SRS Crisafulli introduces the Rotomite model 6000-CD Dredge
SRS Crisafulli designed and built the self-propelled, steerable, diesel powered all-purpose dredge for both abrasive and soft slurries with a cast alloy pump, and 8” discharge, in the fall of 2013. The dredge was tested at Fisher Sand and Gravel’s pond on Circle Highway northwest of the Company’s Glendive, Montana manufacturing plant, just before winter set in.
Photos: R6CD dredge testing at Firsher Sand and Gravel, Glendive MT, 2013
2014 Job Site
During the winter, the SRS Crisafulli Dredge Sales and Rental Department worked with a copper mine in the American Southwest on a Dredge Rental contract. The mine needed to restore their basin capacity without stopping mine processes, which is the perfect application for hydraulic dredging.
Problem: The customer has a plastic-lined tailings dam that collects outflow from various processing facilities. The mixture is generally acidic, with lye added to balance ph levels. A floating pump transfers water and material from this small catch basin into a very large permanent tailings impoundment. The limited ability of the floating pump to pull in slurry led to a build-up of solids, which reduced the pond’s holding capacity.
The customer wanted to restore this capacity to original levels without stopping any mine processes or damaging the liner.
Solution: The new SRS Crisafulli Rotomite model 6000CD was selected for its ability to handle abrasive tailings materials. The Rotomite 6000CD also proved to be well suited for pumping through 500 ft. of 8 in floating discharge pipe, 1500 ft. of 10 inch fused pipe, and over an 80 ft. berm at 1300-1500 gpm. No booster pump was required, reducing cost and complexity of the system. The cutterhead was outfitted with a liner protection cage, preventing its horizontal auger from damaging the liner as it pushed slurry into the pump. This cage restricted the auger from digging into settled solids, so SRS Crisafulli’s unique cutterhead articulation became indispensible as the primary method of breaking up material.
The hydraulic thruster on the back of the Rotomite 6000CD was also a critical component. Both the perimeter and floor of the basin are irregularly shaped, and it is surrounded by a fence, making cable positioning difficult and cumbersome. The thruster’s 180 degree range of motion and hydraulically variable depth allowed quick and easy positioning of the dredge during operation and docking.
The project began with an estimated 76,000 cubic yards of material to be removed. A satisfactory quantity of tailings was removed to restore the impoundment’s capacity.
Thanks to the SRS Crisafulli dredge rental program, the copper mine’s project was completed in less than six months.
The inaugural season of the R6CD was a great success.
Please call the offices to schedule a rental for 2015, or inquire about an equipment purchase.
Stormwater in the Florida canal system is slow moving. The green, murky water in the lakes fed by the Apopka-Beauclair canal is caused by an overabundance of algae-feeding compounds, mainly phosphorus, resulting in chronic algal blooms. The Nutrient Reduction Facility (NuRF) project designed a system to inject aluminum sulfate (alum) into the nutrient-laden water in direct proportion to the stormwater volume.
Environmental Research and Design, Inc. (ERD) was founded in 1986 by Dr. Harvey H. Harper, P.E. as a water quality research and engineering firm. Work efforts at ERD are devoted primarily to the areas of surface water and groundwater management, stormwater treatment, lake restoration and sediment/water interaction. This specialization has allowed ERD to develop complete field, laboratory, computer and engineering related resources in these areas.
ERD has designed, permitted, and administered construction on more than 50 alum stormwater treatment systems, reflecting more than 90% of the existing systems world-wide. During 2008, construction was completed on the Lake County Nutrient Reduction Facility (NuRF) which has a treatment capacity of 300 cfs and is the largest system in existence. The system includes two floc storage ponds, a dedicated dredging system, floc dewatering system including centrifuge, and a floc storage area.
SRS Crisafulli participated with ERD and Dr. Harvey on the Lake County Nutrient Reduction Facility build. In fact, SRS Crisafulli shipped two FLUMP remote-controlled dredge systems and an electric rail traverse system to this job in the summer of 2008.
