Dragflow hydraulic dredging pumps on excavator boom

DRAGFLOW HYDRAULIC DREDGING PUMPS ON EXCAVATOR BOOM

Prepared by DRAGFLOW SRL

INDEX Paragraph

Page

PRODUCT INFORMATION

3

EXCAVATOR MACHINE SELECTION DETAILS

5

AUXILIARY POWER PACKS

7

EXCAVATOR MACHINE BOOM CONNECTION

8

How to connect Dragflow Pump and accessories on the excavator boom

HOW TO OPERATE WITH DRAGFLOW PUMP

11 13

Installation of Dragflow pressure controls for the operator

13

Dragflow rotation speed check

15

Dredging operations

16

Excavator machine boom movements

17

Stop the pump operation

20

Warnings

20

2/20 Author: DRAGFLOW SRL

PRODUCTS INFORMATION DRAGFLOW HYDRAULIC DRIVEN PUMPS AND ACCESSORIES (FROM 24 TO 400 HP): Hydraulic Submersible Dredging Pumps: MODEL

OIL FLOW MOTOR SUPPLY (L/min) 40

PRESSURE MOTOR SUPPLY (bar) 200

EXERTED POWER (HP) 18

ROTATING SPEED (rpm) 2000

WEIGHT (Kg)

HY 18

HYD. MOTOR DISPLACEMENT (c.c.)

20

HY 24

20

40

350

32.5

2000

320

HY 35 A

55

65

300

45

1180

600

HY 35 B

55

65

300

45

1180

620

HY 50 A

75

90

300

60

1180

700

HY 50 B

75

90

300

60

1180

720

HY 50/108 A

108

160

300

110

1450

710

HY 50/108 B

108

160

300

110

1450

730

HY 50 HC

75

90

300

60

1180

800

HY 85 A

108

130

300

90

1180

800

HY 85 B

108

130

300

90

1180

830

HY 85/160 A

160

240

300

165

1450

850

HY 85/160 B

160

240

300

165

1450

880

HY 85 HC

108

130

300

90

1180

1130

HY 85/160 HC

160

240

300

165

1450

1180

HY 300 A

500

380

350

300

750

5500

HY 300 B

500

380

350

300

750

5530

HY 400 A

710

605

300

405

850

6530

HY 400 B/C

710

605

300

405

850

6600

HY 400 HC

710

605

300

405

850

6500

270

3/20 Author: DRAGFLOW SRL

Hydraulic Submersible Dredging Side Cutters: MODEL

OIL FLOW MOTOR SUPPLY (L/min) 35

PRESSURE MOTOR SUPPLY (bar) 250

EXERTED POWER (HP) 19.8

ROTATING SPEED (rpm) 50

WEIGHT (Kg)

EXHY20

HYD. MOTOR DISPLACEMENT (c.c.)

700

EXHY20 S

1200

60

250

34

50

600

EXHY35

1200

60

250

34

50

600

500

Hydraulic Submersible Dredging Cutter Head: MODEL

OIL FLOW MOTOR SUPPLY (L/min) 40

PRESSURE MOTOR SUPPLY (bar) 250

EXERTED POWER (HP) 22.6

ROTATING SPEED (rpm) 30

WEIGHT (Kg)

DTM 50

HYD. MOTOR DISPLACEMENT (c.c.)

1240

DTM 85

1240

40

250

22.6

30

450

DTM 400

2500

125

250

70.4

50

1070

450

4/20 Author: DRAGFLOW SRL

EXCAVATOR MACHINE SELECTION DETAILS Before driving a Dragflow unit with the excavator machine it’s important to check if this has enough power to run the pump at full performances.

This can be done checking the hydraulic oil requirements of the equipment at “PRODUCTS INFORMATION� section and check the oil flow motor supply and the pressure motor supply of any device (pumps, side cutters and cutter heads).

The values shown in the chart (same values shown on Dragflow datasheets) refer to the maximum performance of the equipment: - hydraulic motors running at the maximum speed (max rpm) - hydraulic motors working under the maximum load (max pressure) EXCAVATOR MACHINE CHARACTERISTICS TO BE CHECKED: Dragflow suggests that the Excavator Machine diesel engine continuous power should be at least a 25% more than what the Dragflow equipment needs.

