Comprehensive training for Cutter Suction Dredger crews: enhancing skills with realistic simulation.
With the introduction of its new Cutter Suction Dredger (CSD) range, Damen has developed a highly realistic dredge training simulator. The setup imitates the behavior of a real CSD in a true-to-life presentation. This includes a dredge control system that is completely identical to that of the CSD, plus various screens showing the dredger in its surroundings. Education is essential to the modern dredging industry as the dredge master and other dredge crew members are key to maximising the CSD’s performance. The CSD dredge simulator is located at the Damen Dredging yard, but can easily be transported to the owner’s location for local training sessions.
Dredging is a skill
The need for dredge simulator training has become more and more apparent in recent years. Trained dredge masters are scarce, yet there is a dire need of them. A well-trained dredge master will boost the dredger’s production while reducing operational costs by, for instance, avoiding risky situations, reducing fuel consumption, and responding appropriately in challenging situations. These dredger masters’ skills will avoid downtime of the dredger and reduce damage and wear to the dredging components. Moreover, the dredging experience gained will enhance operational safety. All in all, the dredging time scale will be reduced, and overdredging and underdredging prevented.
Digital twin
The CSD training simulator aims to familiarise the dredge crew with the monitoring and control equipment on board. As a result, the simulator setup is an exact copy of the systems on board: the operators chair with controls integrated in both arm rests, a small control screen by the right armrest, and another large screen for monitoring the dredging process. The advanced 3D graphics of the surrounding large screens ensure an immersive experience. In a natural landscape different dredging actions can be trained in a day or night setting. The training instructor can tweak the dredge operation to trigger the dredge master, thus developing and increasing dredge process insight and decision making skills. Underwater views enhance the understanding of the dredging process.
All the works
In the manually controlled dredge simulator, all working principles and functionalities can be trained. All actions a dredge master would usually perform are part of the training programme. These include the complete start-up procedure, including for instance lowering the cutter ladder, adapting the swing speed by operating the side wire winches, adjusting the cutter speed and controlling the dredge pump rpm. Moreover, the general dredge reposition routines are trained, including moving the spud carriage, shifting the spud positions etc. During these dredging routines, all processes are shown on the monitoring screen with realistically calculated data such as production, dredge pump output, etc. The trainer can set parameters for a training session and adjust them during the session.
Comprehensive training programme
The CSD dredge simulation training sessions are customised for each dredge crew. The simulator scenarios include the exact options the owner has chosen to add to his dredger, such as, for instance, a spud carriage pontoon. The immersive, hands-on experience allows training candidates to learn and practice various dredging skills and the decision making procedures required for the dredging process. Insightful mistakes can be made in a zero-risk environment at no great cost, thus minimising the risk of equipment damage for the dredge operator. The realistic setup is a significant contribution to boosting operational efficiency, improving dredge production, and enhancing overall profitability.
As the effective dredge simulation training focusses on real-life work processes, dredging companies are assured that once on site, the CSD will be started up swiftly and that the dredge project can start without delay. Moreover, future dredge projects can be loaded into the simulator, ensuring optimal crew preparation.
Wherever the training is required
Usually the complete crew of a CSD is trained in the training room at the Damen Dredging yard in Nijkerk, the Netherlands. Ideally, the trainer would start with a classroom session to explain general topics such as the dismountable CSD design, the physics of dredge pumps and their performances, the overall dredge operation including repositioning the dredger, and so forth. Then the CSD operators can put the newly learned into practice on the dredge simulator.
Having started the training session with the basics, the dredging process simulator is gradually adjusted by the trainer to make sure the dredge operators master all skills. To start with, the dredge operators’ project can be configured in the training scenario, where dredging depth, soil types and discharge distances are replicated. Over time, the trained crew will have to face real-life challenges such as anchors that do not hold, a stalling cutter, breaking side wires or clogged pipes, or altering operational situations such as increased side currents, the sea state or other weather phenomena. Due to the hardware-in-the-loop simulation technique, the connected controls and HMI, the digital environment behaves as the real world. It creates a stressful realistic situation in which the operators learn to make the correct decisions under pressure. As all data is logged, a training session can be reviewed afterwards for an optimal learning experience.
The simulator itself can travel the world as well: its compact design of screens, operating chair, and computers can be transported anywhere in three crates only. The dredge simulator trainer can set up the simulator to train all crew members locally.
Whether in a dedicated training room or traveling to the operators location – the Cutter Suction Dredger Training Simulator is an valuable addition to the dredge operator training and the effective operation of dredgers.