SRS Crisafulli's Senior Application Engineer, Eric Lillberg at the Ribbon Cutting Ceremony, Lake County Water Authority, Florida
Dr. Harvey's research, which is very measured, indicates that "alum treatment of stormwater consistently provides removal efficiencies of 85-95% for total phosphorus, >95% for total suspended solids (TSS), 35-70% for total nitrogen, 60-90% for metals, and 90-99% for total fecal coliform bacteria."
The Nutrient Reduction Facility (also known as "NuRF") is a $7.272 million cooperative water quality improvement effort by the Lake County Water Authority, the St. Johns River Water Management District and the Florida Department of Environmental Protection. The project uses off-line alum injection to remove pollutants flowing out of Lake Apopka into the rest of the Harris Chain of Lakes. Lake Apopka was historically one of the most polluted lakes in Florida, but restoration efforts are underway and there have been some signs of improvement. Still, discharge from the lake is the single largest source of controllable pollution in Lake County, Florida.
Gibbs & Register, Inc., a general contractor licensed in Florida was the general contractor on the project. SRS Crisafulli worked with Equipment Plus, it's Florida Representative, on this pilot project. Equipment Plus has been providing leading edge solutions to Florida's Water and Wastewater Industries since 1987, and collaborating with SRS Crisafulli from the beginning.
Larry Hickey at Equipment Plus reminds us that nutrient reduction is a key focus driven by the EPA and now adopted in State standards. Florida has recently implemented a set of numeric nutrient standards for lakes, springs, and streams. Those are available at the Florida FDEP website.
We can think of a few other regions which might consider this approach to manage the excess nutrient load in their lakes and streams.
To read more about our business partners on this innovative nutrient removal process, here are the links:
Environmental Research and Design, Inc. (ERD)
Lake County Nutrient Reduction Facility
Gibbs & Register, Inc.,
Florida FDEP website
SRS Crisafulli has discovered the Rural Water Association. This winter, Troy Fercho, Frank Robinson, Tristan Hoff and I attended shows in North Dakota, Montana, Minnesota, and Idaho. At these Rural Water Association Trade Shows, we promoted SRS Crisafulli's dredge equipment and rental services to assist communities in managing the long term, low cost resource of their wastewater lagoon systems.
When lagoon operators use proven, successful, operating and maintenance procedures, Wastewater Lagoon Plants can get in compliance, and can stay in compliance. Many lagoons have been in service for 30, 40, or 50 years. Lagoons should be desludged every 8 to 10 years for optimum performance.
One of our dredge systems, the remote controlled Flump Dredge System, pictured here, is an electric, unmanned system that is available for sale or can be rented directly by a facility or by a contractor. All of our dredge systems are made in the USA – in Montana to be exact. We provide installation and operator training for dredge sales anywhere in the world, and for rentals anywhere in the USA and Canada.
What have we learned at the Rural Water Shows? One of the high notes of the Great Falls conference was meeting Steve Harris, an independent consultant from Arizona, who has provided lagoon optimization and troubleshooting services for over a decade. Steve gave several presentations on lagoon troubleshooting at the Montana Rural Water Association convention in Great Falls.
How to Upset a Wastewater Treatment Plant
Steve Harris put a little bug in my ear about the impact of methamphetamine laboratories on wastewater treatment lagoons. Quick investigation produced a similar article in the December, 2012 issue of Treatment Plant Operator, by wastewater treatment plant Laboratory Detective, Ron Tygar, entitled, "Knowing What’s Coming." Ron writes: “Industries are not the only sources of discharges that can upset treatment plants. Residential abusers can have big impacts, too.” In his article, Ron, gave two specific examples of residential sewage abusers - deep fat turkey fryers, and methamphetamine labs.
In the first case, residents sometimes face the dilemma of what to do with 7 to 8 gallons of used cooking oil once the Thanksgiving holiday has passed. Some ingenious homeowners have discovered that the 3-inch PVC clean-out cap sticking up in the yard is conveniently connected to the local sewer system.
