Ship Building

Process

The process of ship building is done in

seven (7) stages. Each stage has a department and is
completely responsible for its part in the ship construction.
The seven stages are as follows:

1. Designing

2. Lofting

3. Material Processing

4. Pre-Fabrication

5. Erection

6. Hull Outfitting

7. Delivery

Prior to the first stage the corporate

activity - this includes the agreement, Master Design of the
ship which specifies the basic parameters of the ship such as
the capacity (DWT), length, height etc.

1. Design:-The Design department deals with the basic and

working design such as cutting design for CNC machines,
assembly design for fabrication, erection sequence and
outfitting works. These designs are made through CAD/CAM
and program is fed into the CNC so that when model number
is typed and four corners are located it automatically adjusts
the co-ordinates and cuts the required shapes.

2. Lofting:-The lofting department is present in the HULL

Shop, PRE_FABRICATION and ERECTION as this is required till
the hull is constructed. This department is after Design dept.
and this estimates the material required, NC formats,
Wooden Templates, Specified Measurements for the ship
construction.

3. Material Processing:-The material processing is the core

part in the ship construction process. Here the material plate
which is imported is sent to the PLATE TREATMENT PLANT
where the plate is made corrosion resistant and sent to the
HULL SHOP for metal cutting .

4. Pre-Fabrication:-Pre Fabrication deals with the PANEL,

HATCH COVER constructions for the DWT ships, construction
of IPV vessels, Propellers.

5. Erection:-Erection department is where one can see the

assembling of different panels for the ship construction and
the entire HULL of the ship is constructed along with the
engine and is released into the sea.

6. Hull Outfitting:-Piping and Electrical works are done in

this department.
7. Delivery:-After the entire construction and tests
conducted for the ship to be in perfect condition the ship is
delivered to the customer.

STEEL STOCK YARD

The MS plates (Mild Steel

plates) used in the construction of HULL were imported
from other countries by the customer to HSL and stored in
the steel stack yard. These plates are stored as PILES. The
details of Steel Stock Yard are as follows:-

Total Area: 9.293 Sq.mtrs of hard standing area for storing

the plates of 4 mm to 60 mm thick range and other required
sections of various sizes.
 The inspected plates are given
IR(Inspection Report) number and stored as Piles. For
Example:

87/ DNV-A 36 / 2766 / 10

↓ ↓ ↓ ↓

Consignment Classification IR Number Year of

Manufacture Number of Grade

PLATE TREATMENT PLANT

Here the steel plates are processed

under various machineries to make them fit for production of
ship panels. The sequence of operation is as follows:-

CAPTIVATOR

CAPTIVATOR MANGLES

R1 MANGLES
 HYDRO LEVELLER

R2 MANGLES

R3 MANGLES

HEATING CHAMBER

BLASTING CHAMBER

SPRAY PAINTING

DRYING CHAMBER

MANGLES to HULL Shop

CAPTIVATOR (10 T):-This is an electrical controlled

conveyor used to take the inspected plates from the Steel
Stock Yard to the plate treatment line. The plates are put on
to the rollers of the captivator by a group of electro
magnetic blocks. The first roller of the machine is an electro
magnetic type to hold the MS plate such that it would not
move down because of gravity. Then by the forward
movement of the remaining rollers the plates are conveyed
from the captivator to the R1 rollers of the plate treatment
section that is from home to away position.
Specifications:

Max Plate Load 10 tons

Max Plate Size Length-14m, Width- 3.65m

Min Plate Size Length-3.65m, Width-1.5m

Plate Thickness Max-50mm, Min-5mm

Hoisting Speed 4-8 M/Min

Travelling Speed 30-90 M/Min

Roller speed 30M/Min

Trolley Speed 30M/Min

NO of Piles 3

Max height of piles 600mm

Main Voltage 3 phase 440 V, 50 Hz

Pilot Voltage 220 V, 50 Hz

Automatic operation controlled through PLS (programming

loop system).

One 16 T Magnetic pick crane (EOT)

handling the MS plates with Piles and one 10 T EOT crane is
also available for handling the sections like Flats, Bulb
plates, Angles, I beams, C channels etc..
HYDRO LEVELLER: The name itself indicates the function it
performs .It is a plate leveler functioned hydraulically. There
are oil tanks at the top portion of the machine and the rollers
movement is operated by the hydraulics of the fluid.

