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MOTAS receives order for a Water Injection Dredger package for Malaysia

MOTAS Dredging Solutions will design, build, supply and commission an equipment package for a Water Injection Dredger (WID) for Malaysia.

The Water Injection Dredger will be built in Malaysia by JICORE Group Incorporated (M) Sdn Bhd. for the Penang Port Authority.

The custom design of the equipment package has already started and will be done inhouse by our engineers in The Netherlands in close co-operation with the JICORE team.

“It is an honour to work together with JICORE and to build this first WID for Malaysia” says Mr. Loh Meng Seng, MOTAS Business Development Representative (South East Asia). The sea trials of this WID will take place early next year, after which the WID will be handed over to the Penang Port.

Production of key equipment is underway and will be done by one of MOTAS’s long term international fabrication partners. Equipment will be installed on the dredger under MOTAS’s supervision.   

MOTAS will deliver among others the complete jet-arm with adjustable nozzle beam equipped replaceable nozzles, the gantry, sheave blocks, the swell compensator, the winch, the jetwater pump sets with the Cummings diesel engines, the main hydraulic power pack, Class approved butterfly valves.

Main details of the equipment:

  • Dredging depth – 18.5 [m]
  • Length jet arm – approx. 27 [m]
  • Water flow – 2x 3500  [m3/hr]
  • Number of pumps – 2
  • Pump power – approx. 2x 375 [kW]
  • High efficiency pump – Yes
  • Nozzle beam – Adjustable
  • Swell compensator – Yes

Keywords:

  • Water Injection Dredger (WID)
  • Dredge Equipment
  • Fabrication
  • Engineering and design
  • Jet arms
  • Jet beams
  • Jetwater pumps
  • Jetwater nozzles
  • Swell compensator
  • Hoisting gantry
  • Hydraulic installation
Fig. 3 – Jet arm lowered onto seabed.

Interview with Georges Teheux, General Manager at MOTAS Dredging Solutions

Designing and developing great components is not enough to make a dredging vessel work in the most efficient way. It’s the way the different components and systems work together and communicate what makes a good machine a great machine.

By Eldin Ganic – DredgingToday.com

A couple of days ago, we took an opportunity to talk about sustainable dredging solutions in today’s world with Georges Teheux, General Manager at MOTAS Dredging Solutions – the IJmuiden based ship builder, equipment manufacturer and technical service provider in marine, dredging and offshore industries.

DT: As an introduction to some of our readers who are not familiar with your company, what can you tell us about your business, the beginnings and where is MOTAS Dredging Solutions today?

Georges Teheux: MOTAS Dredging Solutions was founded 5 years ago and from that point of view it is a relatively young company. Nevertheless, majority of the people working here have a lifetime experience in the dredging industry and as a consequence they bring in a huge amount of knowledge.

As a company, we focus on the development, design and fabrication of dredging equipment and systems. Basically, you can come to us for a single component to a complete dredger.

Often, we go into a process together with our customer. Therefore, we help them in defining the best possible configuration (concept) of equipment for the intended use.

We do not only limit ourselves to a technical/conceptual design, but we also can take complete CAPEX/OPEX analysis into the project, helping our customer in making the right choices and lowest possible ‘total cost of owner ship (TCO)’.

MOTAS photo

DT: Overall, 2020 and 2021 were challenging around the globe in many ways, how did your company sail through that period?

Georges Teheux: In 2020 Q1, we signed some big/complex contracts, so we were quite busy these two years.

The major difference was that we were more or less unable (or difficult) to visit our customer on a regular basis due to the travel and entrance restrictions. Since it is of paramount importance to have intensive communication with all stakeholders in such projects, we had to organize our projects in a different way. Our IT infrastructure was key in facilitating this.

The advantage of being a relatively young company is that we could design our IT infrastructure from the scratch. Moreover, we already made crucial choices in 2016.

As a result, all of our systems were so to say ‘COVID/lock down ready’ before we even knew about the existence of COVID. We only had to refine our working methods to make them more suitable for communication via video conference.  

As a result, I can say that it actually helped us in organizing complex processes and projects in a more efficient way. So, from that point of view, we benefited from it in terms of business processes.  

MOTAS photo

Of course, we have also seen some downsides. For example, a huge increase in prices of world-wide transport caused some big challenges for us.

Basically, availability of containers had gone down drastically and prices went up dramatically – meaning that for the running projects we had to cope with this which put a lot of strain on some of our projects or project phases, especially in the first year of the pandemic.

