Handbook819 Old

OPERATING INSTRUCTIONS
HOPPER SUCTION DREDGER

1500 m³
DREDGE CONTROL AND MONITORING SYSTEM
VOSTALMG - Yard-No. : 819

VOSTALMG - Assembly group :
Year of construction : 2004
Status : Rev 0
Contractor: VOSTALMG BV
23554 Lübeck
Einsiedelstr. 6
Telefax : +49 (451) 8085-121
Phone : +49 (451) 8085-0
E-Mail : info@vostalmg.com
© Copyright by VOSTALMG Printed in Germany
Automation VOSTALMG 2-710-66552 Rev. 0 1

Contents
1 INTRODUCTION.............................................................................................................. 5
2 DREDGE CONTROL AND MONITORING SYSTEM ....................................................... 6
2.1 General........................................................................................................................ 6
2.2 Functional displays.................................................................................................... 6
2.2.1 Headline ............................................................................................................... 6
2.3 Dredging, Dumping and Discharging ....................................................................... 6
2.3.1 Right Mouse Key .................................................................................................. 7
2.4 Loading Computer ..................................................................................................... 8
2.5 Hydraulics................................................................................................................... 8
2.6 Alarm........................................................................................................................... 9
2.7 Settings......................................................................................................................11
2.7.1 User Settings.......................................................................................................12
2.7.2 Data logging ........................................................................................................14
2.7.3 Password Protection............................................................................................17
2.8 System .......................................................................................................................18
2.9 Help ............................................................................................................................19
2.9.1 DCMS Schematics ..............................................................................................19
2.9.2 Symbol declaration ..............................................................................................19
2.9.3 System Keys .......................................................................................................20
2.9.4 DCMS Handbook.................................................................................................20
2.9.5 Print Fail ..............................................................................................................20
2.9.6 Service Logon .....................................................................................................20
2.9.7 Restart Key..........................................................................................................20
2.10 Side suction pipe position indicator ....................................................................21
2.10.1 General ...............................................................................................................21
2.10.2 Features and Functions .......................................................................................21
2.10.3 Functions.............................................................................................................24
2.10.4 Connection to the control and monitoring system ................................................24
3 SWELL COMPENSATOR ..............................................................................................25
3.1 Sensors and Controls ...............................................................................................25
3.1.1 Sensors ...............................................................................................................25
3.1.2 Hydraulic Controls ...............................................................................................25
3.1.3 Desk Controls......................................................................................................25
3.2 Pressure and Level Monitoring ................................................................................25
3.3 Operational Functionality .........................................................................................26
3.3.1 First time ground detection ..................................................................................26
3.3.2 Range control ......................................................................................................26
3.3.3 Ground detection by pressure difference .............................................................26
3.3.4 Broken rope detection .........................................................................................27
3.4 DCMS Visualisation...................................................................................................27
3.4.1 Desk ....................................................................................................................27
3.4.2 Side Suction Pipe Display and Hydraulics Page ..................................................27
4 OPERATION OF THE SIDE SUCTION PIPE..................................................................28
4.1 Manual Operation ......................................................................................................29
4.1.1 Swinging the side suction pipe out.......................................................................29
4.1.2 Lowering the side suction pipe.............................................................................30
4.1.3 Hoisting the side suction pipe to high position .....................................................30
4.1.4 Swinging the side suction pipe in.........................................................................30
4.2 One Lever Operation.................................................................................................31
4.2.1 Swinging the side suction pipe out.......................................................................31
4.2.2 Lowering the side suction pipe.............................................................................31
4.2.3 Hoisting the side suction pipe to high position .....................................................31
4.2.4 Swinging the side suction pipe in.........................................................................31
4.3 Automatic depth control of draghead......................................................................32
4.3.1 Dredging depth....................................................................................................32
4.4 Service Mode .............................................................................................................33
4.4.1 Gantry Pushbuttons.............................................................................................33
4.4.2 Winch levers........................................................................................................33
4.5 Emergency hoisting ..................................................................................................34
4.6 Hydraulic Emergency Stop.......................................................................................35
5 DREDGE PUMP OPERATION .......................................................................................36
5.1 Drive Chain Auxiliaries .............................................................................................36
5.2 Hydro Coupling .........................................................................................................37
5.3 Dredge Pump Gear....................................................................................................37
5.4 Right Mouse Click .....................................................................................................37
5.5 Mode Selection..........................................................................................................38
5.6 Starting the dredge pump.........................................................................................38
5.6.1 Dredge Pump Start Conditions ............................................................................39
5.6.2 Dredge Pump Running Conditions ......................................................................39
5.7 Stopping the dredge pump.......................................................................................39
5.8 Restarting the dredge pump.....................................................................................39
5.9 Emergency stop of the dredge pump ......................................................................40
5.10 Main Engine Shutdown .........................................................................................40
6 JET PUMP OPERATION ................................................................................................41
6.1 Jet Pump Clutch........................................................................................................41
6.3 Starting the jet water pumps ....................................................................................42
Jet Pump Starting Conditions..........................................................................................42
6.3.2 Jet Pump Running Conditions .............................................................................42
6.4 Stopping the jet water pumps ..................................................................................42
6.5 Emergency stop of the jet water pumps..................................................................43
7 DUMP VALVE OPERATION ..........................................................................................44
7.1 Operating Pressures .................................................................................................45
7.3 Emergency dumping.................................................................................................45
8 SLUICE AND JET VALVE OPERATION ........................................................................46
9 WEIR ..............................................................................................................................47
10 FLUSHING WATER AND BALLAST WATER................................................................47
11 SEALING WATER ..........................................................................................................48
12 LOADING COMPUTER ..................................................................................................49
12.1 General...................................................................................................................49
12.2 Manual inputs ........................................................................................................50
12.3 Functions ...............................................................................................................50
Empty Ship Weight..........................................................................................................50
Operation Mode ..............................................................................................................51
12.3.2.1 DREDGING Operation Mode ...................................................................................................51
12.3.2.2 SAILING LOADED Operation Mode ........................................................................................52
12.3.2.3 DISCHARGING Operation Mode .............................................................................................52
12.3.2.4 DUMPING Operation Mode .....................................................................................................52
12.3.2.5 SAILING UNLOADED Operation Mode ...................................................................................52
12.3.3 LC Data ...............................................................................................................53
12.3.4 Draft Calibration...................................................................................................53
Sensor Override..............................................................................................................54
12.3.6 Report .................................................................................................................54
13 MAINTENANCE FUNCTIONS ........................................................................................56
13.1 Lamp test and dimmer ..........................................................................................56
13.2 Right Mouse Click Functionality ..........................................................................56
13.2.1 Valve Status Window...........................................................................................57
13.2.2 Valve More Window.............................................................................................58
Pump Motor Status Window............................................................................................58
Sensor Status Window....................................................................................................59
Online Trending Functionality .........................................................................................61
13.4 Calibration of rope length sensor ........................................................................62
14 ALARM LISTING ............................................................................................................63
14.1 Alarm Types...........................................................................................................67
14.1.1 Feedback Failure.................................................................................................67
14.1.2 Broken Wire.........................................................................................................67
14.1.3 Equipment Alarms ...............................................................................................67
14.1.4 Limit Alarms.........................................................................................................67
15 LOADING COMPUTER CALCULATIONS .....................................................................68
15.1 Draft........................................................................................................................68
15.1.1 Centreline Draft ...................................................................................................68
15.1.2 Trim .....................................................................................................................69
15.1.3 Centreline Draft Interpolation ...............................................................................69
15.1.4 Draft at Arbitrary Positions...................................................................................70
15.1.5 LPP/2 Draft..........................................................................................................70
15.2 Hopper Level..........................................................................................................70
15.3 Tables for Volume and Displacement ..................................................................70
15.3.1 Volume and mass................................................................................................71
15.4 Production .............................................................................................................72
APPENDICIES
Appendix A DCMS Electrical Drawings
Appendix B Data Sheets
⇒ Rope length sensor
⇒ Pipe on Deck
⇒ Gantry In/Out Sensors
⇒ Winch High Emergency Stop Sensor
⇒ Sluice Valve Position Sensor
⇒ Sluice Valve Proximity Switches
⇒ Bottom Valve Proximity Switches
⇒ Sealing Water Pressure and Flow Sensors
⇒ Dredge Pump and Jet Pump Pressure Sensor
⇒ Draft sensor
⇒ Hopper Level Sensors
⇒ Inclinometer
⇒ Simatic PLC Installation Reference Guide
⇒ Compaq PC: Hardware Parts Service
⇒ Monitors
⇒ HP Printer User Guide Reference Guide

1 Introduction
These operating instructions describe the use of the dredging control and monitoring
system. The following sub-systems are included:
⇒ DCMS Dredge Control and Monitoring System

⇒ LPM Load and Production Monitoring
⇒ SSPI Suction Pipe Position Indicator
PC with LCD Legend:

15‘‘ TFT Monitor
SPPM = Suction Pipe Position Monitoring
LPM = Load and Production Monitoring
SPPM PCMS = Process Control and Monitoring
System
PC with LCD
15‘‘ TFT Monitor
LPM
&
PCMS
Main PLC with CPUs and I/O‘s for
Control and Monitoring,
Profibus Network
I/O Desk SB
DREDGEMASTER DESK
I/O from/to various sensors and controlers
The system provides remote manual operation with specific automatic functions for
dredging, dumping and discharging . The side suction pipe is controlled using joysticks for
each winch with a 17” LCD display showing the position of the pipe in relation to the ship.
The bottom valves, piping valves, dredge and jet water pumps, auxiliary pumps, hydraulics
and sensors are controlled and / or monitored from the dredge control desk. This manual
guides the operator in a step by step way through the system.

2 Dredge control and monitoring system
2.1 General
The control and monitoring system combines the monitoring and control functions of the
dredging installation by means of task oriented mimic diagrams.
2.2 Functional displays
The control and monitoring system controls and monitors the dredging installation mainly
using task oriented mimic diagrams. The mimics show in real time the status of the
equipment by means of different colours. All relevant process data are shown in graphical or
numeric form. The operation is done mainly by a trackball. Changing to other screen pages
is done by clicking on the respective screen buttons. The trackball is again used to click the
appropriate symbols which change in colour and start to flash to confirm their function. When
an action has been completed, e.g. the selected position of the sluice valve has been
reached, the symbol stops flashing.
Function keys can also be used to perform many operations.
The control – monitoring – software includes following graphical pages:
⇒ start up page
⇒ page for controlling all stages of the dredging process
− opening closing of dredging valves
− monitoring all relevant data
− automatic control of the overflow weir
− opening closing of jet water valves
− stop/start of auxiliaries
− loading curve
⇒ loading computer
⇒ hydraulic page
⇒ alarm monitoring
⇒ settings pages (input of set points, limits etc.)
⇒ system page
⇒ help including pages for data logging, legends
⇒ side suction pipe
2.2.1 Headline
At the top of every page there is a headline with a description of the most recent alarm, a
counter of the active alarms, ship speed, date and time.
2.3 Dredging, Dumping and Discharging
The modes dredging, dumping and discharging are shown on a single screen page. The
page show the different pipe schemes with their related slide valves, valves and pumps for
controlling and monitoring. If the pipes are flooded due to the position of the valves and
pump status, this is indicated by a change in colour. Loading / unloading is indicated in a
trend curve.

2.3.1 Right Mouse Key
By clicking with the right mouse key on the symbols for valves and pump additional status
information is obtained via pop-up windows. From this status window a “times” window can
be selected and depending on the type of devices further windows may be available. Below
are the windows for the a valve with both digital and analogue position measurement.
A detailed description of these windows is provided in section 13.2.