Consider the following approximated formula:

đ?‘Źđ?’?đ?’ˆđ?’Šđ?’?đ?’† đ?‘Şđ?’?đ?’?đ?’•đ?’Šđ?’?đ?’–đ?’?đ?’” đ?‘ˇđ?’?đ?’˜đ?’†đ?’“ (đ?‘Żđ?‘ˇ) =

Oil flow motor supply (l/min) ∗ pressure motor supply (bar) 330

Example: Calculate the minimum continuous power required at the diesel engine to run the Dragflow pump HY85 coupled with two side cutters EXHY20 at the maximum performance: o o

Check the Dragflow HY85 pump required oil flow motor supply and pressure motor supply oil flow motor supply = 130 l/min pressure motor supply = 300 bar 130 ∗ 300 đ?‘´đ?’Šđ?’?đ?’Šđ?’Žđ?’–đ?’Ž đ?‘Şđ?’?đ?’?đ?’•đ?’Šđ?’?đ?’–đ?’?đ?’–đ?’” đ?‘šđ?’†đ?’’đ?’–đ?’Šđ?’“đ?’†đ?’… đ?‘ˇđ?’?đ?’˜đ?’†đ?’“ (đ?‘Żđ?‘ˇ) = = 118,18 HP 330 The value of 118,18 HP is the minimum power to run the pump HY85 only.

-

Check the n.2 Dragflow EXHY20 side cutters required oil flow motor supply and pressure motor supply oil flow motor supply = 35 l/min (for each cutter) pressure motor supply = 250 bar 35 ∗ 250 đ?‘´đ?’Šđ?’?đ?’Šđ?’Žđ?’–đ?’Ž đ?‘Şđ?’?đ?’?đ?’•đ?’Šđ?’?đ?’–đ?’?đ?’–đ?’” đ?‘šđ?’†đ?’’đ?’–đ?’Šđ?’“đ?’†đ?’… đ?‘ˇđ?’?đ?’˜đ?’†đ?’“ (đ?‘Żđ?‘ˇ) = ( ) ∗ đ?&#x;? = 53,03 HP 330 The value of 53,03 HP is the minimum power to run the two EXHY20 cutters only.

Required continuous power of excavator machine engine to run at the max performance the dredging unit composed by pump HY85 + (2) cutters EXHY20 is: 118,18 HP (power for the pump) + 53,03 HP (power for the cutters) = 171.21 HP

If the excavator machine has the necessary engine power to run the Dragflow dredging unit the next step is to check if the hydraulic plant can really supply to the dredging unit the required oil flow at the required oil pressure.

It’s important to be sure that the working pressure and the oil flow required by Dragflow equipment can be supplied simultaneously and continuously!!!

5/20 Author: DRAGFLOW SRL

IMPORTANT NOTE: The excavator machine hydraulic plant can work with two different types of oil pumps: -

some oil pumps cannot support the same oil flow quantity when they increase the working pressure (see example here below)

-

some oil pumps can support the same oil flow quantity even when they increase the working pressure (see example here below)

6/20 Author: DRAGFLOW SRL

AUXILIARY POWER PACKS: In case of lack of hydraulic power from the excavator machine Dragflow can supply auxiliary hydraulic power units.

These power packs are a stripped-down version of the standalone power pack and specially designed to place it on the back of an excavator.

They can be used for driving: • • •

Only the Dragflow dredging pump Only the side cutters or the frontal cutter head The complete dredging unit (pump + cutter device)

Dragflow can supply a small remote-control panel as well to be install in the excavator operator cabin with all the controls required to operate efficiently the dredging unit.

7/20 Author: DRAGFLOW SRL

EXCAVATOR MACHINE BOOM CONNECTION In order to apply safely the Dredging Pumps on the excavator machines Dragflow developed different frames to sustain the pumps with the boom simply removing the hydraulic tools used and change it with Dragflow pump.