In the second case, the high levels of waste ammonia discharged into the sewer system along with other hazardous substances create a high-strength, or even toxic waste to the fragile micro-organisms.
Troubleshooting your Lagoon
Steve is the author of Wastewater Lagoon Troubleshooting - An Operators Guide to Solving Problems and Optimizing Wastewater Lagoon Systems. Steve's textbook charts eight general problems in lagoon management:
(1) low dissolved oxygen, (2) toxicity, (3) odors, (4) low temperature, (5) high coliform, (6) high BOD (biological oxygen demand), (7) TSS Control (total suspended solids), and my favorite, (8) “Short Circuiting” which refers to hydraulic inefficiencies that allow wastewater to exit a lagoon over a time shorter than necessary to completely stabilize it.
In terms of the potential value to lagoon operators of a dredging resource, removing sludge scores a 7 out of 8. Steve offers at least five strategies for each of the eight major issues on the way to optimum lagoon performance and compliance.
There are many fine points in managing wastewater systems. Our interest as a supplier of "sludge removal systems" is to support the longevity and efficiency of lagoons as operating systems.
As Steve Harris writes in the preface to his textbook, “The knowledge concerning diagnosing and solving operational problems in wastewater stabilization ponds has been greatly expanded over the last twenty years. Many papers have been published in scientific journals and several excellent books have been written on the subject of wastewater lagoon systems. Years of consulting with lagoon operators across the US, Canada, Mexico and Central and South America has shown me that little of this valuable information ever reaches lagoon operators.”
Another resource that addresses that same knowledge gap is the Maine Lagoon Systems website, which has a mission is to promote clean water resources through the enhanced communication of wastewater lagoon system operators in the state of Maine and beyond. This website provides an online presence in which operators of lagoon systems can network with each other on various issues of wastewater treatment relative to today's demand of a clean water environment.
A technical note from the Maine Lagoon Systems offers the following:
It has been reported that as many as 60 percent of the BOD5 (The amount of dissolved oxygen consumed in five days by bacteria that perform biological degradation of organic matter) violations nationally may have been caused by nitrification in the BOD5 test rather than by improper design or operation (Hall and Foxen 1983). Consequently, millions of dollars may have been spent needlessly on new treatment facilities.
To decide if you too want to meet Steve Harris, a 2009 lecture is available on YouTube.
H&S Environmental is committed to helping you get better performance from the wastewater lagoons you're already using. Their goal is to provide wastewater lagoon operators with practical, easy to use and cost effective tools to solve their toughest wastewater lagoon challenges. H&S Environmental is committed to the belief that wastewater lagoons are capable of producing high quality effluents...effluents that will consistently meet tougher new permit limits. Some of the chief problems with wastewater lagoons are operational, but many lagoon problems are the result of design deficiencies that can be fixed.
To learn more about Lagoon Dredging or
to inquire about dredge rentals or purchasing options...
Steve Harris, H & S Environmental
Maine Lagoon Systems
Rural Water Association
Treatment Plant Operator
Four Major Benefits of Horizontal Hydraulic Auger Dredges
By Jordan Webb, Design Engineer, SRS Crisafulli, Inc.
I attended the 42nd Texas A & M University dredging short course in January 2013. Despite the mountain of excellent information I gleaned from the course, I was disappointed that my dredging field wasn’t featured. Horizontal hydraulic auger dredging has been around for nearly 50 years, but remains the unknown stepchild of the dredging world. That may be changing as environmental dredging becomes more prominent. Horizontal hydraulic auger dredges are ideal for environmental projects for several reasons.
First, horizontal hydraulic auger dredges are small. I know everybody wants bigger, but small has advantages. One advantage is cost. Small horizontal hydraulic auger dredges are priced for as little as $200,000 for a new unit. Even the largest horizontal hydraulic auger dredges don’t break the $1,000,000 mark. Another advantage is transportability. Most horizontal hydraulic auger dredges can be carried on standard step-deck trailers. These units come fully assembled and are ready to begin dredging as soon as you put them in the water. A final advantage of small size is dredge productivity. Current dewatering and decontamination methods handle about 1000 gallons per minute with larger units handling about 2500 gallons per minute, numbers that match closely the productivity of horizontal hydraulic auger dredge pumps.