Also, our business concept helps in dealing with the current situation: by having co-makers all over the world we can relatively easy shift from for example far east or middle east production to mainland Europe production or the other way around. It all depends on where we need to deliver our final product.  Another advantage of this concept is that we could keep our price levels more under control (less increase) then a lot of other companies.

DT: Over the years, MOTAS has added a lot of innovative equipment to the dredging industry. What is currently in the pipeline or what are you and your team currently working on?

Georges Teheux: In general, we can say there is a lot of activity in the market and we are working on quite a few innovative projects and products.

Especially on a product level, we have a more or less continued development – in terms of improving dredging equipment.

Next to looking to our products and services, we put a lot of emphasis on development of our working methods and business culture. All with the aim to have a fast response time and high level of quality and service for a reasonable price.

MOTAS photo

DT: Do you believe that dredging industry can make a difference in improving the environment’s quality, and what is your opinion on this?

Georges Teheux: Yes, it can make the difference. When we look into some of the drivers of the global dredging market, we see that a growing world population is moving to coastal areas, requiring land to be reclaimed and protected.

Global warming, amongst other things, leads to rising sea levels and floods disasters are more likely to occur.

Dredging plays a crucial role in protecting the people living in coastal areas. Also, removal of contaminated sediments from the bottom of lakes and other waterways is a perfect example of how dredging can be beneficial for the environment.

MOTAS photo

DT: Sustainability now comes in many forms, and as a producer of dredging equipment, you have knowledge, data and expertise to make a positive difference. What are your priorities when it comes to creating sustainable dredging solutions?

Georges Teheux: The word sustainable is a ‘big word’ and gives room for a wide range of interpretations.

Nevertheless, looking to the ‘classic’ sustainability pillars: ‘people, planet and profit’, our main focus lies on ‘people’ (customers and suppliers), since we need to do it together.

I think we are very good in creating one team (or blending in) together with our customers and other stakeholders, as we go into projects or product developments.

Maintaining a long-term relationship is our main focus. Next to that, it is of a crucial importance that we get a clear feedback from the end user in order to develop sustainable dredging solutions.

So, definitely our priority is ‘people’ when it comes to sustainable developments.

MOTAS transports large Cutter Ladder

MOTAS Dredging Solutions designed, fabricated and shipped a cutter ladder for a large Cutter Suction Dredger.

The ladder has been custom designed inhouse by our engineers in The Netherlands and will be installed on the dredger currently under construction. Fabrication and partial outfitting of the ladder was done by one of MOTAS’ long term international fabrication partner.  It will be further outfitted once installed on the dredger under MOTAS supervision. The cutter ladder is part of an engineering and components package, that next to delivery of the main dredging components also includes the basic and detailed design of the complete dredge.

Dimensions.

The ladder has a total weight after outfitting of about 200 tonnes.

Dimensions are approximately the following (LxHxW) 35.8 x 6.8  x 5.2 m.

The logistics.

Loading and shipping was organized by the MOTAS logistics department. Due to substantial weight and sizeable dimensions of the shipment, the logistics were an interesting challenge for our Team. The object was rolled out of the factory onto a barge along quay at the port of shipment. The barge was towed to a seagoing heavy transport vessel where cranes hoisted the ladder onboard. The total journey from the port of loading to the port of destination took around 30 days, where it arrived in time to start installation. 

Specifications of the ladder.

The ladder is made of a heavy duty steel box construction fitted with an underwater dredge pump directly driven by a submerged E-motor.  The cutterhead is electrically driven as well, however the cutter drive E-motor is mounted on a gearbox above the waterline. From the gearbox a long cutter shaft is installed, fitted with several bearings up to the cutterhead.

Keywords:

  • Cutter Suction Dredger (CSD)
  • Logistics
  • Seagoing transport
  • Heavy duty application
  • Dredge Equipment
  • Fabrication
  • Engineering and design
Fig. 1     Final loading before rolling out to barge
Fig. 2     Final loading before rolling out to barge
Fig. 3     Loaded on the barge
Fig. 4     3D view of the complete ladder.

MOTAS delivers two dragheads to DC Dredging

For customer DC Dredging, MOTAS Dredging Solutions produced two dragheads, which will be installed on the sand & gravel dredgers DC Ostend and DC Brugge.

Both dragheads will be used to dredge sand and gravel offshore at concessions in the North Sea.    