The unevenness in the plate will

obstruct the nozzle movement and also there is a chance of
backfire. Hence Mangling (leveling) of the plate is done.

As shown the upper rollers

are DRIVER and the bottom ones are DRIVEN. This machine
is operated both in Automatic, Semi Automatic and manual
conditions. There are two speeds, Clutch speed for
straightening the irregular plate and Ordinary speed for
passage of regular plate. The 450 T hydro levellers with
automatic thickness measurement for actuating the required
pressure is capable of straightening the plate ranging from
6mm to 20mm and 3.66M wide.

Specifications:

Hydraulic Pressure 315 Bar and 100

Bar

Hydraulic Medium Mineral Oil

Working Pressure Centre beam

(Down) 315 Bar

Test Pressure centre beam 395 Bar

Working Pressure centre beam (Up) 100 Bar

Test Pressure 125 Bar

Working Pressure side beam down 315 Bar

Test Pressure Down/Up 395/395 Bar

Speed 9.1M/Min

HEATING CHAMBER: The moisture content in the MS Plates

is removed through heating chamber. The heat is provided
both at the top and bottom of the plates to remove the
moisture content so that it does not cause a problem during
blasting. This chamber can be operated with both Automatic
and manual facility.

BLASTING CHAMBER: The dry plates after passing through

the heating chamber are passed through this chamber to
remove the rust, mill scales so that the plate gets ready for
the cutting stage.

It consists of 8 motors, the top

and bottom consisting of four (4) motors each. Small
spherical grits made of mild steel are made to incident on
plates with great force and high velocity due to centrifugal
force of the impellor. Since the Impellor is connected to the
motor both rotate at the same RPM.As shown when the grits
from the overhead tank reach the impellor, due to the
centrifugal force the grits cover the entire plate surface and
remove the rust, millscale and dust get removed from the
plate and fall into the conical shape at the bottom. These are
transported by the spiral way to the elevator where the grits
reach the overhead tank. This process is repeated till the
entire steel grit is converted into powder; this occurs due to
the friction between the grit and the plates and is replaced
with new Grit. The grit has both axial entry and radial entry.
The basic idea of this chamber is as shown,

Wet plate subjected to blasting will cause the

formation of grit material, which is undesirable so in order to
prevent the formation of grit material the plates are usually
passed through heating template before entering the
blasting chamber.

The Blasting process is said to be complete if

the plate has silvery white look otherwise the plate is sent
back and the blasting process is repeated.
 In the Blasting chamber, shot blasting machine
is used where the mill scale and rust are removed from the
plate at a rate of 5Meters/Min. The width measuring sensors
are available to enable effective and economic shot blasting.

Specifications:

Material Mild Steel (Dry and Oil

free)

Max Plate Width 3650 mm

Max Conveyor load 1000 kgs.pre linear

meter

Max working length 2500 mm

No of Rotoblast wheels 8

Power Req. 37 KW

Rotoblast motor Speed 3600 rpm

Impellor Speed 3600 rpm

Steel Shots 12 Tone

Separation type Air wash

Separation size 7”
 Ventilation Req. 41,650 Cubic meter/hr

Steel Shots act like tiny

hammers and Steel Grit acts like small Chisels. Among the
two Grit provides a better cleaned surface. Some special
finishes whether to use Grit-for example where a toothed
surface is needed to provide good bond for paint, plating,
cloatings and other special finishes whether to use shot or
grit or both can be determined by experimenting.

STEEL SHOT: Spenstead steel shot is the result of

technological development in metallurgy and related
sciences. It is a supreme steel abrasive designed to provide
users of high powdered modern blast cleaning machines
with a better, long lasting and more economical abrasive
than any previously available.

From premium raw materials, Spenstead steel

shot is precision electric melted, cast by an exclusive
process heat treated,

Quenched and drawn in a completely controlled (zero

Oxygen) atmosphere in the industry’s first fully automatic,
continuous equipment. Result a new characteristics know to
affect performance, wear life and cost.