2.4 Loading Computer
The Loading Computer is used for continuous, quantitative determination of the dredged
material of a hopper dredge. A detailed description of the loading computer functionality is
provided in section 15.
2.5 Hydraulics
The hydraulic display offers a quick overview of the actual measured values and status of
the hydraulic system including the active drag head hydraulic system. From this page it is
also possible to manually stop and start the following hydraulic pump motors:
⇒ Main pump unit no. 1

⇒ Main pump unit no. 2
⇒ Pressurisation pump no. 1
⇒ Pressurisation pump no. 2
⇒ Circulation pump
⇒ Filtration pump
It is also possible to select which of the two pressurisation pumps will operate as the master
pump.
The selection of main system high pressure when using the bow coupling is also made on
this page.

2.6 Alarm
The graphical alarm page shows messages and alarms with date, time, type, message text,
duration, class and status number. The status will shows in different colours.
⇒ Status and colours
– alarm active, not acknowledged => red
– alarm gone, not acknowledged => pink
– alarm acknowledged, still active => white
– warning acknowledged, still active => yellow
– warning gone, not acknowledged => pink
– warning acknowledged, still active => white
– message gone, not acknowledged => green
– message acknowledged, still active => orange
– message acknowledged, still active => white

The alarm page has a toolbar at the top of the page and a status bar at the bottom of the
page. The tool bar provides the following functions from left to right:
⇒ Message List – a list of all current alarms, warnings and messages

⇒ Long Term Archive – a list of up to the last 1000 alarms, warnings and messages
⇒ Individual Acknowledgement – only the last alarm, warning or message is
acknowledged
⇒ Group Acknowledgement – all alarms, warnings and messages visible on the page
are acknowledged
⇒ Selection – via a dialog a selection of the alarms, warnings and messages to be
displayed can be made
⇒ Report – the current selection of alarms will be printed

⇒ Beginning – the cursor jumps to the beginning of the current selection
⇒ End – the cursor jumps to the end of the current selection
The status bar provides the following information from left to right:
⇒ Current Date
⇒ Current Time
⇒ Number of current alarms, warnings and messages
⇒ Number of alarms, warnings and messages in selection
⇒ Number of unacknowledged alarms, warnings and messages
⇒ Selection active

2.7 Settings
The selectable limit and set point values determine when a colour change should take place
in the bar charts of the operating displays or are used in the control algorithms. The set
values apply to the connected systems. Inputs only have to been made once centrally.
Changed limit values can be saved by using the F10 function key or previously saved values
can be reloaded using the F9 function key. The system date and time can be changed from
the limit page using the F4 function key. A print of the limit page settings can be obtained by
pressing the hotkey combination Ctrl P.

2.7.1 User Settings
Pipe
SETPOINT AUTOMATIC DEPTH CONTROL MAN

⇒ This manual value determines the maximum depth to which the
draghead will be allowed to be lowered when automatic depth
control is active. This value is used when the on button is
activated. If the off button is activated the value is taken from the
DOMS system.
SETPOINT LOWER PIPE VERTICAL ANGLE CONTROL

⇒ This is the angle between the lower pipe and the sea floor at which
the lower pipe will be controlled.
AUTOMATIC LOWER PIPE VERTICAL ANGLE CONTROL

⇒ With these two buttons the function for the automatic control of the
lower pipe vertical angle control can be switched on or off.
NO BUZZER HIGH INT JOINT VERTICAL ANGLE

⇒ .With these two buttons it is possible to switch off the buzzer for the
high intermediate joint angle alarm generated by the automatic
lower pipe vertical angle control when this function is limited by the
intermediate joint vertical angle.
SETPOINT INT JOINT HORIZ ANGLE FOR ALARM HOISTING

⇒ This value determines the maximum horizontal angle of the
intermediate joint at which alarm hoisting will be initiated.
INT JOINT HORIZ ANGLE ALARM HOISTING

⇒ With these two buttons the alarm hoisting for automatic horizontal
angle control can be switched on or off.
NO BUZZER INT JOINT HORIZ ANGLE ALARM HOISTING

⇒ With these two buttons the alarm for intermediate joint horizontal
angle alarm hoisting can be switched on or off.
SWELL COMPENSATOR AUTOMATIC WIINCH CONTROL

⇒ With these two buttons the function for the control of the head
winch to automatically position the swell compensator can be
switched on or off.
WINCH OPERATION MAINTENANCE MODE

⇒ With these two buttons the maintenance mode for the winch
operation can be switched on and off. In winch maintenance mode
no interlocks are active and extreme care is required when
operating the side suction pipe. Maintenance mode is normally
only used for changing ropes or when a failure occurs where further
normal winch operation is not possible. These switches are
password protected.
Tide
TIDE VALUE
⇒ This is a manually input value for the current tide level which is
used to determine the position of the draghead relative to zero chart
level. With the on/off switches a selection can be made between a
manual tide value and that received from the DOMS system.

Loading Computer
SHIFT
⇒ This is a number which can be manually entered to track the shift
number and which is saved in the loading computer report.
PIPE INTERNAL DIAMETER

⇒ This is the internal diameter of the dredge pump discharge pipe and
is used to perform the production calculations.
SEA WATER DENSITY

⇒ This is the value of sea water at the dredging site to be used in the
loading computer calculations.
INSITU DENSITY
⇒ This is the value for the density of the material on the sea floor also
referred to as wet density. It is used in the tons dry solid
calculations.
DRY DENSITY
⇒ This is the value for the density of the dredged material in the
completely dry state with all moisture removed. It is used in the
tons dry solid calculations.
OPERATOR
⇒ The name of the current dredge operator can be enter here. It is
saved in the loading computer report.
DREDGING SITE
⇒ The name of the current dredging site can be enter here. It is
DUMPING SITE
⇒ The name of the current dumping site can be enter here. It is
COMMENT
⇒ A comment regarding the current dredging cycle can be entered. It
is saved in the loading computer report.
LIMIT FOR HEEL ALARM

⇒ This the set point for generating the maximum heel alarm.
LIMIT FOR DRAFT FORE ALARM

⇒ This the set point for generating the maximum fore draft alarm.
LIMIT FOR DRAFT AFT ALARM

⇒ This the set point for generating the maximum aft draft alarm.
LIMIT FOR HOPPER FORE ALARM

⇒ This the set point for generating the maximum fore hopper level
alarm.
LIMIT FOR HOPPER AFT ALARM

⇒ This the set point for generating the maximum aft hopper level
alarm.
LIMIT FOR TRIM ALARM

⇒ This the set point for generating the maximum trim alarm.

Weir
SETPOINT DRAFT FOR AUTOMATIC CONTROL

⇒ This is the draft set point for the weir automatic mode when
dredging sand. The automatic weir control lowers the weir to
maintain this draft if it is exceeded during sand dredging.
WEIR AUTOMATIC MODE

⇒ Slit or sand can The weir is lowered step wise by this amount by the
automatic control.
Dredge Pump
SETPOINT MAXIMUM VACUUM DREDGE-PUMP

⇒ This is the value at which an alarm for the maximum dredge pump
vacuum will be raised and/or alarm hoisting is initiated.
NO BUZZER HIGH VACUUM

⇒ These buttons can be used to select if a high vacuum alarm buzzer
is sounded when alarm hoisting is initiated during dredging.
DREDGE HIGH SPEED MODE

⇒ These buttons can be used to select high speed for the dredge
pump in discharging mode. In dredging mode low speed mode is
always selected automatically.
SETPOINT DREDGE-PUMP FLOW FOR DISCHARGING

⇒ This is the set point value which is used by the dredge pump
automatic speed controller during discharging.
SETPOINT MIN DREDGE-PUMP FLOW FOR DISCHARGING

⇒ This is the set point value which is used by the dredge pump
automatic speed controller during discharging.
2.7.2 Data logging

The data logging page is accessed from the page selection mimic under
SETTINGS/CAPTAIN. Data logging is activated during dredging, dumping and discharging.
During this time process data is logged in a *.txt file named with the current date and trip
number, and stored in the folder C:/Projekt_Bau_819/Logging on the DCMS computer.
At the end of each trip the trip data is logged in the table “Wadreco” in the file named
Trips.mdb and stored in the folder Projekt_Bau_819/Data on the DCMS computer.

Data Transfer to Floppy
The logged files can be transferred to Floppy disk on the DCMS computer by pressing the
save data button. The windows explorer is started and files can be transferred using
standard windows functionality.
RAM usage
This display shows the current RAM usage.

Disk usage
This display shows the used memory space, but not before 5 minutes after start the system.
CPU usage
This display shows the current CPU usage.

2.7.3 Password Protection
The changing of some settings and performing of some functions in the system is password
protected . To obtain access the following steps must be taken:
Login by pushing the key combination Ctrl+ L

- input of Login
- input password:
- press the OK key
If a wrong password or Login was entered, a corresponding message is shown on the

display. After confirmation of this message, the Login can be made again by pushing Ctrl+ L.
No message is shown for a successful Login.

2.8 System
This page gives an overall view of the PC and PLC system. It shows the PLC devices and
their connection to the different components.
Clicking with the left mouse key on the PLC symbol opens an additional window which
shows the status of the PLC digital and analogue, inputs and outputs. This window can be
very useful when fault finding and during general maintenance operations.

2.9 Help
On the help page the following pages can be selected using the buttons at the bottom of the
page.
2.9.1 DCMS Schematics
Pressing the F1 button starts Acrobat Reader and displays the DCMS electrical schematics
which can then be used for fault finding and general maintenance purposes.
2.9.2 Symbol declaration
The DCMS includes many are many different symbols for visualisation. The legend pages
describe and explain the symbols by example. The dynamic symbols always show the
current status of the devices. The different status information is provided by varying the
colour and condition of the symbol.
Selecting the F2 button opens the legend page for valves.

Selecting the F button opens the legend page for pumps.
2.9.3 System Keys
The system keys page is a password protected page and is only accessible by train
personnel for maintenance purposes.
2.9.4 DCMS Handbook
Pressing the DCMS Handbook button displays this handbook in adobe acrobat format.
2.9.5 Print Fail
Should a loading computer printout or a print screen order be unsuccessful due to a

temporary printer problem the failed print is stored in the system. Using this button these
prints can be accessed or reprinted if required.
2.9.6 Service Logon
This key provides a quick logon for the normal service mode without the necessity for
entering a user name or password.
2.9.7 Restart Key

Should a restart of the DCMS PC be required this is performed by pressing the F12 key.
This function is password protected.
2.10 Side suction pipe position indicator
2.10.1 General
The side suction pipe positioning system calculates and displays the position of the side
suction pipes with reference to the ship’s side. The calculation of position is performed using
the following sensor data:
⇒ winch rope lengths

⇒ the position of the swell compensator
⇒ transverse angles of the winch ropes
2.10.2 Features and Functions

The suction pipe is represented in plan and side view on the colour monitor. Together with
these views the following instrumentation is shown on the monitor:
⇒ draught at trunnion numeric

⇒ trim numeric
⇒ heel numeric
⇒ dredging depth below keel numeric
⇒ dredging depth below waterline numeric
⇒ dredging depth below chart null numeric
⇒ distance suction head - ship’s side numeric
⇒ position of swell compensator bargraph
⇒ pressure of swell compensator bargraph
⇒ mixture velocity graphical
⇒ mixture density graphical
⇒ production graphical
⇒ tide manual input numeric
⇒ upper pipe vertical angle numeric
⇒ lower pipe vertical angle numeric
⇒ intermediate joint vertical angle numeric
⇒ upper pipe horizontal angle numeric
⇒ lower pipe horizontal angle numeric
⇒ intermediate joint horizontal angle numeric
The following onscreen messages are also provided to indicate the position and status of the
side suction pipe:
⇒ Pipe on Deck – the pipe is resting in the saddles and both pipe on deck sensors have
operated
⇒ High Position – the pipe has been raised to the high position where the gantries can
now be operated to swing the pipe in or out
⇒ Trunnion Line – the pipe has been swung out and lowered to the position where the
trunnion is covering
⇒ Service Mode for Pipe Active
⇒ Alarm Hoisting
⇒ Sensor Failure Pipe Position Unknown

The displayed dredging depth is referenced to the drag head visor bolt.
The displayed distance of suction head to the ship side is referenced to the centre of the
drag head and to the vertical ship’s hull.
The value of tide displayed is either that manually input on the user settings page or that
obtained from the DOMS system..
The bottom right hand corner of the display includes a window which switches between a
production indicator when the pipe is below trunnion line and an indicator showing the status
of the side suction pipe sensors and actuators when the pipe is in or above trunnion line.
When view the side suction pipe mimic on the DCMS display this window can be locked to
display the the sensors and actuator information by the key combination Ctrl R.