With the target to standardize the excavator machine boom connecting system Dragflow produces two different types of frames:

Frame type F85

8/20 Author: DRAGFLOW SRL

Frame type F300

9/20 Author: DRAGFLOW SRL

Correct FRAME selection and available accessories: MODEL

FRAME TYPE

CUTTERS OPTIONAL

CUTTER HEADS OPTIONAL

HY 18

ON REQUEST

NA

NA

HY 24

ON REQUEST

NA

NA

HY 35 A

F85

EXHY20 / EXHY20S

NA

HY 35 B

F85

EXHY20 / EXHY20S

NA

HY 50 A

F85

EXHY20 / EXHY20S

DTM 50

HY 50 B

F85

EXHY20 / EXHY20S

DTM 50

HY 50/108 A

F85

EXHY20 / EXHY20S

DTM 50

HY 50/108 B

F85

EXHY20 / EXHY20S

DTM 50

HY 50 HC

F85

EXHY20 / EXHY20S / EXHY35

DTM 50

HY 85 A

F85

EXHY20 / EXHY20S / EXHY35

DTM 85

HY 85 B

F85

EXHY20 / EXHY20S / EXHY35

DTM 85

HY 85/160 A

F85

EXHY20 / EXHY20S / EXHY35

DTM 85

HY 85/160 B

F85

EXHY20 / EXHY20S / EXHY35

DTM 85

HY 85 HC

F85

EXHY20 / EXHY20S / EXHY35

DTM 85

HY 85/160 HC

F85

EXHY20 / EXHY20S / EXHY35

DTM 85

HY 300 A

F300

EXHY35

DTM 400

HY 300 B

F300

EXHY35

DTM 400

HY 400 A

F300

EXHY35

DTM 400

HY 400 B/C

F300

EXHY35

DTM 400

HY 400 HC

F300

EXHY35

DTM 400

10/20 Author: DRAGFLOW SRL

HOW TO CONNECT DRAGFLOW PUMP AND ACCESSORIES ON THE EXCAVATOR BOOM Step 1: Remove the actual tool from the existing excavator boom

TO BE REMOVED

DISCONNECT THE OIL HOSES SUPPLY

Step 2: Fix the Dragflow pump on the excavator machine boom using the existing support frame.

Customer should arrange the screws fixing following the Dragflow Frames drawings.

DRAGFLOW FRAME FIXING SCREWS

BOOM SUPPORT FRAME

11/20 Author: DRAGFLOW SRL

Step 3: Connect hydraulic hoses on the flow divider system as indicated below: Remove all dirt, chips and all foreign bodies from flanges connecting inlet and delivery ports.

DRAINAGE: Drainage pipe between the flow divider system and the drainage connection on the earth moving machine boom (it must be free from clogging and ensure no back-pressure inside).

RETURN: Return line hose between the flow rate divider system and the return connection on the excavator boom. The return hose must be free from dust internally.

DELIVERY: Delivery hose between the the flow rate divider system and the delivery connection on the excavator boom. The delivery hose must be free from dust internally.

Oil hoses connections on the flow divider system: Flow divider system model

Oil delivery

Oil return

Drainage

"SAE" FLANGE

"GAS" CONNECTION

"SAE" FLANGE

"GAS" CONNECTION

"SAE" FLANGE

"GAS" CONNECTION

FRDS 2 WAYS (2xEXHY20/35)

6000 - 3/4"

MALE - 3/4"

6000 - 3/4"

MALE - 3/4"

3000 - 3/4"

MALE - 1/2"

FRDS 2 WAYS (HY50 + 1xEXHY35)

6000 - 1"¼

MALE - 1"

3000 - 1"¼

MALE - 1"¼

3000 - 3/4"

MALE - 3/4"

FRDS 3 WAYS (HY50 + 2xEXHY20)

6000 - 1"¼

MALE - 1"¼

3000 - 1"¼

MALE - 1"¼

3000 - 3/4"

MALE - 3/4"

FRDS 3 WAYS (HY85 + 2xEXHY20)

6000 - 1"¼

MALE - 1"¼

3000 - 1"½

MALE - 1"½

3000 - 1"

MALE - 1"

FRDS 3 WAYS (HY85-160 + 2xEXHY20)