A second benefit is ease of use. Alternative cutter-suction dredges are complicated. To use a cutter-suction dredge the operator must worry about step angle, advance, moving into the cut, cutting the bank, Net Positive Suction Head Required (NPSHR) and vacuum, winch placement, cut angle and a host of other problems. Horizontal hydraulic auger dredges move forward; that’s it. Just point the dredge where you want to cut, lower the cutterhead, and move forward. This simple system can be taught to any employee/operator in less than half a day. The pump is mounted on a “ladder” eliminating worry about NPSHR. Dredge cuts are in broad lanes, which are easy to track even without a complicated sonar assembly.
A third benefit, and perhaps the most important, is turbidity. Cutter-suction dredges kick a cloud of dredged material into the water and then the operator hopes he can suck all that undesirable material into the mouth of the dredge pump. Unfortunately, cutter-suction dredges are never able to suck all that material up, and leave as much as much as 20% of all disturbed solids. In environmental cleanup projects that’s 20% of polluted material left in suspension, enough to get most job sites shut down. By contrast, horizontal hydraulic auger dredges push the dredged material into a shroud that directs the material into the pump’s suction mouth. The shrouding of material enables horizontal hydraulic auger dredges to suck up as much as 99% of dredged material, a highly desirable result.
The final reason to consider a horizontal hydraulic auger dredge for your project is closely related to the second reason. The cable traverse system of horizontal hydraulic auger dredges makes them easy to control remotely. Unmanned horizontal hydraulic auger dredges provide safety in jobs where you don’t want your people in the water. If the material is bad enough that it requires an environmental cleanup, you probably don’t want your people in the water. I know that when I’m operating a dredge I prefer to be sitting in a lawn chair sipping a cool drink, rather than on a dredge surrounded by 5 million gallons of toxic material.
This isn’t a comprehensive list of the reasons you might use a horizontal hydraulic auger dredge for environmental cleanup, but it covers many of the high points. No dredge is perfect. There are benefits and uses for every dredge type, but horizontal hydraulic auger dredges are ideally designed to handle most environmental dredging projects.
By Laura Fleming, SRS Crisafulli President and CFO
SRS Crisafulli follows the activities of our larger corporate cousins tackling tough environmental remediation dredging projects. One of the toughest is the Hudson River EPA PCB GE cleanup.
Dredging has resumed in the Upper Hudson River for the 2012 season - Phase II Year 2. Massachusetts based Cashman Dredging & Marine Contracting Co., LLC is performing the dredging. The crews are working 24/6 on this seasonal, multi-year project.
350,000 cubic yards, or 400,000 tons, of sediment will be dredged from the Hudson River this year. The sediment will be unloaded, processed, dewatered, and disposed of.
Cheers to Cashman Dredging & Marine Contracting as they move forward on this difficult river cleanup.
The Hudson River Dredging Project - read more
GE has published a series of technical papers for the Hudson River Dredging Project. As this is a PCB project, evaluation of resuspension is critical. A more abstract issue is a future looking model of species weighted fish fillet average PCB concentration for 2020 and 2046.
You may also read about the Hudson River PCBs Superfund Site on the EPA website. This project was debated and then planned for many years. It is good news to see the execution phase vigorously continued.
Whether you have just installed your new dredge or you have been dredging for a while, you should follow a lubrication and maintenance schedule in order to ensure a long and useful life for your dredge. SRS Crisafulli includes a suggested maintenance schedule in our dredge Operations and Maintenance (O&M) manuals.
The following suggested maintenance schedule is included in all SRS Crisafulli dredge Operations and Maintenance (O&M) manuals.
