet
above the water. They are placed 300 to 500 feet apart on the front or
rear cables. They hold these cables above the water and prevent them
from sinking to the bottom and dragging in the mud, which would inhibit
the dredge when swinging. They are bolted together, come apart, and are
placed in a wooden rack for ease of shipping. Click
here
to see a picture of the floats.
e) Barges: Fuel barge: One 18X
6X 2.5 hopper barge with a 500 gallon fuel tank in the hopper. The
hopper provides spill containment.
One, landing barge: 6.5 X 9.5X 2 Used to tie up work boats at shore.
Comes with a 35 feet long by 3 feet wide bridge that provides a walkway
from the landing barge to the shore. Is ideal when the water level
varies due to tides or rain. The bridge is bolted together and comes
apart for ease of shipping. Click
here to see the
landing barge and bridge.
One utility deck barge. 14 X 6 X 2.
One 300 gallon fuel tank with steel spill containment, used on shore.
f) Tool Boxes & Shipping Boxes:
Two, Knaack steel job boxes, 5 X 2 X 2. One, 3 X 2 X 2 steel tool
box with slide tray that is on the dredge. One, Craftsman 12 drawer
mechanics tool box, with mechanics tools. Mounts on a stand on the
dredge.
Three, steel frame, plywood covered, open top shipping boxes, 8 X 4 X
4. Used to ship pipeline clamps, gaskets, elbows and other items.
g) Anchors: Nine, shore anchor
plates with 25 car axels, which are driven with a sledge hammer through
holes in the anchor plates. Two, heavy anchors for use in the water.
h) Pinch Valves: Three, hand
operated pinch valves for 10 inch hose. One, hydraulically operated
pinch valve for 10 inch hose. Pinch valves are used to pinch hose
together to stop backflow which causes turbidity, and stop backflow to
clean out the booster pump.
i) Work Boats: One, 15 feet long
flat bottom Jon boat with 9.8 HP Nissan electric start outboard motor.
One, 14 feet long flat bottom Jon-boat with 6 HP Mariner outboard motor.
j) Rigging Items:
i)
Assortment of Open Wedge
Sockets. [often called Beckets or wedge blocks] Used to attach a cable
to an anchor plate. Used to attach two cables together.
ii)
Assortment of screw pin
shackles.
iii)
Assortment of cable clamps.
iv)
Two cable grabbers.
v) Assortment of chains with
grab hooks on each end.
k) Spare Parts:
i)
Dredge pump cartridge.
Consists of the impeller, shaft, shaft housing, bearings, and seal. The
cartridge is assembled and can be changed in 2 hours. Seal life
approximately 500 hours.
ii) Two dredge pump seal
assemblies.
iii) Spare motors for swing
winches, forward and rear winches.
iv) Filters for dredge, booster
pump, and hydraulic system.
v)
Solenoids for hydraulic
valves.
vi) Seals
for booster pump.
vii)
Other items too numerous to
list.
l) Tools and Equipment.
i)
Electric tensioning tool for
Bandit banding.
ii) Hand operated tensioning
tools for ½, Ύ and 1 Bandit banding.
iii) Assortment of ½ and Ύ
banding and clips.
iv) Tools to press steel fitting
on the ends of aluminum pipe.
v)
Tools to press steel
fittings in 12 hose.
vi) Tools
to rebuild the dredge pump and booster pump.
vii)
Other tools too numerous to
list.
To inspect the dredge call Don Searles at
217-259-2229
|