Pound for pound, Pellet for Pellet, by any

standard of measurement Spenstead steel shot is the best
blast cleaning shot peening or descaling abrasive.
STEEL GRIT: Spenstead steel grit is made from the same
premium materials as the steel shot, with the same
exclusive manufacturing methods. Solid, dense shot crushed
into sharp, chunky grit. It is fully heat treated, then
tempered to provide toughness, uniform hardness and long
wear life. To serve a variety of requirements, Spenstead
steel grit is tailored to the job in three hardness ranges.

SPRAY PAINTING: To protect the MS Plates from rust and

other corrosive factors painting is done. Here the method of
painting is by spraying.

The plant is equipped with micro computer

which enables paint spray in either direction - Top and
bottom after cleaning. This has 8No.s airless spray and DFT
(Dry film thickness) of 25µ (microns) can be achieved. The
treatment line is also provided with the pre heater before
shot blasting and drying chambers after painting.

The grits those are spherical in shape while

removing rust and millscale it may also form some
indentation on the plate. The indentation formed in the plate
is covered during spray painting. Two pumps supply paint
one to the top nozzle and other to the bottom nozzle. The
painting is done in uni-direction and the process is controlled
through sensors equipped.
 The paints used and their durability is as
follows:

 IOESP- IRON OXIDE EPOXY Spray Paint (3 months)

 ZRESP-ZINC RICH EPOXY Spray Paint (9 months)

 ZSESP-ZINC SILICATE EPOXY Spray Paint (6 months)

DRYING CHAMBER: The wet paint on the MS Plates is to be

dried with in two minutes so that the odour of the paint
vanishes into the atmosphere through chimney.

After all these processes, the MS Plate gets

fit to undergo the Mechanical formation process for the
construction of the HULL. All the methods used above
produce errors; these are identified by years of experience
and not by any instrument.
 HULL SHOP

The Overview of the Hull shop is as follows:

 The HULL SHOP is divided into four
bays. The details of the BAY’s are as follows:

BAY 1: This Bay consists of a PLASMA CNC and CNC cutting

machines. For transporting the MS Plates three EOT cranes,
two Magnetic blocks type (10 T) and one C hook crane (10
T).The details of the machines are as follows:
PLASMA CNC CUTTING Machine: PLASMA is a gas having
atoms and molecules which are partly split into ions and
electrons and having high electron conductivity.

In a plasma torch the gas becomes

heated up extremely and leaves it through the nozzle with a
high speed. Due to the high concentration all electrically
conductive materials will melt and due to the high speed and
pressure of the plasma arc the molten material will be blown
away forming a very small cut in the material.

The plasma arc is hereby transferred

from the cathode installed in the plasma torch and
conducted to the negative pole of the plasma power source,
to the work piece (transferred arc). The nozzle is the
cathode, and the electrode is the anode. When the plasma
gas begins to flow, the nozzle is blown forward and the cut is
made.

Specifications:

Marking Torch Fuel LPG, OXYGEN gas

Cutting Torch Fuel OXYGEN, Air, water

Range of Thickness for MS plate 4 mm-35 mm

Speed 5M/Min

Marking pattern Powder Marking

 Skid Area 4m

Initially the plate is transferred by EOT

to the surface of the PLASMA CNC where with the marking
torch the four corners of the plate are marked. Then the
pattern of cut is fed through a floppy into the machine and
the machine starts cutting the pattern preferred. The depth
of cut is varied through variation in voltage. The plate can be
aligned in any manner; this is the main advantage in
PLASMA CNC. The marking torch is operated in Semi-
Automatic and the cutting torch is operated in fully
Automatic condition. The nozzle is of brass type and it is a
Tungsten arc produced from it. A coolant is used to cool
water used in the cutting process.

The marking for other process like

welding, rolling etc. are marked with blue color by marking
torch so that there would be no difficulty in the after
process.

CNC FLAME CUTTING Machine: CNC –Computerized

Numerical Control, It is a gas cutting machine where the
cutting is done by a flame produced by fuel (gas).Here the
MS Plate is to be arranged in correct manner .In this machine
the marking torch is absent so the plate should be aligned
straight with the platform of the CNC. Then the nozzle is kept
manually at the position to be cut and the torch is started by
switching the gas through the nozzle and creating a high
intense pressure with a small starter and thus flame is
produced.