6000 - 1"¼

MALE - 1"¼

3000 - 1"½

MALE - 1"½

3000 - 1"

MALE - 1"

FRDS 3 WAYS (HY85 + 2xEXHY35)

6000 - 1"½

MALE - 1"½

3000 - 1"½

MALE - 1"½

3000 - 1"

MALE - 1"

FRDS 3 WAYS (HY85-160 + 2xEXHY35)

6000 - 1"½

MALE - 1"¼

3000 - 1"½

MALE - 1"½

3000 - 1"

MALE - 1"

FRDS 3 WAYS (HY85 + 2x18Lt)

6000 - 1"½

MALE - 1"¼

3000 - 1"¼

MALE - 1"½

3000 - 3/4"

MALE - 1"

FRDS 3 WAYS (HY85 + DTM85)

6000 - 1"¼

MALE - 1"¼

3000 - 1"½

MALE - 1"½

3000 - 1"

MALE - 1"

FRDS 3 WAYS (HY85/160 + DTM85/160)

6000 - 1"¼

MALE - 1"¼

3000 - 1"½

MALE - 1"½

3000 - 1"

MALE - 1"

12/20 Author: DRAGFLOW SRL

HOW TO OPERATE WITH DRAGFLOW PUMP A) Installation of Dragflow pressure controls for the operator: Excavator machine turned off!!

1) Remote inside the operator cabin the pressure gauges in order to let the operator sees the working pressure. These manometers must be scaled in accordance with the pressure of Dragflow tool’s hydraulic motors: The hoses to bring the pressure inside the operator cabin must be connected with a “T” on the delivery high-pressure hoses between the flow divider block and the hydraulic motors of the flow:

13/20 Author: DRAGFLOW SRL

Schematic diagram for connecting the manometers between the flow divider and the operator cabin Flow divider system manifold diagram

14/20 Author: DRAGFLOW SRL

B) Dragflow rotation speed check: Do not start the system at very low temperatures under load conditions or after long stops.

2) Leave the diesel engine running at minimum speed for 5 minutes to make sure the oil circuit is completely full of hydraulic oil.

At the end of these 5 minutes running it's good practice to open/disconnect the drain port on the flow divider (with diesel engine off!!) to bleed air off the circuit.

3) Check hydraulic oil level in the tank after loading all components.

4) Start running the pump for max speed and step by step listen from the hydraulic circuit and piston pumps the noise to be sure everything is working correctly (this operation must be done the first start only or when the pump has been out of service for long time, 5 weeks).

5) In case of a monodirectional motor check for the direction of rotation to be consistent with the inlet side.

6) Accelerate the engine to the according proper working engine speed.

7) Check rotation of Dragflow pump with infra-red RPM counter, rotation must be in accordance with the pump data sheet when pump it's free out of water, (see previous chart at “PRODUCTS INFORMATION� section).

1) Place the reflective sticker on the main pump shaft 2) Run the pump and check with the infrared device the pump speed 3) Set the excavator machine at correct oil flow in accordance with the right RPM of the pump

15/20 Author: DRAGFLOW SRL

C) Dredging operations: 8) With the pump shaft running at correct speed as previously controlled lower Dragflow into the water – do not lower the pump into solids yet.

NOTE: NEVER START THE PUMP IN SOLIDS 9) Pump clear water only until it reaches the end of the discharge pipeline.

10) After a solid water stream exits the pipeline lower pump into the solids and start dredging.

The operator who manages with Dragflow pump must be able to find the best efficiency point by using the pump inside the solid material: - Having the discharge point visible to keep the solid concentration under control.

- A spy camera can help in case the discharge point cannot be seen by the operator.

- If the discharge point has no any possibility to be seen from the operator while the pump is running some solution has to be adopted: 1) Leaving a very small thickness (1 or 2 mm) between two flanges near the pump just outside the water and visible from the operator. While the pump is running below the surface and the operator see the water welling from this small opening means that only clear water is being pumped. Once the pump starts to extract material solid (mud, clay, sand, rocks, etc.) the mixture stop welling out from the leak.

2) Fixing a transparent piece of discharge hose (ex. Plexiglas) along the line and place this in a position visible by the operator.

