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How To Build Greener Hopper Dredges - final
- 1. How To Build The Next Generation of Greener Hopper Dredges Vinton Bossert, P.E. Stephen Wright Ethan Wiseman Presentation for: IMarEST New York, NY November 2015
- 2. How To Build Greener Hopper Dredges Dredging Efficiency (Hopper Dredge Design 101) Least Cost vs. Maximum Production
- 3. How To Build Greener Hopper Dredges Dredging Efficiency Least Cost Most Efficient Hull Most Efficient Propulsion System Most Efficient Pumping System Crew Size Matched to Automation Least First Cost Least Maintenance
- 4. How To Build Greener Hopper Dredges 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
- 5. How To Build Greener Hopper Dredges Best Available Technologies (BAT) Today Hull Technologies Dredging Technologies Machinery Technologies
- 6. How To Build Greener Hopper Dredges Hull 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
- 7. Maximize Hopper Size for Hull Envelope LtWt + Dwt = Disp Every lb Steel = lb Sand Cannot Carry Older Newer
- 8. Maximize Hopper Size for Hull Envelope Less Sloping Plate Larger Hopper Doors 2012 Hopper Plan
- 9. How To Build Greener Hopper Dredges Better Maneuverability Z-Drive Propulsion Drawing from Thrustmaster of Texas
- 10. How To Build Greener Hopper Dredges Machinery Least Weight, Lowest Cost Tier IV Engines CFD Analysis To Optimize Propulsion Shared Power Systems Environmentally Acceptable Fluids
- 11. How To Build Greener Hopper Dredges Machinery
- 12. How To Build Greener Hopper Dredges CFD Analysis
- 13. How To Build Greener Hopper Dredges Machinery 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
- 15. How To Build Greener Hopper Dredges Machinery DC Grid No Synchronization of Generators Minimize Harmonics Gen RPM Matched to Load
- 16. How To Build Greener Hopper Dredges Machinery 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.
- 17. How To Build Greener Hopper Dredges Machinery 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
- 18. 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.
- 19. How To Build Greener Hopper Dredges Machinery 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
- 20. How To Build Greener Hopper Dredges Dredging New Dredge Pumps Over-The-Bow Pumpout Systems Shallow Draft Active Dragheads Large Hopper Doors Automated Dredging Process Control VOSTA LMG Bow Coupling
- 21. How To Build Greener Hopper Dredges Dredging New Dredge Pumps High Efficiency > 87% Better Wear Characteristics Hi Chrome White Iron Diverter Technology Better Suction (NPSH) Characteristics (skewed vanes)
- 22. How To Build Greener Hopper Dredges Dredging New Dredge Pumps
- 23. How To Build Greener Hopper Dredges Dredging Active Dragheads More Pump NPSH is available for Density Jet-assisted Excavating Teeth Adjustable Visor IHCs Wild Dragon速 Draghead VOSTA LMG Draghead
- 24. How To Build Greener Hopper Dredges Dredging 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
- 25. Automation Highest Efficiency Gains Optimize Interrelationship of Propulsion, Draghead Visor, and Dredge Pump Speed
- 28. 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
- 29. 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
- 30. Initial Cost - Water Hydraulics vs Oil Hydraulics
- 31. 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.
- 34. Dredge MURDENs Water Hydraulic System
- 35. How To Build Greener Hopper Dredges Eliminate Inefficiency Wasted Fuel Environmental Impacts Personal Injuries Unnecessary Exhaust Aftertreatments Unnecessary Fines Over-crewed Vessels Antiquated Practices Legacy Equipment
- 36. DISCUSSION & QUESTIONS Contact Information: Vinton Bossert President Bossert Dredge Consulting vintonbossert@comcast.net (302) 740-1841 Stephen Wright Partner SanSailTEC, LLC swright@sansailtec.com (917) 374-2836 Ethan Wiseman Naval Architect & Marine Engineer ethan.wiseman@gmail.com (516) 640-0554