Straight cutting, SVTS (Simple VEE

Top Side),

SVOS (Simple VEE Other Side), DV (Double VEE) are

performed by this machine.

Specifications:

Fuel OXYGEN, Coal Gas

Cutting Range Length-14,000 mm

Width-6500 mm

Speed 1 M per 3 Min

Thickness 250 mm

Number of Torch 4
 The SVTS, SVOS and DV are shown
above, after cutting the inspected plates are given their
respective identities such as

SVTS 25 3 mm NOSE

This suggests that the cut is Simple VEE Top side and the
angle is 25 degree. The NOSE is the thickness left from
bottom surface without cutting at the edge. For Double VEE
the NOSE is as shown above.

320 HYDRAULIC PRESS: This hydraulic machine is used for

making FLANGE parts

Specifications:

Capacity 320 T

Power of Motor 30 H.P

Pressing speed 6.7 mm/sec

Working Pressure 5000 PSI

Approach Speed 75 mm/sec

Return Speed 95 mm/sec

Vertical die space 450 mm

Weight of the press 40 T

BAY 2: This bay consists of CNC Gas cutting machine and
three different Hydraulic Press listed below. It consists of 3
EOT cranes, two C hook (10 T) and one Magnetic block crane
(10 T).

CNC:

Specifications:

Length of the Track 60 Mtrs

Rate of Speed 75-2500 mm

Supply Voltage 3 phase 220 V

Power Supply 3KVA

Thickness range 3 mm- 100 mm

2000 T HYDRAULIC PRESS: This machinery is used for

making both flange and semi circular sections.
 As shown the press contains one
upper and two bottom rollers. The movement of upper roller
is operated hydraulically. To stop the extra bending there
are groups of a pair of cylinders along with the upper
cylinder. The position of these rollers is adjusted according
to the shape to be bent and then the upper roller is brought
down to press the plate and pressing is done. To control or
set the position of plate on the roller there are two small
hand operated cranes with double C hooks to catch the
plate. END PINCHING is done in order to produce correct
curvature. Wooden Templates made by lofting department
are used to verify the amount of bending.

Specifications:
 Size of Top Roller 19’

Capacity 41’ x 2000 T

Size of Bottom Roller 15’

Centre between bottom rollers Max-28”

Min-19”

Max thickness of plate with 60 mm

28” centre distance

Max thickness of plate with 40 mm

19” centre distance

Approach Speed 6 mm/sec

Return Speed 46 mm/sec

Plate Rolling Speed 4300 mm/Min

800 T HEAD FLANGING PRESS: This machinery is used for

making flange parts. This machine consists a v shaped press
unlike 2000 T press.
Specifications:

Capacity 10 M x 800 T

No of Dies 5

Length of each Die 791/2

Total Flanging Length 260 mm

250 T BEA HYDRAULIC PRESS:

Specifications:

Capacity 250 T

Main Ram Dia 15-11/16

Return Ram Dia 3-9/16

Stroke 34”

STRUCTURAL ROLLS MACHINE: This is a manual rolling

machine without any electrical equipment. It is used to
produce circular shaped plates.
PUG MACHINE: This machine is used to cut either of SVTS
or SVOS of a MS Plate. The angle is set by the workman
manually and there is a small rail over which the PUG moves
by the start of a switch and when the end point is reached
the PUG is turned off. The fuel used is the same as the one
used in CNC gas cutting machine.

BAY 3: This bay consists of Plasma CNC with OXY Fuel

cutting, PUG Machines, Hydraulic Press (500 T), SHEAR and 4
EOT cranes, two magnetic blocks (10 T) and two C shaped
Hook cranes (5 T).
PLASMA CNC: This CNC is different from the CNC in the first
bay. This also includes the OXY-Fuel cutting other than
Plasma Cutting.

HYDRAULIC GUILLOTINE SHEARING MACHINE: This

machine is used for both Press and Shear. The cutting tool is
of Wedge shape and the metal part to be cut is placed under
it. The WEDGE shape is ensured such that the cutting is not
spontaneous but continuous that is load is not uniform but is
concentrated and is utilized in cutting part by part.