LUBRICATION & MAINTENANCE SCHEDULE (ROTOMITE):
- General condition of unit
- Engine oil, leakage, pressure gauge registration, pressure warning lamp
- Fuel leakage, level
- Coolant level and condition, temperature registration
- Radiator filler cap fitting condition
- ALL belts (fan, alternator, air conditioning, water pump)
- Grease zerks
- Hydraulic hoses, pumps, valves and components, reservoir and cylinder
- Gauges and sight bottles
- Pivoting Traverse Gear Box (if applicable)
|Lubrication Points on a Rotomite
- Cutterhead bolts and tines
- Engine oil filter element
EVERY 100 HOURS:
- Primary and secondary fuel filter
- Main dredge pump
EVERY 250 HOURS:
- Engine oil and engine oil filter element replacement
EVERY 500 HOURS:
EVERY 1000 HOURS:
- Sample hydraulic oil
- Hydraulic filters
- Valve clearance check
- Traverse winch drum, idler pulleys and cable
- Lateral positioning cables and winch drum
- Safety decals
Watch new video! SRS Crisafulli's Rotomite 6000C Series.
Watch how to install discharge tubing.
Download a Dredge Application form.
Calculate cost of replacement parts.
By Elizabeth Kaiser, SRS Crisafulli Marketing Manager
A popular magazine at the SRS Crisafulli offices is Treatment Plant Operator (TPO), which serves municipal water system operators.
The November 2011 issue of TPO featured the Natchez, Mississippi Wastewater Treatment Facility in their Top Performer - Biosolids section, with an article titled "Sun Dried Success".
"Natchez is the site of a new “greenhouse” solar biosolids drying system" states TPO.
The American Council of Engineering Companies recently awarded WGK, Inc., the general civil/engineering and surveying firm for this project, their Grand Conceptor's Award for the design of the upgrades to the plant. Congratulations to WGK!
Natchez has two, 3-acre holding ponds. Prior to their system upgrade, the disposal process for the sludge from these holding ponds was expensive and time consuming. Natchez WWTF hauled their biosolids - with solids content of 10% - and disposed of the material using liquid injection at a nearby site.
Today, the wastewater treatment plant produces a biosolid with at least 75% solids that meets class A standards. A SRS Crisafulli FLUMP dredge helps the plant accomplish this new standard successfully.
Installing a FLUMP dredge eliminated transportation and equipment rentals costs, and reduced environmental risks. The total project impact has reduced operating expenses by at least $200,000/per annum.
Michael Stewart, Natchez Wastewater Treatment Plant Manager, told SRS Crisafulli their goal was "not to make money but to save money." Michael said they "save money every time they start the FLUMP dredge."
The Natchez Wastewater Treatment system went online a little over a year ago. Today, their Crisafulli FLUMP dredge is operating 8 hours a day, while in production, and is going strong. The Crisafulli FLUMP dredge pumps the dredged sludge from the ponds to a 65,000 gallon tank. The sludge is then pumped to a belt press conveyor system. The FLUMP dredge fills this 65,000 gallon tank twice a day.
The Natchez Wastewater Treatment Facility intends to resell the sun dried product to farmers. The wastewater treatment facility will not only save money with their new system, but will also make money.
Do watch the November 2011 TPO video of the Natchez system, narrated by Michael Stewart, Plant Manager. He does an excellent job of explaining the art of this 5 million galls/day rated wastewater treatment facility, serving a population of 30,000.
Read the TPO "Sun Dried Success" article.
Read Natches Democrat article "Water Works awarded for dealing with your waste".
Watch a Crisafulli FLUMP video.
Read Crisafulli FLUMP case histories and testimonials.
By Elizabeth Kaiser, SRS Crisafulli Marketing Manager
Energy production and consumption worldwide is influenced by many factors. Resource availability, economic activity, population growth and environmental regulations, for instance, all affect the types of energy production that may be available to consumers. One of the cheapest methods of energy production is hydroelectric power.
Last spring’s press release by the U.S. Department of the Interior, Departments of Energy and Interior Announce $26.6 Million in Funding to Develop Advanced Hydropower Technologies, announced “funding for research and development projects to advance hydropower technology, including pumped storage hydropower.” Hydropower is a sustainable and clean power generating process. “These funding opportunities will help unlock innovative approaches to hydropower development that emphasize sustainable, clean power generation while reducing environmental impacts.”