The side suction pipe sensors and actuators window displays the following information:
(1) Rope length of each winch

(2) Rope length to the high position
(3) Distance measured by the emergency stop ultrasonic sensor
(4) Winch speed
(5) Winch hoist solenoid
(6) Winch lower solenoid
(7) Winch brake solenoid
(8) Gantry in solenoid
(9) Gantry out solenoid
2.10.3 Functions
Once the pipe leaves the “pipe on deck” position, the rope length values are automatically
reset by the limit switches so that changes of the rope length due to the rope stretching do
not have any effects on the indication. The value of the trunnion winch is reset to zero when
the sliding piece reaches the high position.
2.10.4 Connection to the control and monitoring system

The suction pipe indicator is connected via profibus-network to the DCMS. In case of a
failure or a break down of the network connection all bargraphs and numeric outputs are
displayed with a dark grey colour.

3 Swell Compensator
3.1 Sensors and Controls
3.1.1 Sensors
The swell compensator is provided with the following sensors:
(1) Pressure vessel min and max fill level switches

(2) Differential pressure switch < 4bar for ground detection
(3) Differential pressure switch > 4bar for broken wire detection
(4) Pressure transmitter for cylinder pressure
(5) Swell compensator position measurement
3.1.2 Hydraulic Controls

The swell compensator is provided with the following control valves:
(1) Solenoid to switch the cylinder active

(2) Solenoid to switch the cylinder inactive
(3) Solenoid to fill the pressure vessel
(4) Solenoid to empty the pressure vessel
3.1.3 Desk Controls

The dredge control desk pushbuttons and lamps for the swell compensator are:
(1) Pushbutton ON (Active)

(2) Pushbutton OFF (Inactive)
(3) Pushbutton Increase Pressure
(4) Pushbutton Decrease Pressure
When the swell compensator is switched active it is free to move quickly in both directions.
When the swell compensator is switched inactive the it can only extend slowly.
The pushbutton ON is interlocked with the differential pressure switches to ensure that the
active solenoid cannot be operated unless the pressure difference between the cylinder and
pressure vessel is in the range +- 4bar. When the ON pushbutton is pressed it begins to
flash and remains flashing until the active solenoid has been operated when it then becomes
steady.
3.2 Pressure and Level Monitoring
The pressure and fill level are monitored in the following ways:
(1) Using the fill min and max level switches

(2) using the pressure transmitter on the cylinder
When either the min level or min pressure is reached the emptying of the pressure vessel is
automatically stopped.
When either the max level or max pressure is reached the filling of the pressure vessel is
automatically stopped.
The pressure transmitter is also used to indicate the cylinder pressure. A separate analogue
instrument is provided in the dredge control desk for this purpose.

3.3 Operational Functionality
The swell compensator is normally switched on (i.e. active) in all four suction pipe modes
(service, manual, one lever and auto-depth) and is free to move in both directions. In the on
deck position the swell compensator is fully retracted. The swell compensator automatic
functions are:
(1) First time ground detection

(2) Range control
(3) Ground detection by pressure difference
(4) Broken rope detection
All four functions are included in one lever and auto-depth control modes. In manual pipe
mode only the function broken rope detection is included.
3.3.1 First time ground detection

First time ground detection is a function which determines when the draghead has reached
the seafloor for the first time after being lowered from the deck. The position of the swell
compensator is monitored and when the piston has extended more than a pre-set
percentage of the stroke length it is assumed that ground has been reached. At this time the
head and intermediate winch are automatically stopped.
3.3.2 Range control

The DCMS has settings for min and max position of the swell compensator.
After ground has been detected the range control function becomes active. This function
controls the draghead winch so that the swell compensator is returned to the mid-position if
it moves outside the min and max range.
In one lever mode the swell compensator can then be re-positioned within the operating
range using the draghead winch lever. If the swell compensator is driven by lever to the
max limit the range control automatically re-positions it to the mid-position. If the swell
compensator is driven by lever to the minimum position the range control does not operate
to ensure that the draghead can be raised quickly if required. In one lever mode the
draghead winch lever only operates the draghead winch while ground is detected.
In auto-depth pipe mode the levers are inactive.
3.3.3 Ground detection by pressure difference

During alarm hoisting the swell compensator is switched inactive and the pressure in the
swell compensator cylinder is greater than the pressure in the pressure vessel. When alarm
hoisting is over and the draghead is lowered again the swell compensator must be switched
active again when the seafloor is reached.
Before the swell compensator can be switched active the pressure in the cylinder must have
reduced to within 4 bar of the pressure in the vessel pressure. This condition is used to
detect when the draghead has reached the ground and the differential pressure switch <
4bar is used for this purpose.
It should be noted that in manual pipe mode the swell compensator is switched on and off
manually using the controls on the dredge desk.

3.3.4 Broken rope detection
The purpose of broken rope detection is to prevent damage to the swell compensator in the
event of a broken or suddenly loose rope. The detection of this condition is performed using
the differential pressure switch > 4bar. When this condition is detected the swell
compensator is immediately switched inactive and the piston is unable to extend quickly
although a sudden negative pressure difference has arisen between the cylinder and the
pressure vessel.
3.4 DCMS Visualisation
Indication for the swell compensator are provided as follows:
3.4.1 Desk
⇒ Pressure analogue meter
3.4.2 Side Suction Pipe Display and Hydraulics Page

⇒ position of swell compensator bargraph
⇒ pressure of swell compensator bargraph
⇒ compensator on/off indication button
⇒ compensator broken rope indication button
⇒ ground detection pressure switch indication button

4 Operation of the side suction pipe
Before operating the side suction pipe the hydraulic system must be running and the swell
compensator must be switched on. The hydraulic system is started from the hydraulics
page. Refer to the hydraulics section of this manual for details.
The side suction pipe can be operated in four modes. These are:
⇒ Service mode
⇒ Manual mode
⇒ One lever mode
⇒ Depth control mode
Note that in manual and service modes pushing the levers 4, 5 and 6 forward lowers the
pipe and pulling the levers back raises the pipe. In automatic mode pushing the lever 4
forward deploys the pipe and pulling the lever back recovers the pipe.
4 5 6

7 8 9
10 11 12
4.1 Manual Operation
4.1.1 Swinging the side suction pipe out
a) Press push button 1 (illuminates white) and the manual winch

control is active.
b) Using three control levers 4, 5, 6 (pull backwards) and move the
side suction pipe from the support brackets to the uppermost
position of the gantries. Winches automatically stop in high position.
This position is calculated from the winch rope length sensor
feedback signals.
c) Press push buttons 7, 8, 9 (illuminate white) to extend the three
gantries
Attention: The three gantries must be operated in such a

manner that no damage occurs to the pipe due to a collision
with the ship structure.

4.1.2 Lowering the side suction pipe
a) By pushing the control levers 4, 5 and 6 forward the side suction

pipe can be lowered manually. The levers should be held in
approximately the same position to ensure that all three winches
run at the same speed and that the pipe is lowered horizontally.
When the trunnion winch slack rope limit switch has operated the
trunnion winch stops. Lowering of the head and intermediate
winches is still possible. It is however a good practice to stop the
pipe at trunnion line before proceeding further.
b) By pushing the control levers 4 and 5 forward the side suction pipe
can be lowered further with the head and intermediate winches
running at variables speeds set by the lever position. The pipe
pivots around the trunnion and lowering of the pipe continues until
contact with the sea floor is made. There is no pipe angle limitation
in this mode and the operator must monitor the configuration of the
pipe at all times. Lowering of the pipe in manual mode is stopped
by either releasing the levers or by the end of rope limit. When the
drag head reaches the sea floor the swell compensator cylinder
extends and the operator stops the winch to position the swell
compensator as required. In manual mode there is no automatic
control of the swell compensator.
4.1.3 Hoisting the side suction pipe to high position

1. The pipe cannot be raised past trunnion line before the jet water
pumps and the dredge pump are stopped and no rope limit switch
is active.
2. The swell compensator is normally left on and the cylinder retracts

fully when the drag head is lifted from the sea floor.
a) Using control levers 4 and 5 (pulled backwards) the side suction

pipe can be raised with the head and intermediate winches
operating at variable speeds set by the lever position. The winches
do not stop automatically at trunnion line, however in manual mode
it is good practice to stop the pipe at this point before raising it
further.
b) Using control levers 4, 5 and 6 (pulled backwards) the side suction
pipe should be raised with the head, intermediate and trunnion
winches operating at the same speed set by the lever position.
When the high position of the respective winches is reached these
are stopped automatically.
4.1.4 Swinging the side suction pipe in
a) Press push buttons 10, 11 and 12 and the three gantry cylinders
retract. The winches are not active while the side suction pipe is
swung in.
Attention: The three gantries must be operated is such a
manner that no damage occurs to the pipe due to a collision
with the ship structure.
b) When the gantries have retracted the head and intermediate gantry
winches can be operated to lower the pipe into the cradles using
three control levers 4, 5 and 6 (pushed forwards). The respective
pipe on deck proximity switches stop the winches automatically.

4.2 One Lever Operation
4.2.1 Swinging the side suction pipe out
a) Press push button 2 (illuminates yellow) and the suction pipe

automatic winch control is active.
b) In auto mode the gantries are controlled by single lever operation of

the head winch lever 4. When the pipe is in the on deck position
pushing lever 4 forward hoists the pipe by operating all three
winches until the respective high positions have been reached.
Then all three gantries are simultaneously extended. When all three
gantries have reached the out position all three winches operate to
lower the pipe. When the trunnion service frame low position limit
switch has operated and the head and intermediate rope lengths
have reached predetermined values all three winches stop. The
pipe has then reached the trunnion line position.
Note: Releasing the lever at anytime will stop the movement of

the pipe.
4.2.2 Lowering the side suction pipe
a) After reaching trunnion line the rope speeds of the intermediate and
head winches are adjusted so that the pipe is configured in
accordance with the user settings for the pipe. Lowering of the pipe
in automatic mode is stopped by either releasing the lever, by the
end of rope limit switch or when the swell compensator cylinder
extends which indicates that the pipe is on the ground. After this
time the head winch is controlled to maintain the swell compensator
in the operating range and the intermediate winch is controlled by
the lower pipe angle function.
4.2.3 Hoisting the side suction pipe to high position

a) Using control lever 4 (pulled backwards) the side suction pipe can
be raised automatically with the head and intermediate winches.
b) When the pipe reaches trunnion line all three winches operate at
approximately the same speed set by the lever position and are
stopped automatically when the respective high positions are
reached.
4.2.4 Swinging the side suction pipe in

a) Using single control lever 4 (pulled backwards) the three gantry
cylinders can be retracted swinging the pipe in. When the cylinders
are fully retracted the head and intermediate gantry winches
automatically lower the side suction pipe into the cradles. The
respective pipe on deck proximity switches stop the winches
automatically.
Note: Releasing the lever at anytime will stop the movement of

the pipe.