Specifications:

Length of blade 2600 mm

Free space between stops 2630 mm

Angle 1 to 3 degree

Correspondence to SHEARING:

Capacity 4 to 20 mm

Adjustability of back gauge 10 to 1000 mm

Max.Pressure in hydraulic system 250 atm

 Min pressure in hold down system 90 atm

Capacity of oil tank 6000 L

500 T HYDRAULIC PRESS: This is also a press machine

which is used for small bars.

Specifications:

Capacity 500 T

Working Pressure 320 Kg/Sq.cm

Stroke 99 mm

Bed Area 1850 x 1550 mm

BAY 4: This bay consists of a bending machine, cambering

machine and two EOT cranes, one C hook crane (5 T) and
the other Magnetic Block crane (10 T).

This bay produces bent bars, bulb plates

through the bending machines.

BULB PLATES: These are the flat bars with a bulb at one
end such that when the plate is joined with the other side at
the double bottom the force acting from the downwards is
resisted by the moment produced by the BULBS.
400 T COLD FRAME BENDING MACHINE: Here bending of
flat bars, angles, flat panels are done. The centre block of
the machine is fixed and the ends of the bars move
producing a bent bar.

Specifications:

Bending Capacity: Cold Flat Frames 17” deep

Cold Angles up to 15” x 15” in pairs

Cold Flat Plates 24” x 1 3/4” (Breadth)

Weight 21 T

Output of Pump 4300 Cu.in/Min

Tank Capacity 150 Gallons

HP of Motor 40
 Horizontal Stroke 16”

Forward Stroke 36”/sec

Working Pressure 4500 PSI, 400 T each way

Clamp Pressure 4500 PSI, 77 T each way

Clamp Speed 64”/sec

Return Pressure 2000 PSI, 23 T each

Return Speed 92”/sec

Min Bending Radius Outside 6”

Inside 10”

200 T CAMBERING MACHINE: Cambering is also a bending

machine where there is bending at the centre and the ends
are free.

Specifications:

Bending Force 200 T

Weight of the machine 10 T

Stroke Max 380

Min 40

SECTION TREATMENT PLANT: This plant is used for the

preparation of sections brought from the steel stack yard.
There are three basic procedures done in this plant. They
are:

1. Blasting Chamber

2. Spray Painting Chamber

3. Paint Dry Chamber

The procedure is same as the PLATE

TREATMENT PLANT. The details are as follows:

BLASTING CHAMBER: In blasting chamber, shot blast

machinery is used

Specifications:

Type 5 Wheel Rotoblast descaling plant for

section

No. of wheels 5

Power 37 KW

Speed 2500 RPM

This is operated in automatic

condition; opening and closing of valves are done depending
upon the width of the plates.
SPRAY PAINTING CHAMBER:

Specifications:

Type Air less

No of guns 4

No of paint pump 1

Speed 1.5 M/sec

Air Compression 6 MK3/Min

Operation Computer controlled

DRYING CHAMBER:

Specifications:

Exhaust fans cap: 12,000 cubic metre/hr

Motor 5.5 KW,1400 rpm.

PRE-FABRICATION

The main purpose of PRE-FABRICATION

is PANEL construction. The different parts manufactured in
the HULL shop like flat bars, Angles, Bulb plates, rolled
plates etc, are brought together and welded to form a
PANEL. Even IPV (Insure Patrol Vessel), propellers and Hatch
Cover are also constructed along with the PANELS.

This Shop is divided into four sections as shown:

Panel construction is
done by two subsequent process Sub Assembling and
Assembling.
The PANEL is as shown:
 Here welding of different parts
and surface finishing is done in order to create a panel.

BRACKETS: These are the joining parts where one section of

a panel or different surfaces can be joined. These are the arc
like structure sa shown.

STIFFENERS: These are the parts which provide stiffness to

the panel sides.

The panels are given the numbers as

DS 317 S / RV 02/ 1137 D:14507 B/

11139
 Double Starboard Aft end
SHIP No.

Bottom Side

{Even numbers (RV 02, RV 04) indicate

Starboard side and odd numbers (RV 01, RV 03) indicate Port
Side.}

SS 327 P / RV 01/ 1137 D:14607 A/

11138

Side Port Side Fore end

SHIP No.