What is the hydropower process? In short, falling water is passed through a hydroelectric generator to produce electricity. Another hydropower process involves what is called “pumped-storage”. As explained by the Tennessee Valley Authority, “A pumped-storage plant uses two reservoirs, one located at a much higher elevation than the other. During periods of low demand for electricity, such as nights and weekends, energy is stored by reversing the turbines and pumping water from the lower to the upper reservoir.”
Watch this YouTube video "Hydroelectic Power - How it Works"
How is dredging part of this scenario? The most serious technical problem for hydroelectric dams is accumulation of silt which reduces the water storage capacity of the dam. Reduced storage capacity limits both electricity generation and the availability of fresh water for downstream uses. Periodic maintenance dredging removes silt deposits from the dam reservoir and restores water storage capacity, thereby allowing the hydroelectric dam to function more effectively. Periodic dredging can reduce potential negative impacts on fresh water availability without interrupting energy production.
Want to learn more about hydroelectric dam dredging? Contact us.
Watch or download Crisafulli dredge videos.
Subscribe to this blog’s RSS feed for the soon to be announced Rotomite 6000 C Series Dredge.
By Elizabeth Kaiser, SRS Crisafulli Marketing Manager
Many situations can complicate a shoreline’s integrity. These can range from flooding, hurricanes and man-made disasters and can even include aquatic harvesting and human recreation. Making efforts to protect a shoreline from these intrusions helps protect economic and recreational interests. Shoreline remediation is an investment in the overall economic and natural habitat of a community.
As defined by the Erosion Control Technology Council (ECTC), Sediment Control is A practice that captures soil particles on site that have been detached and moved by wind or water. While different methods and practices are used when it comes to shoreline remediation and sediment control we will examine a specific method, dredging and shoreline remediation.
Let’s look at the Southwest Mordecai Ecosystem Restoration Project or “SWMER”. According to the SWMER Project Scope found at mordecaimatters.org, “The SWMER Project focuses primarily on several rapidly eroding areas on the southern rim of Mordecai Island.
SWMER complements Mordecai Land Trust’s wave barrier project with the Army Corps of Engineers which involves the planned installation of a barrier off the western coast of Mordecai north of the SWMER area.”
The SWMER project required careful planning on the part of Mr. Jim Dugan, President of Pond Recovery Services of Hainesport New Jersey and contractor for the SWMER project.
Jim Dugan has owned and operated dredges for many years and has used them in conjunction with Geotubes for the purposes of shoreline remediation. He has contracted his restoration services throughout New Jersey and surrounding waterways including the Chesapeake Bay. President of the Mordecai Land Trust, Jeffrey Hager, wrote of Jim Dugan, regarding the SWMER project, “He (Jim Dugan) proved to be an extremely competent and conscientious field manager,…”
Jim Dugan describes the SWMER project as a material handling challenge. “We had to move 900 tons of sand to an island in the bay.” As described in the Mordecai Matters Newsletter, Winter 2010 issue, SWMER involves the installation of close to 600’ of huge sand-filled fabric tubes called Geotubes, slightly off the south-western edge of Mordecai Island. “The erosion has been severe here and the hope is to stabilize this fragile part of the Island and encourage the deposition of grasses and other organic materials between the island’s edge and the two long sections of Geotube.”
Jim explained that they couldn’t use the sand from the bay so they transported 900 tons of clean sand from a nearby quarry by truck. But how do you get the sand to the island? “You have to pump it.” Jim said there were 2 major challenges involved.