4.3 Automatic depth control of draghead
The automatic depth control mode is used to ensure that no over dredging occurs and when
spot hopping. The automatic depth controller maintains the draghead within the required
dredging depth when the water depth exceeds the set dredging depth
1. The set point for automatic depth control is entered on the user
settings page refer section 2.7.1.
2. The side suction pipe must be at or below trunnion line.
3. The automatic depth control is selected by pressing pushbutton 3

(illuminates yellow).
4. When pushbutton 3 is pressed the suction pipe is lowered or raised

from the present position (at or below trunnion line) to the set depth.
This mode includes the suction pipe transverse angle control and vertical angle control. The
swell compensator operates in a similar manner to one lever control with the following
differences
(1) The lever command to lower the pipe is inactive. A lever command to raise the pipe
immediately switches the control mode to one lever control.
(2) When approaching the auto depth control set point the swell compensator
automatically retracts in that the draghead winch is hauled in. The result is that
when the draghead is at the depth set point the swell compensator is fully retracted.
In this way it is not possible for draghead to go below the set depth.
4.3.1 Dredging depth

The measuring point of the dredging depth is in the lower edge of the draghead.

4.4 Service Mode
The service mode is provided for maintenance functions such as rope changing and for
situations where the suction pipe must be recovered due to sensor malfunction. In this
mode no control or safety interlocks are active. All three winches and gantries can be
operated individually at any time and driven to any position. In this mode the utmost care
and attention is required to avoid damage and/or injury during the operation of the pipe.
The selection of service mode is password protected and can only be made from the DCMS
main display. Service mode can be entered from any other mode and independent of the
pipe position. While the pipe is in service mode a text indication is displayed on the side
suction pipe indicator and the manual control mode pushbutton flashes.
If the swell compensator is switched active in service mode it operates passively i.e. there
is no automatic control of the winches to position the compensator.
The side suction pipe controls act in the following way when service mode is selected:
4.4.1 Gantry Pushbuttons
The gantries only move in or out as long as the respective pushbutton is being pressed.
4.4.2 Winch levers
The winch pays out only as long as the lever is pushed forward.
The winch hauls in only as long as the lever is pulled back.

4.5 Emergency hoisting
Emergency hoisting is a hard wired control feature designed to enable the dredge operator
to raise the drag head to a sufficient level above the seafloor, allowing manoeuvring of the
vessel in the event of an emergency involving the loss of main electrical power or the failure
of the automation system.
Power for operating the winch is provided by the emergency hydraulic pump which is fed
from the emergency switchboard. This pump should be maintained in an available status at
the dredge control desk at all times (lamp 21 illuminated green).
The following steps are required to perform this:
1. Start the emergency hydraulic power pack by pressing the push

button 22. This button illuminates green when the pump motor has
started. The pressure developed by the pump can be monitored
with the analog instrument 25.
2. Press the emergency hoisting pushbutton 24. The swell

compensator is switched off and the necessary hydraulic valves are
operated to start raising the drag head.
If the dredge master still has use of the suction pipe display (i.e. no failure of the automation
system) he can use this display to determine the position of the drag head/pipe and when to
stop hoisting the pipe. In the case that the displays are not functioning the dredge master
must use his experience to determine when the drag head has been raised sufficiently, and
to switch of the emergency hoisting before damaging / over bending the pipe.
The automation system receives a signal when emergency hoisting is taking place and does
not take any action which would work against the emergency hoisting function.
24 21
22
25

4.6 Hydraulic Emergency Stop
A hydraulic emergency stop pushbutton is installed in the dredge control desk for the event
that the complete motion of the pipe must be stopped quickly. This button can also be used
to stop the hydraulics in the event of other emergencies associated with the other
hydraulically operated equipment.
When the power is reconnected to the hydraulic system after an emergency stop the
gantries and winches will remain stationary until a new command is given from the dredge
control desk via the pushbuttons or levers.

5 Dredge Pump Operation
The dredge pump is connected to the starboard main engine via a hydro coupling and a two
speed gear and is displayed as shown below on the dredging page without the hydro
coupling. The dredge pump cannot be controlled from the DCMS mimics and starting and
stopping of the pump is always performed from the hardware controls on the dredge desk.
The most important measured values for the dredge pump are displayed in bargraph form
on the dredging page:
5.1 Drive Chain Auxiliaries
The auxiliary drives associated with the dredge pump drive chain are:
⇒ Hydro coupling fill pump

⇒ Hydro coupling output shaft brake
⇒ Gear box lube oil pump
⇒ Dredge pump sealing water pumps (2 off)
The hydro coupling fill pump also lubricates the hydro coupling bearings and must run
whenever the main engine is running. The fill pump is started automatically by the main
engine controls.
The shaft brake is operated by two air operated valves and must be closed to enable gear
changing. Conversely the brake must be open to enable filling of the hydro coupling. The
brake is operated by the DCMS automatically as part of the starting and stopping of the
dredge pump. There are no manual controls on the DCMS for the brake.

The gearbox lube oil pump must be running before any operations of the gearbox are
allowed. Starting and stopping of the pump is performed manually from the DCMS mimics.
In addition the lube oil pump is also stopped automatically a pre-set time after the dredge
pump has been stopped.
Starting of the dredge pump is always interlocked with the running of the sealing water
pumps. Starting and stopping of the pumps is performed manually from the DCMS mimics.
In addition the sealing water pump is also stopped automatically a pre-set time after the
dredge pump has been stopped.
5.2 Hydro Coupling
The hydro coupling input shaft is directly connected to the main engine shaft. When the
hydro coupling is empty the output shaft only rotates slowly, idling without effective torque
transfer. For gear changing purposes a brake ensures that the hydro coupling output shaft
is stationary at this time. As the hydro coupling is filled with oil the torque is increasingly
transferred to the output shaft.
5.3 Dredge Pump Gear
When dredging mode is selected on the navigation console the gear is automatically
selected in low speed. If discharging mode is selected in the navigation console hopper
discharging can be performed with the gear selected in high speed or low speed. This
selection is performed on the user settings page see section 2.7.1.
5.4 Right Mouse Click
Via the right mouse click function the following windows can be displayed to provide further
information about the status of the dredge pump drive chain and it’s associated release
interlocks, starting and running conditions.

5.5 Mode Selection
The required operation mode is selected via a three position switch on the navigation
console. The positions are:
⇒ Dredging
⇒ Sailing
⇒ Discharging
When dredging mode is selected the low gear for the dredge pump gear is automatically
selected and the propulsion control system reserves 420kW of starboard main engine power
for the dredge pump and 420kW of port main engine power for the jet pumps..
When discharging mode is selected the propulsion control system blocks the operation of
the starboard propulsion lever and reserves 420kW of port main engine power for the jet
pumps. Either high or low gear is automatically selected depending on the selection on the
user settings page.
5.6 Starting the dredge pump
1. Start the flushing water pump and open the necessary sluice to
ensure that a flow path is available for the task at hand (dredging or
discharging)
2. If discharging is to be performed select the required gear speed
range on the user settings page.
3. Start the gearbox lube oil pump.
4. Start the sealing water pumps.
5. Select the required mode on the navigation console (dredging or
discharging). At this time the gearbox switches to the required
speed range.
6. Ensure that manual speed control for the dredge pump on the
dredge control desk is selected. Note: Automatic speed control can
be selected but only becomes active once the dredge pump is
running.
7. When all interlock conditions have been met the “M/E READY FOR
DP CLUTCH IN” lamp (60) will be illuminated on the dredge control
desk.
8. Press the “CLUTCH IN” (62) button to start filling the hydro coupling
and the button flashes. The DCMS opens the brake and as the
hydro coupling fills the pump will begin to turn. Observe the pump
speed and hydro coupling slip indications on the dredge control
desk.
9. When the pump has reached the minimum allowable speed (ca
15% slip) the “CLUTCH IN” button extinguishes and the “CLUTCH
OUT” button (65) illuminates. The dredge pump is now running.
Dredge pump manual speed control
10. The dredge pump speed can now be varied manually within the
allowable range of 85 to 100% by using the “INCREASE” (63) and
“DECREASE” (66) buttons on the dredge control desk.
Dredge pump automatic speed control
11. Automatic speed control is only available in discharging mode.
Once the dredge pump is running stable in the manual mode press
the “AUTOMATIC” button (64) to switch to automatic control. The
DCMS now controls the pump speed according to the parameters
set on the user settings page.
12. Pressing the “MANUAL” button (61) at any time returns the pump to
manual control.
Note: The increase and decrease buttons can be used at anytime
during starting or in automatic mode to take-over control of the
hydro-coupling and reduce or increase speed.

5.6.1 Dredge Pump Start Conditions
The status of the dredge pump start conditions is available in the DP more window by using
the right mouse click function as shown above in section 5.4
5.6.2 Dredge Pump Running Conditions

There are few conditions which will cause the dredge pump to stop automatically as this can
lead to a blocked pipeline during discharging resulting in a long delay and loss of time.
Therefore the operator must use his judgement to ensure that the dredge pump or it’s
drive chain components are not damaged when alarm conditions such as low gear
box oil pressure or no sealing water flow occur. The dredge pump will automatically stop
under the following conditions:
(1) If the mode switch is switched to sailing the hydro-coupling will be emptied. If the
mode switch is returned to sailing or dredging before the pump has stopped the
hydro-coupling will be automatically filled gain.
(2) If a main engine shutdown occurs the dredge pump will stop. The DCMS
automatically closes the hydro-coupling fill valve and opens the hydro coupling empty
valve. When the shaft has stopped rotating the gearbox is switched to neutral and
brake is opened. As a safety measure all further operations with the dredge pump
are blocked until the mode switch has been set to sailing and the main engine has
once again reached full speed.
5.7 Stopping the dredge pump
The dredge pump can be stopped at any time by pressing the “CLUTCH OUT” button.
When the button is pressed the DCMS em.pties the hydro-coupling of oil. During this time
the “CLUTCH OUT” button flashes. When the hydro coupling output shaft speed has
reduced to the minimum idling speed the brake is closed and the “CLUTCH OUT” button
stops flashing and the “CLUTCH IN” button illuminates. If the dredge pump was stopped in
automatic speed control, manual speed control is automatically selected when the pump has
stopped.
Two minutes after the dredge pump has stopped the sealing water pumps are stopped
automatically.
To return the gearbox to the neutral position sailing mode must first be selected on the
navigation console. Two minutes after the DCMS has switched the to neutral the gearbox
lube oil pump is automatically stopped.
5.8 Restarting the dredge pump
The dredge pump can be restarted at any time provided the mode has not been switched
back to sailing. It may however be necessary to restart the sealing water pumps.

5.9 Emergency stop of the dredge pump
In the case of an emergency where the normal clutch out button is not operational the
dredge pump can be stopped via a latching emergency stop push button (67) on dredge
control desk. This is a hard-wired function which directly deactivates the hydro coupling fill
valve and operates the empty valve.
60
61 64
62 65
63 66
67
5.10 Main Engine Shutdown
In the event of a main engine shutdown the dredge pump drive chain will stop turning quickly
and the hydro coupling will become stationary when still filled with oil. It will then take some
time for the oil to drain. To ensure that after a shutdown the main engine cannot be started
with the load of the dredge pump, the DCMS takes the following actions:
⇒ The gearbox is switched to neutral

⇒ The brake is opened
⇒ Restarting of the dredge pump is blocked till the switch on
the navigation console has been switched back to sailing
mode

6 Jet Pump Operation
The jet pumps are connected mechanically in series via a remotely controlled clutch to the
port main engine. When the clutch is engaged jet pump no.2 is always started. If both
pumps are required the shaft of jet pump no.1 must be connected locally to jet pump no.2.
6.1 Jet Pump Clutch
The jet pump clutch is air operated. The available air pressure is monitored and used by the
DCMS as an engaging interlock for the clutch. If the clutch is engaged and the air pressure
falls below a set value the clutch is automatically disengaged by a local hard wired control
function. Clutch engaged signals are supplied to the DCMS, main engine and shaft
generator controls from locally mounted pressure switches.
Via the right mouse click function the following windows can be displayed to provide further
information about the status of the dredge pump drive chain and it’s associated release
interlocks.