Specifications

The draghead visors are fitted with knife plates, which are able to cut effectively into the soil. Furthermore both dragheads are fitted with jetwater nozzles in the heel plates. These nozzles inject water into the sand, which expands and loosens it before being dredged up. Internally, the dragheads are lined with so called “chocky bars”. These wear resistant tiles protect the draghead from excessive wear when dredging abrasive sands and gravels.

The production

The dragheads were fabricated by a co-maker under the supervision and following the QC procedures of a dedicated local MOTAS production manager. Having a dedicated production manager is of paramount importance for MOTAS, since this enables us to ensure high quality end products independent of the co-maker.

The dragheads were delivered on time and within budget.

Short specifications:

Draghead TSHD  “DC Ostend”

  • Suction diameter             : 850mm
  • Total weight                     : approx. 8 ton
  • Width                                 : approx. 2.5 m
  • Excavating knifes             : YES
  • Jetwater through heel   : YES
  • Chocky blocks                  : internally lined

Draghead TSHD “DC Brugge”

  • Suction diameter             : 600mm
  • Total weight                     : approx.. 6 ton
  • Width                                 : approx. 2.4 m
  • Excavating knifes             : YES
  • Jetwater through heel   : YES
  • Chocky blocks                  : internally lined

Keywords:

  • Sand & gravel dredging
  • Knife plates
  • Jetwater nozzles in heel
  • Wear resistant chocky bars
  • Heavy duty
  • Trailing suction hopper dredger (TSHD)
Fig 1. 3D model of the 850 draghead
Fig 2. Side view of one of the dragheads
Fig 3. Top view of the 850 draghead, ready for transport.
Fig 4. Bottom view of the 850 draghead, ready for transport
Fig 5. Rear view of the 850 draghead.

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MOTAS Dredging Solutions delivers Fenders for CSD Spartacus

IJmuiden- The Netherlands. MOTAS Dredging Solutions has produced and delivered a first set of high-quality Fenders for the CSD Spartacus, the largest Cutter Suction Dredger in the world.

MOTAS Dredging Solutions engineered, produced and delivered a set of Fenders for DEME’s CSD Spartacus. The Fenders are custom made for the CSD Spartacus and exist of several high-quality components that can be mounted on the vessel but can just as easily be dissembled.

Protection

The Fenders safeguard the CSD Spartacus from large vessels, such as hopper barges, which moor alongside while the CSD Spartacus is in full operation. The Fenders are engineered in such a way that they give the CSD Spartacus maximum protection from vessels approaching at every possible angle and speed. This because MOTAS Dredging Solutions paid close attention to 3 critical components: first being high energy absorption capabilities of the fenders, second the durability and wear resistance of the fenders and third, easy use and secure mounting to the side of the hull.

“MOTAS designed, constructed and delivered the Fender System in close cooperation with DEME’s project team.”

Georges Teheux, MOTAS dredging solutions

A high quality package

The Fender units themselves consist of several different parts, such as the main frame which is made from steel which is the part that is mounted on the hull. The rubber fender elements are capable of high energy absorption and have a low reaction force.  The fender wear pads, also called liners, are made from Ultra-high-molecular-weight polyethylene (UHMWPE). The combined qualities of these materials, whilst being wear resistant, as well as the unprecedented size make the whole modular system unique and innovative. While always offering maximum protection to the CSD Spartacus.

Proof in testing

The rubber fenders and liners were thoroughly tested throughout the full manufacture process to ensure DEME received a high-quality Fender System in a unique size. The rubber fenders were tested through compression under a 1000-ton bench. Whereas samples of the liners were checked for quality and approved by the internationally renowned inspection society.

Specifications for this project

  • Rubber Fenders
  • Ultra-high-molecular-weight polyethylene (UHMWPE) Liners
  • Wear resistant
  • Modular
  • Dismountable
  • DEME
  • CSD Spartacus
  • Quality Checked
  • Largest and most powerful Cutter Suction Dredger in the world
Fig 1. Rubber Fender compression test.
Fig 2. Fully assembled unit.
Fig 3. Fully assembled unit.
Fig 4. Artist impression of the CSD Spartacus with the fender units depicted on the side of the vessel.

Custom made Fall Pipe System for Rohde Nielsen’s Grane R

IJmuiden- The Netherlands, On the 10th of September Rohde Nielsen inaugurated DP2 fall pipe rock installation vessel Grane R in a name giving ceremony.