- Don’t plug the pipeline with too much sand
- Water/tide problem
Jim needed to use the water in the bay to mix with the clean sand in order to pump the sand underneath a navigation channel, across the island, and through floating line to the Geotube feed ports. Jim needed a flexible solution. Since he was pumping downhill under a 15 foot channel, he couldn't risk shutting down with sand in the line. He used one of his Crisafulli dredges to act as a mobile sand pump to adapt to the wind and tide level fluctuations in the bay. The dredge would be flexible enough that his operator could adjust the articulating cutterhead height, angle and distance to the feed, thus keeping the sand-water mix at an constant rate. This also allowed frequent start-stop operation to flush the line and switch Geotube feed ports, thus filling the Geotubes evenly.
Jim used a hopper with a belt to deliver the sand to a sand spreader. The sand spreader distributed the sand evenly to match the 8 foot wide dredge cutterhead. The cutterhead mixed the sand and water allowing for an optimal pump mixture.
Using the dredge as a sand pump Jim was able to pump the sandy mixture up to ½ a mile directly into each of the geotube ports spaced 20’ apart. “(This project) needed a lot of flexibility which the dredge allowed for” Stated Jim.
Read Jim Dugan’s SWMER blog of his progress in the Mordecai Matters Winter 2010 newsletter.
Watch video of the shoreline with the installed geotubes at Mordecai Island Geotubes in Action on YouTube.
If you would like to email Jim Dugan, send your email inquiry to firstname.lastname@example.org.
Watch SRS Crisafulli videos.
By Troy Fercho, SRS Crisafulli Rental Equipment Specialist
We have all been there. You are right in the middle of a project and something goes out. Of course it’s going to happen in the middle of your project – parts don’t usually go out while they are just sitting there idle. So the age-old question is does it pay to stock those critical replacement parts?
In my 15 years in the sales industry, I can remember countless times when I had to overnight parts to contractors or customers who were in the middle of a project and who needed a critical replacement part that had put a stop to all production. In the best case, the part is in stock and can be sent overnight. Let’s not talk about the production parts that take a week to manufacture, or the part that is on backorder and will take 7-10 days to arrive.
In the dredging industry what is the actual cost of not having those critical spare parts? The following are just averages but you can plug in your own numbers.
Let’s use an impeller for example:
Cost with having spare part on hand
Initial Cost of Impeller - $1,500.00
Downtime replacing part – 3 hours
Cost of downtime (lost wages) – 3 hours x $200.00 per hour = $600.00
Shipping Charge - $50.00
Total = $2,150.00
Cost of not having spare part
Impeller Cost - $1,500.00
Downtime, 7 days manufacturing time + 2 days shipping – 9 days x 8 hours per day = 72 hours
Cost of downtime (lost wages) - 72 hours x $200.00 per hour = $14,400.00
Next day Shipping Charge - $500.00
Total = $16,400.00
Spare Parts Management
Use this calculator and try it for yourself.
Calculator by World-Class-Manufacturing.com
It is an understatement to say that keeping critical spare parts on hand is imperative. When you look at factors such as unpredictable demand, time tracking the part down, product availability, as well as the downtime waiting for the part, I would say stocking critical spare parts is a key business decision that will save you a lot of money in the long run.
We do have spare wheels but this one is for another customer. I can expedite one for you, have it ready in about 6 months!
Now there are a couple of questions that you have to ask:
- What parts do you keep on hand?
- Where do you keep these parts?
To answer question number one, you should consider the working parts that will be subject to wear and tear (i.e. bearings, impeller). These are the parts you need at the worst possible time – right in the middle of the job. They are the job stoppers. If you are not sure which items would be best to keep on hand, speak with your operators or mechanics or call the manufacturer and have them give you a list.
Now let’s take a look at the second question. This is as important as having the parts in the first place. You planned ahead and stocked key parts, but when the time comes and you need them, you can’t remember where they are. The best thing to do is to develop an inventory system for storing these parts and make sure that key people are aware of the system.
You are not working your tail off to lose money or even to break even; you started your business to make money. I know most of us think we don’t need these parts because we’ll change them out before needed and they won’t go out on you. The reality is that a majority of people are just too busy and changing them out slips through. Take a moment and consider the real cost of not stocking your critical replacement parts.
Need information about replacement parts for your Crisafulli product?