6.3 Starting the jet water pumps
1. Prepare the required flow path for the pumps depending on the task
to be performed i.e. series operation for dredging or parallel operation
for discharging.
2. When all interlock conditions have been met the “JET WATER
AVAILABLE LAMPS” lamps (70) (71) will be illuminated on the
dredge control desk.
3. Press the “START JET PUMPS” (72) button and this button begins to
flash. When the jet pump clutch is engaged this button stops flashing
and the “STOP JET PUMPS” button (73) is illuminated.
70
71
72
73
6.3.1 Jet Pump Starting Conditions

The status of the jet pump start conditions is available in the JP more window by using the
right mouse click function as shown above in section 6.2. Depending on jet pump
arrangement to be used serial, parallel or JP2 only different flow path conditions are required
and the connection of JP1 maybe or maybe not required.
6.3.2 Jet Pump Running Conditions

There are three running conditions for the dredge pump which disengage the clutch:
(1) Air Pressure Ok. The local controls for the jet pump disengage the clutch. The
DCMS also does this as a backup.
(2) Switching to sailing mode automatically disengages the jet pumps.
(3) A blackout or main engine shutdown automatically disengages the jet pumps.
6.4 Stopping the jet water pumps
1. The jet water pumps can be stopped at any time by pressing the jet
water stop button (73). The stop button begins to flash. When the
clutch is out the button stops flashing and the START button
becomes illuminated.

6.5 Emergency stop of the jet water pumps
In the case of an emergency the jet water pumps can be stopped via a latching emergency
stop push button (74) on dredge control desk. This is a hard-wired function which directly
operates the solenoid operated air pneumatic valves on the clutch.
74

7 Dump Valve Operation
The dump valves can be operated in three ways.
⇒ In a group by using the hardware pushbuttons (30, 31, 32

and 33) provided on the dredge control desk
30 32
31
33
⇒ Individually by clicking with the left mouse key on the bottom

valve symbol on the main dredging mimic.
⇒ Individually by clicking on the arrowhead pushbuttons next to

the individual dump valve symbol on the display.
The position of the dump valves is monitored with three limit switches:
⇒ closed
⇒ 50%
⇒ open
Pressing the relevant hardware or software pushbutton opens or closes the valve to the
selected position. The dump valves can stopped in any position by pressing the STOP
pushbutton (31). Using the arrowhead pushbuttons each valve can be driven into individual
positions.

7.1 Operating Pressures
When opening the dump valves the initial movement of the valve is achieved by applying
250bar opening pressure. Once the valve has left the closed position this pressure is
reduced to 100bar.
When closing the dump valves the full length of the stroke is performed with 60bar. When
the closed position has been reached a sealing pressure of 250bar is applied. After a pre-
set time the dump valve holding pressure is then switched on.
The 60bar closing pressure is used to prevent damage to the valve in the event that an hard
object has become caught between the valve and the valve seating. It can be the case
however that the valve will not fully close with this pressure due to a build up of sand or silt
around the valve seating. To overcome this it is possible via the right mouse click window to
temporarily override the closed limit switch for one closing operation so that 250bar can be
applied to close the valve. WARNING: The operator must ensure that no hard objects are
blocking the closing of the valve before performing this operation.
Right mouse click windows are also provided for the dump valves.
7.3 Emergency dumping
At any time during dredging or sailing it may be necessary to perform an emergency

dumping operation. An emergency dumping push button is located on the navigation
console for this purpose. Emergency dumping is a hard wired control which opens the
bottom valves independent of all automation and hydraulic system functions.

8 Sluice and Jet Valve Operation
The mixture sluice and jet valves are hydraulic operated valves controlled via the DCMS
using two discrete outputs ’open’ and ’close’. Operation of the valve is performed manually
at the dredge control display. Either two discrete inputs ‘open’ and ‘close’ or an analogue
position sensor (where installed for sluice suction valves) are used for indication of actual
valve position. The respective open or close output is energised until the limit switch is
reached or until the time out detection has operated. There is no local electrical operation of
the valves. The operation of the sluice valves is interlocked with the availability of flushing
water.
Normal operation of the valves is performed by clicking on the symbol on the dredge page
with the left mouse key. The symbol flashes if the valve is moving. The symbol is filled
when the valve is closed and unfilled when the valve is open. If the valve is open clicking
once will close the valve. Clicking again will open the valve again. Refer to section 2.9.2 for
details of valve symbols and colours.
The right mouse click pages for the valves are:

9 Weir
The overflow weir is controlled by the DCMS in automatic or manual mode. In manual mode
the software arrowed pushbuttons on the main dredging mimic are used to drive the weir up
or down. The weir is driven as long as the pushbutton is pressed.
In automatic mode the operation of the weir is dependent on whether silt or sand has been
selected on the user settings page. When silt is selected the weir is driven to the highest
position and remains there.
If sand has been selected, during dredging the weir is automatically lowered from the
highest position to limit the ship’s draft to the set point thereby allowing a maximum of sand
to be loaded. At the start of discharging the weir is then driven to the highest position.
10 Flushing Water and Ballast Water
Flushing water is required for the operation of the sluice and is obtained from the general
services pump which is also used for filling the fore ballast tank. The capacity of the flushing
pump is sufficient to supply all valves at the same time. The pump and valve A108 are
operated manually from the dredging page. The fore ballast tank can be filled or emptied by
operating the valves A106 or A107 respectively.

11 Sealing Water
Sealing water is required as a starting condition for the dredge pump. There are two sealing
water pumps. One supplies sealing water to the suction side of the dredge pump and the
other sealing water to the shaft side.
The pumps are started and stopped manually from the dredging page by clicking on the
respective symbol with the left mouse key. The pumps are also stopped automatically a pre-
set time after the dredge pump has stopped.

12 Loading computer
12.1 General
The loading computer is used for continuous, quantitative determination of the dredged
material. The system provides the operator with a quick and complete overview of the status
of the ship (draft, trim, heel and hopper level), the operational data (production, density,
displacement, load, solid, etc.) and the operation mode. The measured and calculated data
are shown on a dedicated screen page in a clear manner displaying all relevant data.
Curves for hopper load, hopper volume and tons dry solid are displayed full width at the
bottom of the page.
The determination of the load condition of the ship is performed using the values measured
by various sensors. The fore and aft draft is measured by pressure sensors and the hopper
level is measured by two ultrasonic sensors. Trim is calculated from the values provided by
the draft sensors. The ship displacement and hopper volume are obtained from the tables
stored in the loading computer using the draft, hopper level and trim values. The dredged
material without water content (dry) is calculated using the displacement and volume values
obtained from these tables and the manual inputs of the seawater, insitu and dry density.

12.2 Manual inputs
The following data are entered manually on the limit page of DCMS and appear on the
loading computer screen automatically:
- shift
- dredge master name
- dredging site
- unloading site
- seawater density
- insitu density
- dry density
- comment
- limit in degrees for heel alarm
- limit in metres for draft alarm fore
- limit in metres for draft alarm aft
- limit in metres for hopper level alarm fore
- limit in metres for hopper level alarm aft
- limit in degrees for trim alarm
12.3 Functions
12.3.1 Empty Ship Weight
The empty ship weight is used to determine the

actual ship load by subtracting it from the
displacement obtained from the tables when the ship
is loaded. A function is provided to calculate the
empty ship weight and it is started from a separate
window which is opened by pressing the F1
pushbutton on the loading computer screen. It is
possible to take the empty ship weight with open or
closed bottom valves. Empty ship weight itself is
obtained from the displacement tables when the ship
is in the unloaded condition. If taken with bottom
valves closed the empty ship weight function
assumes that the measured level in the hopper is
sea water and the weight is modified accordingly.
Pressing the CALIBRATE button perform the

calculation and the result is displayed at the bottom
of the window.

12.3.2 Operation Mode
Click on the F2 button on the loading computer page

opens the operating mode window.
In this window the dredging cycle is displayed with the

current mode in green and the possible next modes in
blue. Modes that cannot be entered are displayed in grey.
From this window AUTOMATIC or MANUAL recognition of
the operation mode can be selected. If manual recognition
has been selected each change in the operating mode
during the cycle must be selected by hand on this window.
MANUAL can be selected at any time however
AUTOMATIC can only be selected when the
corresponding conditions for the operation mode as listed
above are met. The LC Data window indicates if these
conditions have been met (see 12.3.3). STANDBY can
also be selected from this page but only when MANUAL
has already been selected. A flashing yellow indication
appears on the screen when MANUAL recognition has
been selected.
A dredging cycle consists of the following operation modes:
• DREDGING
• SAILING LOADED
• DISCHARGING
• DUMPING
• SAILING UNLOADED
• STAND BY
The loading computer stores the duration for each of the operation modes during a dredging
cycle. A dredging cycle commences with DREDGING and is completed at the end of
SAILING UNLOADED. All modes with the exception of standby can be determined
automatically by the loading computer. To do this the loading computer uses the system
status conditions defined below. Once a operation mode has been detected the loading
computer remains in this mode until another mode is detected. If necessary it is also
possible to select all of the operation modes manually. A separate window which can be
opened from the loading computer screen is provided to make the required selections. If
manual is active then all operation modes must be selected manually by the operator. If
automatic is selected no manual selections can be made.
12.3.2.1 DREDGING Operation Mode
The dredging operation mode is set when the following conditions are met:
• One suction pipe below trunnion line
• Dredge pump running
• Density ok (same as for the poor mixture function)
• One hopper loading sluice valve open
• Bow discharge valve not open
The dredging operation mode is reset when one any one of the following conditions are met:
• Sailing loaded conditions met

• Discharging conditions met
• Dumping conditions met
• Standby selected
12.3.2.2 SAILING LOADED Operation Mode
The sailing loaded operation mode is set when the following conditions are met:
• Suction pipe above trunnion line

• All bottom valves closed
• Cycle has been started (Dredging mode has been set in current cycle)
The sailing loaded operation mode is reset when one any one of the following conditions are
met:
• Dredging conditions met

12.3.2.3 DISCHARGING Operation Mode
The discharging operation mode is set when the following conditions are met:

• Bow discharge flow path open
• Hopper loading sluice valves closed
• Dredge pump running
• Density ok (same as for the poor mixture function)
• Sailing Loaded has been performed for current cycle
The discharging operation mode is reset when one any one of the following conditions are
met:
• Sailing unloaded conditions met

12.3.2.4 DUMPING Operation Mode
The dumping operation mode is set when the following conditions are met:
• At least one bottom valve 50% open

• Sailing Loaded has been performed for current cycle
The dumping operation mode is reset when one any one of the following conditions are met:
• Sailing unloaded conditions met

12.3.2.5 SAILING UNLOADED Operation Mode
The sailing unloaded operation mode is set when the following conditions are met:

• All bottom valves closed
• Discharging or dumping have been performed for the current cycle
• Dredge pump not running
• Bow discharge valve not open
The sailing unloaded operation mode is reset when one any one of the following conditions
are met:
• Dredging conditions met

12.3.3 LC Data
The LC DATA window is opened by pressing the F3 button

on the load computer page.
The LC Data window provides information on the elapsed

times for the current cycle and on the current automatically
recognised operation mode. When the conditions for a
particular operation mode have been met then that field is
coloured yellow. In the window shown this mode Sailing
Unloaded.
In this window it is also possible to make a selection to

determine to which operation mode undefined time
accumulated during the unloading process should be
stored e.g. should the discharging process be interrupted
due to a blocked pipeline, it is possible to select where the
duration of the interruption is to be accumulated. The
selected mode is coloured green. In the window shown
this time will be accumulated as Sailing Unloaded.
12.3.4 Draft Calibration
By pressing the F4 button the draft calibration window is

opened.
Using the functionality in this window it is possible to

calibrate the individual draft sensors using readings
obtained from the draft marks on the side of the ship. For
this purpose six readings must taken i.e. port and starboard
draft at the fore, mid and aft marks. A two point calibration
is performed and the two values should be as far part as
practicable i.e. a minimum value (empty ship) and a
maximum value (loaded ship). A full calibration of both
sensors requires 4 sets of 6 readings.
A set of readings is entered to the fields provided. The

sensor to be calibrated is selected by left mouse click on
the respective button. The selected sensor is coloured
green and the calculated draft for the selected sensor is
displayed. This value is then manually entered into the
Range Minimum or Range Maximum field as required. When the accept but is clicked this
value is entered into the DCMS database. Clicking on the calibrate button performs a
calibration with the newly entered values. It is possible to perform a calibration using a new
value for range minimum and an old stored value for range maximum.