MOTAS dredging solutions designed, built, engineered, and installed the custom-made Fall Pipe installation in close cooperation with Rohde Nielsen. It will be used to accurately lay foundations on the seabed for offshore structures such as offshore windmills or to cover underwater trenches in which cables are placed. Due to the limited space on board of the Grane R the engineers of MOTAS had to work with every available m² of space. Therefore they integrated the Fall Pipe System in such a way that it takes up very little place when stored on board. The Fall Pipe System, when retracted, can be stored on the side deck of the ship.

Telescopic pipe and active motion compensation

The system is outfitted with a telescopic pipe extendable 0-10 meters, for flexibility. Due to the telescopic pipe, the Grane R can install rock accurately up to a depth of 60 meters. The telescopic section of the pipe can be operated via a computer which is located on board of the Grane R. Another feature that MOTAS engineered is the active motion compensation system. This system makes it possible to keep the pipe near-static positioned, even when it is being operated in rough seas. This combination of systems makes the Fall Pipe System very accurate when it comes to installing rock.

Turnkey delivery

MOTAS dredging solutions engineered, built and delivered the complete Fall Pipe System to Rohde Nielsen. The project was done in close cooperation with the client, resulting in a turnkey delivery. Offering turnkey solutions in this way is an important distinction of MOTAS Dredging Solutions.

Specifications for this project

  • Rock capacity:                                 4900 t – option to increase
  • Fall pipe size:                                   Ø 1200 mm
  • Max. rock size:                                400 mm
  • Fall pipe operational depth:        8-60 m – options for additional depth

Conversion of the M/V Capt John A. Graham to a side cast dredge

IJmuiden, The Netherlands – MOTAS Dredging Solutions has supplied concept and detailed design services for the dredging installation including hardware.

Brice Civil Constructors is the operator of the dredge, which is currently in operation and doing extensive agitation dredging in the Atchafalaya River near Morgan City in the USA.

The concept was to mount a large dredge pump with two drag arms on the deck of an Offshore Supply Vessel. Rather than pumping material into the hold of a hopper dredge, the vessel would pump the material back overboard. The whole dredging process being assisted by a powerful jetwater system.

The currents in the river will then carry the agitated material further downstream. The whole dredge agitation process is repeated and the river will be opened up and can be maintained at navigational depths for vessels to reach berthing facilities upstream.

The Offshore Supply Vessel “M/V Capt John A. Graham” was selected to be the platform for the whole dredging installation.. The shipyard where the conversion took place was Halimar Shipyard in Morgan City.

We supplied the concept & detailed design services and hardware of the dredging installation.

Together with our partner Hagler Systems, the whole dredging installation was supplied to the shipyard, assembled and installed onboard.

Hardware supplied together with our partner Hagler Systems:

  • The dredge pump
  • Two dragheads with jetwater provision in the heel and adjustable visor
  • The dredge arm
  • The Turning glands
  • Dredge pipes
  • The gantries with several sheave blocks
  • The winches
  • Hydraulic installation and the Hydraulic Power Pack (HPU)
  • The pump inspection piece

Significant cost savings

“We had mechanical challenges we had to overcome” said Brice Civil Constructors,  “but we’ve been pumping now for nearly a year. The average volume we’ve pumped on a month-to-month basis is about 5 million cubic yards per month.  

The cost savings measured per cubic yard of material pumped are significant compared to cutterhead and hopper rates.

What’s more, the system is working. Since the dredge hit its stride toward the start of the year, the dredge has been exceeding its target and steadily deepening the bar channel to a navigable depth.

Water Injection Dredger for port of Bordeaux successfully launched

MOTAS Global Dredging Solutions completes project in France

IJMUIDEN – For the GIE Dragages Ports, MOTAS Global Dredging Solutions engineered a jetwater installation and delivered key components for a Water Injection Dredger. Recently, this WID has been taken into operation and is being used by the Grand Port Maritime de Bordeaux (member of GIE Dragages Ports), France.

The sea trials of this Water Injection Dredger took place in July this year, after which the WID was handed over to the customer. “A great and challenging project has now been successfully concluded,” says Georges Teheux, General Manager at MOTAS Global Dredging Solutions at the offices of MOTAS in IJmuiden, The Netherlands.

Full package and turnkey delivery
For this project, MOTAS provided an integrated system consisting of the design and the construction of the jet arms, jet pumps, swell compensator, jet beam and hoisting gantry for the Water Injection Dredger. The hydraulic installation, the automation, monitoring and the electric systems were also supplied by MOTAS.  