Shell

The ship is divided in to four parts A, B, C,

D.

A-Fore end

B-Aft end

C-Port side (P)

D-Starboard side (S or SBD)

 Welding done is Metal Arc Welding,
consumable electrodes are used and it acts as a pole of
electric charge, when the electrode is brought near the
metal –positive electrode, a medium is created and the ions
transfer creating an arc which in turn melts the electrode
and thus joining the parts.

In section 2, Plate preparation and sub-

assembly is done. Propellers of the ship are also fabricated
here.

Section 3 deals with HATCH Cover (HC)

construction of the ship. Hatch Cover is the covers to cover
the HOLD of the ship. Hatch covers are rested on HATCH
HOMING of the ship. Hatch cover is as shown:
 The Hinge part is connected
to the Hatch Homing and when the door is to be opened the
hinged part is pulled up by the hydraulic system such that
the cover is opened. The surface is a little parabolic or
curved in shape such that the movement of wheels would be
easy. One HOLD consists of four HATCH Covers. The
Mechanism is as shown:
 Section 4 deals with the
construction of IPV and the panels for ship.

In the Pre-Fabrication shop, the

outer parts can be welded from outside and inside part is
joined from inside and the welding tests are performed for
welding defects.

ERECTION DEPARTMENT

In the Erection Dept. the Panels

constructed are joined together by welding to form the hull.
This Dept. consists of two huge 75-75 T EOT cranes with C
hooks. The positioning of the Engine and the piping work is
also done with the HULL construction. Along with the
construction of DWT ships a Submarine is also being
constructed in this department. The construction space of
Submarine is completely isolated from the DWT ship
construction so that there would not be any disturbance for
either of two.
 The Process Map of ship Hull construction
at (HULL BERTH) Erection Department is as follows:
SALIENT FEATURES:

1. Marking of Reference lines on Berth/Building Dock

Floor.

2. Placement of Keel blocks/Bilge blocks on Berth/Building

Dock.

3. Erection of Panels in position on Keel blocks/Bilge

blocks.

4. Alignment of Panels.

5. Consolidation of Panels.

6. Dry survey of Panel joints/spaces/Tanks.

 7. Pressure Test/Hose Test of Tanks/Outer Hull and
Exposed Areas.

FEATURES IN DETAIL:

1. Marking of Reference Lines:

 Ship Center line, Bottock lines and Frame lines at

required intervals are marked on Berth/Dock floor and
painted for easy identification as these lines are to be
used as reference lines through out the course of
construction of the vessel.

 Sufficient working excess should be taken between

dock wall and side shell to be taken into consideration
before marking the ship centre line.

 Straightness of Centre line shall be conformed by

carrying check-ups by Theodolite.

2. Placement of Keel Blocks/Bilge Blocks:

 Keel blocks/Bilge blocks consisting of cement block and

wooden blocks are placed in position as per the docking
plan.

 Required heights and Top surface levels of the blocks

are maintained and checked by water tube.
 

3. Erection of Panels:

 Panels/Assemblies received from Pre-Fabrication

department are erected in position on the Keel/Bilge
blocks by crane according to paneling
arrangement/Block division plan.

• Weight of the panels is taken into account before

lifting the same for suitability of lifting capacity of
crane, D shackles and wire rope slings. Adequacy
of lifting-lug structure also checked before lifting
the panel.

• Shoring-lugs for peak-panels and wherever

necessary and staging arrangements for HOLD-
BHD’s (Bulk head) are provided prior to the
erection of panels.

• Temporary pillars are fitted at INBOARD-End of S.S

Panels at Pre erection stage for supporting of
erection.
  After erecting the panel in position, steel/wooden
shores, rigging wires, supports and lockings are
provided as per the requirement and status of the panel
before releasing crane.

4. Alignment of Panels:

 The first panel taken for alignment is the Datum Panel,

generally located at the mid ship area and on centre
line of the ship is also called Keel panel.

• The alignment of Datum panel (Keel panel) is

carried out with reference to Berth line/Dock lines.