12.3.5 Sensor Override
The sensor override window is opened by clicking on the F5

button.
In case of a failure of one of the following sensors the

operator can manually override the following sensor:
- Draft Fore
- Draft Aft
- Hopper level Fore
- Hopper level Aft
- Trim
- Heel
The window shows a list of the sensors where a simulated

value for each sensor can be entered separately for each
sensor. Clicking on the button activates or de-activates the
override. The colour yellow indicates which sensor are
presently ovrriden.
Note: For the draft sensors the value which is to be entered is the centre line draft at the
actual sensor longitudinal position.
12.3.6 Report
Pressing the F11 pushbutton opens the Loading Computer Report page. All trips of the
hopper dredge are listed here with all important dredging. Functions are provided to sort the
data in the trip report table in different periods of time:
Attention: If the Loading Computer Report page is active the pushbuttons F1 to F12
change in their functionality!
⇒ with the buttons F1 and F2 (from → to) the operator can set a period of time
to show all trips in that period (sort by date)
⇒ the function F3 shows all trips of the same day (sort by trip no)
⇒ the function F4 shows all trips of the same week (sort by date
and trip no)
⇒ the function F5 shows all trips of the same month (sort by date
and trip no)
⇒ the function F7 shows all trips saved in the data base
If the settings (buttons F1 to F5) are made the operator has to accept the input by the
EXECUTE button F6.
The button F8 starts a print the data as selected with the functions F1 to F5 and F7.
The button F12 closes the Report page.
After each cycle a Trip Report is printed automatically by the Loading Computer with all
important dredging data and the loading/unloading diagram.

13 Maintenance Functions
13.1 Lamp test and dimmer
1. Lamp test and silence:

- Press push button 50 and all lights on the dredge control desk
that are not defective light up continuously as long as push button 50
is held down.
Silence:
- If push button 52 is pressed once on the dredge control desk,
alarm 51 is switched off.
The brightness of all push buttons can be adjusted with dimmer 53 on the
dredge control desk.
50
51 53
52
13.2 Right Mouse Click Functionality
The right mouse click function is provided for valves, pump motors, individual special drives
such as dredge pumps and for indicators displaying values measured directly by sensors.
When the symbol for the equipment is clicked with the right mouse key a pop-up status
window for the equipment is opened. This window contains the following symbols:
Check Boxes
Radio Buttons
Buttons
The check boxes indicate the status of interlocks, PLC inputs and outputs, and other
information bits used in the DCMS functions and controls. If the check box is filled with a
cross then the condition has been met. The check box cannot be operated.
The radio box indicates the present control mode of the equipment and can be operated by
clicking on it to change this mode.
The buttons are used to operate the equipment or open further windows with more bit
information or monitoring time information.
The monitoring time pop-up window contains the following additional symbol:
Input/Output Fields
The input/output fields display the set monitoring time for the feedback failure alarm (refer to
section 14.1.1) and the current remaining time if the equipment has been given a command.
The set monitoring time can be changed from this window by entering a new value. Note:
Changing of monitoring times is password protected. Depending on the equipment involved
two set of times may be displayed, one for opening/starting and one for closing/stopping.
13.2.1 Valve Status Window
The following control modes can be selected via the radio buttons:
(1) AUTO LS
In the auto LS mode the valve end position limit
switches are used for the indication of valve position
and for the feedback failure alarm.
(2) PRESUME
In the event that a end position limit switch has failed
and it is known that the valve is operating correctly,
then the presume mode can be selected. In this
mode after the monitoring time has elapsed it is
assumed that the valve has changed status. No
alarm is raised and all control functions dependent
on the correct status of the valve in question are
available.
(3) LOCK
When lock mode is selected the equipment cannot
be operated from the screen.
(4) SERVICE
In service mode the valve functions as in presume mode except that no DCMS
programme interlocks are active. WARNING: When operating in this mode particular
care must be taken to avoid equipment damage.
(5) MAINTENANCE
In maintenance mode no DCMS programme interlocks are active and signals are only
sent to the valve as long as the button is pressed. WARNING: When operating in this
mode particular care must be taken to avoid equipment damage.
The equipment symbol is displayed differently for each of the control modes. Refer to
section 2.9.2 for details.
The following bit information is provided:
(1) LS OPEN
This is the status of the PLC feedback input for valve open.
(2) LS CLOSED
This is the status of the PLC feedback input for valve closed.
(3) PRES. OPEN
This is the presumed status for the opened position when presume mode is selected.
(4) PRES. CLOSE
This is the presumed status for the closed position when presume mode is selected.
(5) FAILURE
This indicates when a feedback failure has occurred.
(6) REL.OPEN
This indicates that all interlocks to open the valve have been met.

(7) REL.CLOSE
This indicates that all interlocks to close the valve have been met.
(8) CMD.OPEN
This indicates that a command to open the valve is active.
(9) CMD.CLOSE
This indicates that a command to close the valve is active.
(10) SV OPEN
This indicates that the PLC output to open the valve is active.
(11) SV CLOSE
This indicates that the PLC output to close the valve is active.
13.2.2 Valve More Window
Valves that have both limit switches and analogue sensors for position indication have a
MORE Status Window. In this window the following information:
(1) FB Digital
This indicates that the analogue valve also has digital open and closed limit/proximity
switches available.
(2) USE DIG FB
With this switch the user can set the DCMS to use the digital open and closed
switches for control functions.
(3) USE ANA FB
With this switch the user can set the DCMS to use the analog position sensor for
control functions.
13.2.3 Pump Motor Status Window
The following control modes can be selected via the radio buttons:
(4) SUPERVISE
In the supervise mode the motor running signal is used for
the indication of the motor status and for the feedback
failure alarm.
(5) PRESUME
In the event that the running feedback has failed and it is
known that the motor is operating correctly, then the
presume mode can be selected. In this mode after the
monitoring time has elapsed it is assumed that the motor
has started/stopped. No alarm is raised and all control
functions dependent on the correct status of the motor in
question are available.
(3) LOCK
When lock mode is selected the equipment cannot be operated from the screen.
(4) SERVICE
In service mode the motor functions as in presume mode except that no DCMS
programme interlocks are active. WARNING: When operating in this mode particular
care must be taken to avoid equipment damage.
The equipment symbol is displayed differently for each of the control modes. Refer to
section 2.9.2 for details.
The following bit information is provided:
(1) FB START
This is the status of the PLC feedback input running.
(2) REMOTE
This is the status of the PLC feedback input remote.
(3) PRES. START
This is the presumed status for the running status when presume mode is selected.
(4) PRES. CLOSE
This is the presumed status for the stopped status when presume mode is selected.
(5) FAILURE
This indicates when a feedback failure has occurred.
(6) EXT. FAILURE
This indicates the status of the PLC feedback input fault.
(7) REL.OPEN
This indicates that all interlocks to start the motor have been met.
(8) REL.CLOSE
This indicates that all interlocks to stop the motor have been met.
(9) CMD.OPEN
This indicates that a command to start the motor is active.
(10) CMD.CLOSE
This indicates that a command to stop the motor is active.
(11) SV OPEN
This indicates that the PLC output to start the motor is active.
(12) SV CLOSE
This indicates that the PLC output to stop the motor is active.
13.2.4 Sensor Status Window

There are two sensor status input windows. The standard window
provides the following information and inputs:
(1) RANGE MIN

The current minimum value for the sensor range is
displayed and a new value can be entered if required.
(2) RANGE MAX
The current maimum value for the sensor range is displayed
and a new value can be entered if required.
(3) SCALE FACT
(4) RAW
This is the raw data value delivered to the PLC CPU by the analogue input module.
The normal range of the value is 0 to 27648. Values between 27649 and 32511
indicate over range. Values equal to or greater than 32512 indicate overflow and a
value of 32767 indicates broken wire.
(5) SIGNAL
The type of sensor connection is displayed here: ???? (not selected), 0 – 20mA, 4 –
20mA, +/- 10V
(6) TREND

A left mouse click on this button opens a trend window where the analogue signal
can be viewed over a period of time.
The scale of the vertical axis can be selected automatically of manually. When
manual is selected the values at the bottom right of the page are used for the scale
maximum and minimum values. These can be changed by entering new values
using the keyboard.
Sensors such as inclinometers have a window which

includes the following additional information and inputs for
zero point calibration:
(1) ENG VALUE

This is the actual engineering value calculated b the
DCMS in the specified units (e.g. m/s for flow)
(2) CALIB VAL
This is the engineering value which has been
determined by independent measurement. It is
entered here for calibration purposes
(3) CALIB
A left mouse click on this button performs a calibration
using the value entered in the CALIB VAL field.

13.3 Online Trending Functionality
The online trending described above in 13.2.4 provides the following dialogs most of which
are also available for the loading curves which are included for the loading computer see
section 12.
"Online-Help System" Calls up the online-help
"Display Value at this Position" With this function, you can determine the coordinate
points of a trend.
"Enlarge Area" With the enlarge area function, you can enlarge any area of the trend
window.
"Activate Original View"With this button, you can return to the configured normal view
from an enlarged trend display.
"Select Time Range"With this button, you open a dialog to set the time range
displayed in the trend window.
"Start/Stop the Update" Stops the updated display. The values are stored in a
clipboard and re-entered after activating the button again.
"Start/Stop the Update" Resumes the display.
Select Time Range

The "Select Time Range" button opens a dialog for specifying the time range to
be displayed. If the trends of a table window are to be displayed with a shared X axis,
the specified time range will apply to all trends.
Field Description
Trend Here, you can select one of the
configured trends.
Time Selection The time interval to be displayed

in the trend window can be
set·by entering a start and an
end point (the "Time Range"
setting not activated).·
by entering a start time and a
time range. ("Time Range"
setting activated). The length of
the time interval to be displayed
is determined by multiplying the
"Factor" by the "Range".
Persistance If the option "Persistent in RT" is

not activated, any changes made
to the settings are only effective within runtime. Whether any
changed settings will also be effective after changing a screen is
dependent on the option "Persistent in RT".Is the option "Persistent in
RT" is activated, any changes made to the settings will also be taken
over by the configuration.

13.4 Calibration of rope length sensor
A special calibration of the rope length sensors is not necessary as these are intelligent
absolute value encoders where each rotation of the shaft is always equal to a defined count.
Each rotation of the winch drum is equal to a specified number of rotations of the sensor and
therefore a set count which never changes.
The sensors are connected via profibus to the PLC control system and the count
corresponding to the number of winch drum rotations is transferred directly to the PLC i.e.
there is no analogue to digital conversions involved.
Every time that the pipe is launched a calibration of the sensor performed. This is done in
that when the pipe on deck sensor operates a new count reference value for this position is
taken (via the profibus interface).