‘A great and challenging project has now been successfully concluded’

Georges Teheux, MOTAS Dredging Solutions

“The largest component of this system is the arm, through which jetwater can be injected into soils at depths up to 22 meters”, says Senior Project Engineer Barend de Wijn.  The resulting fluidized sand mixtures than flow down slopes and are eventually carried away by tides and currents.

Challenge
The biggest challenge of the project was the design of the jet arm suspension and the hinges to the vessel. During operation the arm is subjected to dynamic movements of the vessel, upwards and sideways. For example by the swell or an uneven seabed. We have incorporated several passive and active components in the design to absorb these movements, such as an hydraulic swell compensator and others. Another unique element in this design is the jet beam, which can be tilted for optimal fluidization of the soil.

Improvements
For this project, MOTAS made a completely unique design. The installation is autonomous and is interchangeable for other vessels. MOTAS does not merely supply the hardware, but also provides the automation and monitoring.   

Specifications of this project

  • Several automated dredging modes.
  • Jet arms
  • Jet beams
  • Jetwater pumps
  • Jetwater nozzles
  • Swell compensator
  • Hoisting gantry
  • Hydraulic installation
  • Electrical systems
  • Automation
  • Monitoring
The L’Ostrea Water Injection Dredge, is currently being used by Dragages Ports.
The Water Injection Dredge arm put into use by Grand Port Maritime de Bordeaux, France.

Customised Ladder and Underwater Cutting Wheel combination for ROHR-IDRECO

IJmuiden, the Netherlands – MOTAS Dredging Solutions has designed and constructed a customised Ladder plus Underwater Cutting Wheel combination for Rohr-Idreco. On the 5th of November, ROHR-IDRECO successfully launched the electrical dredger.

MOTAS Dredging Solutions designed and constructed the ladder plus Underwater Cutting Wheel (UCW), which will be used by the South American gold mining company. To increase throughput, the mining company required a new tool and a more efficient way of mining.

The integration of the UCW and the ladder into the ROHR-IDRECO dredger was done in close cooperation between the project management and engineering teams.

“The MOTAS Dredging Solutions design weighs 20% less compared to conventional Underwater Cutting Wheel designs”

(Barend de Wijn, MOTAS)

Soil expertise

Engineers at MOTAS Dredging Solutions have extensive knowledge of different excavating processes, required for different types of soil. With this knowledge, MOTAS Dredging Solutions is capable of providing the most suitable and cost-efficient solution for each mining and dredging application.

Hydraulic driven cutting wheel

During the design process of the cutting wheel, Senior Engineer Barend de Wijn noticed a compelling opportunity: “Conventional designs use electric motors and heavy gearboxes to drive the wheel, this new design has a direct drive from a hydraulic motor giving it a lighter, more reliable result”.

With a wheel diameter of 2.5 meters, the specification of the UCW is impressive. Furthermore the cutting knives of the wheel are fabricated from a wear resistant material resulting in reduced downtime. Provided with a 36 meter ladder, the UCW is able to mine at depths of up to 28 meters.

“We offer the entire process. From design and transport to installation and system integration. ”

(Georges Teheux, MOTAS)

The ladder

MOTAS built the entire ladder for this project. In order to maximise competitiveness,  MOTAS devised a way to do this as timely and as cost efficient as possible. The ladder was divided into 3 sections and shipped by regular container transport from The UAE to Germany. On arrival it was aligned and welded together. It underwent further quality checks before the final painting was applied. The whole transport took MOTAS under 5 weeks; from our location in the UAE until the arrival at the yard in Wesel, Germany.

Offering turnkey solutions in this way is an important distinction of MOTAS Dredging Solutions.

Specifications for this project

  • Underwater Cutting Wheel (UCW) 
  • A ladder of 36 m long
  • A wheel diameter of 2.5 m
  • Custom made  
  • Wear resistant knives
  • Direct drive by high torque hydraulic motor
  • Low spillage
  • Efficient logistics by sea and by road within 5 weeks
  • Co-operation with ROHR-IDRECO

MOTAS Dredging Solutions launches new line of dredge ball joints

MOTAS Dredging Solutions announces today the launch of a new and improved line of dredge ball joints. The in-house developed design has been named the Maximus® ball joint and will become part of the MOTAS Global product portfolio. Read more