• Centre line and Frame lines alignment are

checked by plumb dropping from the lines on
panels to the corresponding lines on Berth/Dock
at Aft end, Port and Starboard (SBD).

• Water level is checked on Tank top from Aft frame

to Fore frame longitudinally on Centre line/Bottock
lines and Port side to Starboard side transversely
on particular frame lines at Aft and Fore ends by
water tube.

• After ensuring the alignment of reference lines

and water level, the panel is locked with
Berth/Dock by eight (8) number of Rigging wires
with Turn-Buckles i.e. four transversely (two No’s
 Port to SBD-BTM and two No’s SBD to Port-BTM )
and four longitudinally (two No’s Fore to Aft-BTM
and two No’s Aft to Fore-BTM).

 To ensure the immovability of the panel, it

may be locked additionally with Keel blocks
by steel plates welded to both cement block
and panel.

 The side panels on D.S panels (P) & (S) are aligned with
the first panel DC/DB panels (datum) and with
reference to the Berth/Dock lines and unitized to form a
datum base of the vessel.

• Hold BHD, Side Shell panels (P) & (S) and U.D
Panels all aligned with first panel Datum-Base (4.2
line) moving from below upwards and utilized to
form a datum unit of Aft ward section of the
vessel.

• Adjacent panels are aligned with datum unit

(4.2.1) and reference lines of Berth/Dock floor and
progress of Hull construction moves towards Fore
end from Fore of the datum unit to Aft end from
the Aft of the datum unit.

 Adjacent panels are aligned at one end (inside) with

Datum panel and at other end with Berth/Dock
reference lines.
 • Dimensional check-up’s of frame spacing/Bottock
spacing, length overall half breadth and height are
carried out while aligning a panel as per the
necessity.

• Water level of the adjacent panels is checked from

a fixed point on the datum panel/already aligned
adjacent panel.

• After conforming the dimensional accuracy and

water level check-up’s, the panel is locked with
the Datum unit/already aligned adjacent panel.

 Other datum units consisting of HOLD-BHD’s (as on

4.2.1) may be formed for convenience and dimensional
accuracy of Hull structure.

 While aligning Engine room panels especially Bottom

Panels (Base panels), extra care to be taken to ensure
the water level of the engine bed and the height of the
shaft centre line above the base line.

 The alignment of Stern-tube panel (SF.01) is carried out

by taking into consideration the stern tube position with
regarding to shaft centre line and the distance between
stern tube Aft end to Engine bed Aft end.

 The alignment of lower aft peak (AP) panel is carried

out keeping in view the verticality of rudder-centre line
 and its matching with ship centre line and the O.frame
line. Dimensional accuracy regarding the height of
Rudder stock (above base line) and its distance from
the aft end of stern tube is also strictly followed.

 Other peak panels such as upper AP and FP panels are

aligned as like as any other adjacent panels except the
careful observance of ships height at AE and FE.

5. Consolidation of Panels

 After alignment of two panels, the joint between them

is prepared for fit-up for welding.

• Both the edges are leveled with standard nose as

per the requirement.

• They are leveled with appropriate gap as per the

welding system and locking pieces are provided in
the opposite side to facilitate free and fair welding.

• Notch build up’s and edge build-up’s if any are

carried out before the leveled edges are ground
smooth and offered for fit-up survey.

• After fit-up survey the joint is cleared for welding.

6. Dry survey of Panel joints/Spaces/Tanks

 After completion of welding, the locking pieces

,temporary supports, strong backs and unwanted lugs
 are removed by cutting/Releasing by gas cutter and the
area is dressed up by Grinding/Chipping.

 Before offering to Class/Owner’s surveyors, the job is

inspected by department and Q.C regarding fairness of
structure, conformation to design and visual inspection
of welding etc.

 The panel joint /Along with space tank is offered for dry
survey by class/owner after satisfactorily completing
the Q.C remarks.

 Dry survey remarks are completed to the satisfaction of

class/owner surveyors and the tanks, outer hull and
exposed decks are offered for pressure test.

7. PRESSURE TESTS (Air test/Hose Test/Hydraulic Test) are

carried out as per the survey and testing plan and according
to the technical specifications.