14 Alarm Listing
Number Description
1 Internal CPU fault
2 External CPU fault
3 Communication fault
4 Module has configuration error
5 Internal power supply fault
6 Watch dog timer stopped module
7 Rack fault
8 DP-Master fault
9 DP-Slave fault
10 Programming Error
11 Module Access Error Read
12 Module Access Error Write
13 Not Loaded Fault
25 feedback failure: DV01 analog Valve Suction pipe
26 feedback failure: DV02
27 feedback failure: DV03 analog Valve to Hopper Section aft
28 feedback failure: DV04 analog Valve to Hopper Section middle
29 feedback failure: DV05 analog Valve to Hopper Section fore
30 feedback failure: DV06 analog Valve Additional water
31 feedback failure: DV07 to Hopper Section middle
32 feedback failure: DV08 to Hopper Section fore
33 feedback failure: DV09 over board Valve & Bow Coupling
34 feedback failure: AP01 to Jet Pump JP1
35 feedback failure: AP02 to Jet Pump JP2
36 feedback failure: AP03 behind Jet Pump JP1
37 feedback failure: AP04 behind Jet Pump JP2
38 feedback failure: AP05 serial Jet Pump
39 feedback failure: AP06 Crossover
40 feedback failure: AP07 Hopper Main Line 1
41 feedback failure: AP08 Hopper Main Line 2
42 feedback failure: AP09 to Hopper Section aft
43 feedback failure: AP10 to Hopper Section aft
44 feedback failure: AP11 to Hopper Section fore
45 feedback failure: AP12 to Hopper Section fore
46 feedback failure: AP13 to Hopper Section middle & aft
47 feedback failure: AP14 to Hopper Section middle & fore
48 feedback failure: AP15 to Suction pipe
49 feedback failure: BV1 Section aft
50 feedback failure: BV2 Section middle
51 feedback failure: BV3 Section fore
52 feedback failure: Head Gantry Starboardside
53 feedback failure: Intermediate Gantry Starboardside
54 feedback failure: Trunnion Gantry Starboardside
55 feedback failure: Aft Weir
56 General or feedback failure: Dredge-Pump Gearbox
57 General or feedback failure: Hydro-Coupling Dredge-Pump
58 feedback failure: Hydro Coulping Brake
65 General or feedback failure: Jet-Pump No.1
66 General or feedback failure: Jet-Pump No.2
67 General or feedback failure: Dredge-Pump Gearbox Loopoil-Pump
68 General or feedback failure: Dredge-Pump
69 General or feedback failure: Flushing water-Pump
70 General or feedback failure: Sealing-Water-Pump 1
71 General or feedback failure: Sealing-Water-Pump 2
72 General or feedback failure: Main Hydraulic 1
73 General or feedback failure: Main Hydraulic 2
74 General or feedback failure: Hydraulic pressure pump 4
75 General or feedback failure: Hydraulic pressure pump 5
76 General or feedback failure: Hydraulic circulation pump 6
77 General or feedback failure: Hydraulic filter pump 9
78 General or feedback failure: Emergency hydraulic pump
241 Broken Wire: Heel
242 Broken Wire: Trim
243 Broken Wire: DRAFT fore
244 Broken Wire: DRAFT aft
245 Broken Wire: Hopper level 1 fore
246 Broken Wire: Hopper level 2 aft
247 Broken Wire: Voltage monitoring +10V
248 Broken Wire: Voltage monitoring -10V
249 Broken Wire: Dimmer
250 Broken Wire: Head winch joystick
251 Broken Wire: Intermediate winch joystick
252 Broken Wire: Trunnion winch joystick
253 Broken Wire: HW Rope length
254 Broken Wire: IW Rope length
255 Broken Wire: TW Rope length
256 Broken Wire: HW Transverse rope pull
257 Broken Wire: IW Transverse rope pull
258 Broken Wire: Emergency stop head winch rope minimum
259 Broken Wire: Emergency stop intermediate winch rope minimum
260 Broken Wire: SWC Position
261 Broken Wire: SWC cylinder pressure
262 Broken Wire: Position overflow
263 Broken Wire: Sealing water PP 1 flow
264 Broken Wire: Sealing water PP 2 flow
265 Broken Wire: Sealing water PP 1 pressure
266 Broken Wire: Sealing water PP 2 pressure
267 Broken Wire: Starboard diesel motor load
268 Broken Wire: Starboard diesel motor speed
269 Broken Wire: Hydro Coupling Output Speed
270 Broken Wire: Hydo Coupling Oil Temperature
271 Broken Wire: Suction pressure
272 Broken Wire: Delivery pressure
273 Broken Wire: Mixture density
274 Broken Wire: Mixture flow
277 Broken Wire: Port diesel motor load
278 Broken Wire: Port diesel motor speed
279 Broken Wire: JP 1 delivery pressure
280 Broken Wire: JP 2 delivery pressure
283 Broken Wire: DV01 analog Valve Suction pipe
284 Broken Wire: DV03 analog Valve to Hopper Section aft
285 Broken Wire: DV04 analog Valve to Hopper Section middle
286 Broken Wire: DV05 analog Valve to Hopper Section fore
287 Broken Wire: DV06 analog Valve Additional water
288 Broken Wire: Emergency pump pressure
289 Broken Wire: Main hydraulic 2 pressure
290 Broken Wire: Pressurisation Pump 1
291 Broken Wire: Bottom valves holding pressure
292 Broken Wire: Hydraulic pump P1.1
321 Winch: STDB Head is in High High-Position (Gantry-Switch)
322 Winch: STDB Intermediate is in High High-Position (Gantry-Switch)
323 Winch: STDB Head is in LowLow-Position (Winch-Switch)
324 Winch: STDB Intermediate is in LowLow-Position (Winch-Switch)
325 Winch: STDB Trunnion Slack Wire activ
326 Winch: STDB Winch-Alarm Trunnion => No moving
327 Winch: STDB Winch-Error Automatic Depth Control
328 Winch: STDB High Intermediate Joint Angle
329 Winch: STDB Winch stopped
330 Winch: STDB Winch Error High Intermediate Joint Angle One Lever & Auto
Depth
331 Winch: STDB Winch and Gantry Basic Interlock active
332 Winch: STDB Swell Compensator protection rope cut
333 Jet pump external shutdown
334 Dredge Pump External Shutdown
335 Dredge Pump Emergency Stop
336 Dredge Pump Stopped from CPP Mode Switch
337 DP Hydro Coupling fault during first filling
338 DP Hydro Coupling fault during emptying
339 Hydraulic Tank Level Low Low
340 DP Density Sensor Fault
341 Earth Fault PLC Cabinet 24VDC
342 Draft table out of range
343 Trim table out of range
344 Level table out of range
345 DOMS Communication Fault
346 Hydro-Coupling turning DP gearbox LO pump not running
347 Winch: STDB High Trunnion Joint Horizontal Angle
348 Winch: STDB High Intermediate Joint Horizontal Angle
349 Maximum heel
350 Maximum fore draft
351 Maximum aft draft
352 Maximum fore hopper level
353 Maximum aft hopper level
354 Maximum fore trim
355 Maximum aft trim
356 Battery fault
2401 Battery fault
2402 Battery empty
2425 Winch: STDB Swell Compensator is blocked
2426 Winch: STDB Alarm-Hoisting is active
2427 Winch: STDB Alarm Vacuum for Alarm Hoisting
2428 Winch: STDB Alarm Horizontal Angle for Alarm Hoisting
2429 Winch: STDB Emergency hoisting
2430 Winch: STBD Swell Compensator Filter Fault
2441 Hydro-Coupling Dredge-Pump
2442 Hydraulic filter fault
2443 Hydraulic tank water warning switch
2444 DP Gearbox oil pressure low low
2445 DP Gearbox oil temperature high
2446 Hydo Coupling Oil Pump fault
2447 DP Gearbox & Brake Air Pressure fault
2448 DP Gearbox oil filter blocked
2449 Swell Compensator filter fault
2450 Main hydraulic tank high temp
2451 Jet pump clutch air pressure fault
2452 Hydro Coupling Temperature in excess of 120°
2453 DP Gearbox oil level switch
2454 DP Gearbox oil pressure low
2455 BV Pushbutton Emergency Dumping
2456 Voltage Monitoring Desk to low
2457 Pressurisation fault
2458 Sealing water-Pump minimum flow for the Dredge-Pump
2459 Hydro Coupling Oil Pressure switch 15 blocked
2460 Hydro Coupling Oil Pressure switch 140 low pressure
2461 Hydraulic Emergency Stop
3201 Maintenance-Mode is active
3225 STDB Feedback Head is on Deck (Saddle)
3226 STDB Feedback Intermediate is on Deck (Saddle)
3227 STDB Pipe is in Range 0 (Pipe on Deck)
3228 STDB Pipe is in Range 1 (Gantry In & Pipe between Deck and High High-
Position)
3229 STDB Pipe is in Range 2 (Pipe in High High-Position)
3230 STDB Pipe is in Range 3 (Gantry Out & Pipe between High High-Pos and
Trunnion Line)
3231 STDB Pipe is in Range 4 (Pipe in Trunnion Line)
3232 STDB Pipe is in Range 5 (Pipe under Trunnion Line)
3233 STDB Manual Winch-Control active
3234 STDB One Lever Winch-Control active
3235 STDB Auto Depth Winch-Control active
3236 STDB Head is in High-Position or higher (Software-Switch)
3237 STDB Intermediate is in High-Position or higher (Software-Switch)
3238 STDB Trunnion is in High-Position or higher (Software-Switch)
3239 STDB Head is in Trunnion-Line
3240 STDB Intermediate is in Trunnion-Line
3241 STDB Trunnion is in Trunnion-Line
3242 STDB Pipe has touch the ground
3243 STDB Alarm Hoisting DelayTime is running
3244 STDB Alarm Vacuum for Alarm Hoisting
3245 STDB Alarm Horizontal Angle for Alarm Hoisting
3246 STDB Winch Error High Intermediate Joint Angle One Lever & Auto Depth
3249 Hydraulic tank level high
3250 Hydraulic tank level low
3252 SWC tank level high
3253 SWC tank level low
3254 JP Clutch local
3255 Hydro Coupling local
3256 DP Gearbox & Brake local
3257 Emergency hydraulic pump local
3258 Main Hydraulic 1 local
3259 Main Hydraulic 2 local
3260 Hydraulic pressure pump 4 local
3261 Hydraulic pressure pump 5 local
3262 Hydraulic circulation pump 6 local
3263 Hydraulic filter pump 9 local
3264 Sealing water pump 1 local
3265 Sealing water pump 2 local
3266 DP Gearbox LO pump local
3267 Flushing water pump local
3268 Hydraulic emergency stop

14.1 Alarm Types
There are four general alarm types generated by the DCMS:
(1) Feedback Fault

(2) Broken Wire Fault
(3) Equipment alarms
(4) Limit alarms
In addition there are alarms generated for failure of the communication buses (ethernet,
profibus and interbus) and some specific software generated alarms to prevent false
operation of the side suction pipe and active draghead.
System alarms are directly generated by Windows NT or WinCC. Information on these

alarms can be taken directly for the Windows and Siemens documentation.
14.1.1 Feedback Failure

A feedback failure is generated for all devices which can be operated by the DCMS when
either one of four conditions arise. These conditions are:
(1) A start/open command has been sent and the feedback

running/open has not been received within the set time.
(2) A stop/close command has been sent and the feedback
not-running/closed has not been received within the set
time.
(3) A device is running/open and without a stop/close
command being given the running feedback disappears.
(4) A device is stopped/closed and without a start/open
command being given the running signal appears.
For motors this alarm is only generated when the device is in remote.
14.1.2 Broken Wire

A broken wire fault is generated for the 4 – 20mA analog input signals when the current falls
below 4 mA. Normally the current is always in the range between 4 and 20 mA. A current
less than 4 mA indicates a fault where the loop resistance of the signal circuit has increased
beyond acceptable limits or the circuit is open.
14.1.3 Equipment Alarms

Equipment alarms are generated by the equipment and sent to the DCMS as digital signals.
The DCMS uses these signals directly to generate alarms.
14.1.4 Limit Alarms

Limit alarms are alarms generated by the DCMS using analogue input signals and internally
set limit values. These limit values my be adjustable on the limit page or fixed non-
adjustable values.