3) Place a flow meter/density counter along the cargo hose and have a look at its screen to visualize the parameters.

4) Using the pressure gauges remoted inside the operator cabin. Once Dragflow EXHY20 start to increase the pressure means the pump is inside the solid material, stop lowering the pump and wait the material exits from the discharge line.

NOTE: It's important to find the correct average point of work to avoid clogging the cargo discharge line or opposite having a low solid production.

16/20 Author: DRAGFLOW SRL

D) Excavator machine boom movements: 11) Dragflow pumps are equipment which use the agitators and cutters system to extract solid material from the bottom of the pond where it’s working:

How it works: 1) The AGITATOR not only prevents solids from blocking the pump inlet by mixing them with the liquid, but with its rotation with pump shaft it creates a downward flow that generates a HIGH PRESSURE AREA in front of the pump that put the settled material in suspension thus creating a cloud of slurry around the pump suction.

2) Above the agitator, inside the strainer, a LOW PRESSURE AREA is created. This together with the action of the impeller allows to pump a high concentration of solids.

3) The SIDE CUTTERS run at low rpm and at every rotation they bring additional material to the suction.

This clearly explain the pump has not to be forced or pushed strongly on the bottom to bring the solid material. It automatically suspends the solids from the bottom.

17/20 Author: DRAGFLOW SRL

12) Do not dredge very close to the excavator machine to avoid the compacted soil underneath the same machine suddenly collapses with the risk of falling for the equipment.

Always consider Dragflow can create a hole of about 4 to 5 meters diameter around itself, depends by the pumped layer.

13) Dragflow tool has to be lowered slowly down to the bottom, use the instruction at “dredging operations� chapter to understand when the pump is extracting solid material.

14) Once the solid starts to fill the pump the operator has to stop lowering and leave Dragflow bringing all the material below and around itself. Depending by the bottom layer the pump can suck for shorter or longer periods.

15) Once the solid concentration in the cargo line decreases move the pump down again and have another shot of dredging operation.

IMPORTANT: Never force the pump pushing it on the bottom if the layer cannot be pumped!! See below picture as a sample.

BIG ROCKS AND STONES LAYER: DO NOT LOWER THE PUMP AT ALL SAND LAYER: PUMP CAN BE LOWERED

MUD LAYER: PUMP CAN BE LOWERED

CLAY LAYER: PUMP CAN BE LOWERED

18/20 Author: DRAGFLOW SRL

16) Main dredging operation has to be carried out moving the pump vertically when it’s in the solid material and horizontally while the pump is in easy water.

If the pump is forced to move itself horizontally inside the solid material the vibrations created by the two side cutters EXHY20/35 could break the lateral frame fixing screws.

CORRECT BOOM MOVEMENTS c. Move b. Remove from solid

d. Down in the solid and dredge

a. Dredge

WRONG BOOM MOVEMENTS

b. Move

a. Dredge

17) Pay attention to avoid a very deep hole with the pump, as previously anticipated the material around could collapse and cover the pump completely.

It’s suggested to pump material creating big layers and slowly reach the bottom of the dredged area.

Always keep in consideration the type of material in which Dragflow works.

19/20 Author: DRAGFLOW SRL

E) Stop the pump operation: NOTE: NEVER STOP THE PUMP IN SOLIDS 18) Remove the pump from the solid material (sand, clay, gravel, etc.).

19) Wait until clean water exits the end of the pipeline.

20) Decrease the engine speed to minimum.

21) Stop the dredging pump rotation.

22) Lift the pump out of the water.

23) Switch off all the engine.

24) Inspect the pump strainer for logged rocks or woods every end of shift.

WARNING!

➢

BE AWARE THE MAX PRESSURE ON THE HYDRAULIC PUMPS.

➢

IF PROBLEMS COMES OUT LIFT THE PUMP AND SHUT THE SYSTEM OFF.

➢

DO NOT TOUCH ANY BUTTONS WITHOUT PRIOR KNOWLEDGE.

➢

DO NOT OPERATE THE DREDGE WITHOUT PROPER PPE.

20/20 Author: DRAGFLOW SRL