15 Loading Computer Calculations
The following calculations are performed by the loading computer
15.1 Draft
Draft is measured directly at two points in the vessel using hull mounted pressure sensors.
Ideally the sensors should be located as close to centreline, baseline and the respective
hopper bulkhead as possible in order to reduce errors due to bending of the ship when
loaded.
The draft sensor is normally calibrated to provide an output representing metres of H2O.
Therefore the measured value must be corrected by dividing the measured value by the
density of seawater. The density of seawater varies from place to place and is manually
input by the operator in the DCMS limit page.
The resulting measured value is the vertical distance from the sensor to the water
surface.
15.1.1 Centreline Draft
Z
Zcorr
Water Line β
β
T
Zsen
Ysen
CL Sensor Position
Using the measured values from two draft sensors, one fore and one aft in the ship, and
along with the heel measured by an inclinometer, the draft at any point in the ship can be
calculated.
First the two measured values are translated to the CL in Ship’s Axis (SA) at the sensor
longitudinal position. These values are also corrected for the height of the sensor above
baseline.
Zsen Height in SA of sensor above baseline in metres

Ysen Transverse position of sensor relative to centreline in metres
T Measured depth of water above the sensor in metres
β Heel measured by inclinometer
CL Centreline
Draft at CL in ship’s axis = Zsen + Z - Zcorr
Z = T / cos β
Zcorr = Ysen * Tan β

Draft at CL in ship’s axis = Zsen + (T / cos β) - (Ysen * Tan β)
It should be noted that for this application with draft mounted hull sensors the value of Zsen
is zero.
15.1.2 Trim
The draft at CL in ship’s axis values are then used to calculate the Trim of the ship. Trim is
calculated in degrees. It should be noted that the tables for the loading computer require
trim in metres therefore trim must also be calculated in metres.
Xdiff Longitudinal distance between the sensors in metres
Trim Angle = Arctan [(Draft CL Fore – Draft CL Aft) / Xdiff]
Xperp Longitudinal distance between perpendiculars
Trim metres = Tan (Trim Angle) * Xperp
15.1.3 Centreline Draft Interpolation
The CL draft in SA at any point along the length of the ship is interpolated as follows:
X Longitudinal position relative to the aft perpendicular where CL draft in SA is to be

calculated
Tx CL draft at a longitudinal position x relative to the aft perpendicular
X1 Longitudinal position of the aft draft sensor relative to the aft perpendicular
T1 CL draft at the aft draft sensor
Tx = T1 + [Tan (Trim Angle) * (X – X1)]

15.1.4 Draft at Arbitrary Positions
Using the Tx calculated in section 4 above and working the formula in section 2 above
backwards the draft in SA at any arbitrary position in the ship can be calculated.
Tasa Draft in SA at a arbitrary position

Za Height in SA of arbitrary position above baseline in metres
Ya Transverse position of arbitrary position relative to
centreline in metres
Tasa = [Tx - Za + (Ya * Tan β)]
By including the factor cos β the draft vertical to the waterline can also be calculated.
Tav Draft vertical to the water’s surface at a arbitrary position
Tav = [Tx - Za + (Ya * Tan β)] * cos β
15.1.5 LPP/2 Draft
The draft used in the displacement tables is the mean CL draft in SA between the
perpendiculars.
Draft LPP/2 = (CL Draft in SA aft + CL Draft in SA fore) / 2
15.2 Hopper Level
The hopper level is measured by two ultrasonic sensors one fore and one aft in the hopper.
The sensors should be placed with a symmetrical geometry in the hopper to allow for a
simple averaging calculation to determine the mean mid-hopper level to be used in the
loading computer.
Mid-hopper level = (Level sensor 1 + Level sensor 2) / 2
The ultrasonic sensor measures the distance from the sensor to the water layer in the ship’s
axis. The control unit supplied with the sensor can be calibrated to provide a signal relative
to the ship’s baseline in the ship’s axis.
15.3 Tables for Volume and Displacement
Three tables are used:

(1) Hopper Volume Table
(2) Ship Volume Displacement Table for open bottom valves
(3) Ship Volume Displacement Table for closed bottom valves
The displacement table for open bottom valves is only used for the empty ship calculation.
The displacement table for closed bottom valves is used for all other displacement
calculations.
Ship load in tons is determined as follows:

Dc Current ship displacement
De Empty ship displacement
DS Density Seawater
Ship load = (Dc – De) * DS

All tables have a column for draft or hopper level and a number of columns for displacement
or volume in cubic metres dependent on trim.
The look up value is interpolated by using the four closest values for displacement based on
draft and trim. For a draft of 0.5 and a Trim of –3.5 the look up displacement out of the table
below would be:
Displacement (m3) = {[(832.6 + 698.4) / 2] + [(1046.6 + 924.3) / 2]} / 2
T TRIM TRIM TRIM TRIM TRIM TRIM TRIM TRIM TRIM

DRAUGHT -6.000 -5.000 -4.000 -3.000 -2.000 -1.000 0.000 1.000 2.000
(m) (m³) (m³) (m³) (m³) (m³) (m³) (m³) (m³) (m³)
0.000 783.6 626.0 478.2 340.0 212.2 98.1 12.1 163.8 336.0
0.200 956.5 794.1 643.4 503.5 376.6 275.5 283.3 373.4 527.7
0.400 1146.9 982.7 832.6 698.4 587.2 536.6 576.6 648.7 763.0
0.600 1355.6 1191.3 1046.6 924.3 842.6 838.9 882.0 946.5 1036.9
The displacement in tons is obtained by multiplying the displacement in cubic metres by the
seawater density which is a manual input in the load computer.
15.3.1 Volume and mass
Using the values for displacement and volume from the tables, the wet and dry mass/volume
calculations are made using the following formulas:
Vwet Volume of insitu material

Vdry Volume of dry material
Mwet Mass of inistu material
Mdry Mass of dry material
ρsw Density of seawater
ρwet Density of insitu material
ρdry Density of dry material
Vol Volume of the hopper
Vwet = [Load – (Vol * ρsw)]

(ρwet – ρsw)
Mwet = Vwet * ρwet
Vdry = (ρwet – ρsw) * Vwet

(ρdry – ρsw)
Mdry = Vdry * ρdry

15.4 Production
For the production calculator the following calculations are made using measured values
from the magnetic flow meters and the radioactive density meter, and the manually input
density values.
ρsw Density of seawater

ρwet Density of insitu material
ρdry Density of dry material
ρmeasured Measured mixture density (t/m3)
Vmeasured Measured mixture velocity (m/s)
Pipearea Area of pipe (m2)
Concentrationwet Ratio of measured density to insitu density
Concentartiondry Ratio of measured density to dry density
WetProduction m3/h Volumetric production of insitu material (m3/h)
WetProduction t/h Mass production of insitu material (t/h)
DryProduction m3/h Volumetric production of dry material (m3/h)
DryProduction t/h Mass production of dry material (m3/h)
Concentrationwet = (ρmeasured – ρsw)

(ρwet – ρsw)
Concentrationdry = (ρmeasured – ρsw)

(ρdry – ρsw)
WetProduction m3/h = Concentrationwet * Vmeasured * Pipearea

3600
WetProduction t/h = WetProduction * ρwet
DryProduction m3/h = Concentrationdry * Vmeasured * Pipearea

3600
DryProduction t/h = DryProduction * ρdry
The total production values are obtained by accumulating “per second production values”.
The “per second production values are obtained by dividing the above calculated production
values by 3600. When a reset button is pressed the current accumulated value of the total
production is saved in a register and then reset to zero. There is only one register for each
total production value and only the last saved total production value is available for display.
Resetting of the total production accumulators is only a manual operation, and is time and
trip independent.

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OPERATING INSTRUCTIONS

HOPPER SUCTION DREDGER

DREDGE CONTROL AND MONITORING SYSTEM

VOSTALMG - Yard-No. : 819

© Copyright by VOSTALMG Printed in Germany

Automation VOSTALMG 2-710-66552 Rev. 0 1

Appendix A DCMS Electrical Drawings

Appendix B Data Sheets

⇒ Rope length sensor

⇒ Gantry In/Out Sensors

⇒ Winch High Emergency Stop Sensor

⇒ Sluice Valve Position Sensor

⇒ Sluice Valve Proximity Switches

⇒ Bottom Valve Proximity Switches

⇒ Sealing Water Pressure and Flow Sensors

⇒ Dredge Pump and Jet Pump Pressure Sensor

⇒ Hopper Level Sensors

⇒ Simatic PLC Installation Reference Guide

⇒ Compaq PC: Hardware Parts Service

⇒ HP Printer User Guide Reference Guide

Automation VOSTALMG 2-710-66552 Rev. 0 4

⇒ DCMS Dredge Control and Monitoring System

PC with LCD Legend:

Automation VOSTALMG 2-710-66552 Rev. 0 5

2.2 Functional displays

The control – monitoring – software includes following graphical pages:

2.3 Dredging, Dumping and Discharging

Automation VOSTALMG 2-710-66552 Rev. 0 6

A detailed description of these windows is provided in section 13.2.

Automation VOSTALMG 2-710-66552 Rev. 0 7

⇒ Main pump unit no. 1

Automation VOSTALMG 2-710-66552 Rev. 0 8

Automation VOSTALMG 2-710-66552 Rev. 0 9

⇒ Message List – a list of all current alarms, warnings and messages

⇒ Report – the current selection of alarms will be printed

Automation VOSTALMG 2-710-66552 Rev. 0 10

Automation VOSTALMG 2-710-66552 Rev. 0 11

SETPOINT AUTOMATIC DEPTH CONTROL MAN

SETPOINT LOWER PIPE VERTICAL ANGLE CONTROL

AUTOMATIC LOWER PIPE VERTICAL ANGLE CONTROL

NO BUZZER HIGH INT JOINT VERTICAL ANGLE

SETPOINT INT JOINT HORIZ ANGLE FOR ALARM HOISTING

INT JOINT HORIZ ANGLE ALARM HOISTING

NO BUZZER INT JOINT HORIZ ANGLE ALARM HOISTING

SWELL COMPENSATOR AUTOMATIC WIINCH CONTROL

WINCH OPERATION MAINTENANCE MODE

Automation VOSTALMG 2-710-66552 Rev. 0 12

PIPE INTERNAL DIAMETER

SEA WATER DENSITY

LIMIT FOR HEEL ALARM

LIMIT FOR DRAFT FORE ALARM

LIMIT FOR DRAFT AFT ALARM

LIMIT FOR HOPPER FORE ALARM

LIMIT FOR HOPPER AFT ALARM

LIMIT FOR TRIM ALARM

Automation VOSTALMG 2-710-66552 Rev. 0 13

SETPOINT DRAFT FOR AUTOMATIC CONTROL

WEIR AUTOMATIC MODE

SETPOINT MAXIMUM VACUUM DREDGE-PUMP