AIR TEST: In this test process compressed air will be filled in

the tank space voids etc. And keeping a manometer at the
other end of the tank and see that the pressure of the filled
air comes to 0.145 bar head and observe the pressed tank
for 24 hours. After that outside of the tank will be inspected
for leaks by applying soap water thus giving air bubbles . In
case of any leaks the test will be repeated after releasing the
air pressure.
HYDRAULIC TEST: This is carried out by filling the water in
the tank, space, voids and keeping water head on top of the
tank as required by the testing rules and inspects them for
any leakage and soundness of the welds.

HOSE TEST: With the help of fine tender water jet will be
forced on weld points with a pressure of 4-7 kg/cm 2 keeping
the water delivery nozzle tip 1.5 meter away from the
testing job and simultaneously inspects the other side of the
job for any leakage of water, if leaks are formed, the same
will be repaired.

FIT-UP: This process is used to level two different surfaces

which are to be joined. Different clamps such as C, L shaped
are used for this process. The clamp is fixed to the lower
surface and a wedge shape block is kept underneath the
clamp at the other surface and is hammered from the open
end so that as the wedge moves inside the lower surface
raises and equals with the other surface as shown.
 The parts to be welded are BEVEL
prepared. The preparation is done by CNC flame cutting
machine as shown.

TURN-BUCKLES- These are used to hold the panels before

welding and after fit-up. The circular part is connected to the
lugs and the hold is turned with a rod to tighten or loosen
the Buckle.

WELDING: - There are two types of welding done here.

1. CO2 Welding: This is done when the welding length is

more than 4 meters. This is a Gas Metal Arc Welding
(GMAW). The metal is supplied continuously along with CO2.

2. Filler Material Welding: This is done when the length is

less than 4 meters.
 There are four steps to complete the welding
process. These are 1. Root 1, 2. Root 2, 3. Build up, 4. Final
Weld.

Hatchings and Notches are the

irregularities formed in the bevel cut during CNC cutting
machine

DOCK PARTICULARS:

1. Capacity 53,000 DWT vessels

a) Length of Dock 240 m (180mm covered

length)

b) Width 53 m

c) Level of Dock Floor 7.25 m

d) Cope Level +4 m

e) Sill Level -5.75 m

2. Dredged level in Front 10 m

of the dock
3. Height of dock cover from 52 m

Dock floor

4. Loading of floor 100 T/m2

5. Main Dock Gate (cassion type) 1 No.s

a) Length 54.86 m

b) Breadth 6.00 m

c) Depth 10.40 m

d) Draught 5.45 m

e) Total Weight 1000 m

f) Top Level +4m

CRANE FACILITIES:

1. Cranes:

a) EOT Cranes 150 T capacities-2 No’s

Gantry Height 33 m from floor level

Span 60 m

b) Level luffing crane 100 T, 14 m track

 (100 T from 12 m
to 30.05 m)

(75 T from 12 m to 35 m)

(50 T from 12 m to 40 m)

2. Capstans 15 T each (4 No’s at

entrance and

2 No’s at head end)

SHIP BUILDING BERTH

There are three Slip ways/building berths

available for construction of vessels upto 30,000 DWT.

The ships built on these berths are fitted

with deck covers, hatch covers, engine room machinery and
other outfitting items to a maximum extent permissible
under the available tide conditions. With this concept the
ship is launched with 60% work completion and launching
weight of nearly 6000 T.

All the service lines like power, oxygen,

acetylene, compressed air and fresh and salt water are
provided for all the 3 berths.

FEATURES:
 Berth No.2 Berth
No.3 Berth No.4

1. Over all length of building berth 140 m 195 m

195 m

From low water line to head of

Slipway.

2. Extreme width of Berth 26.6 m 31.2 m31.2

m

3. Workable width of Berth 22.7 m 25 m 25 m

4. Loading allowed 2.5 T/Sq.ft 2.5 T/Sq.ft 2.5

T/Sq.ft

5. Crane Facilities

Port side 100 T.L.L 60 T.L.L

45 T.H.H

35
T.H.H

8
T.L.L
 Starboard side 60 T.L.L 45 T.H.H
45 T.H.H

35 T.H.H

8 T.L.L

THE ENGINEERING DEPARTMENT

The Engineering department deals with

manufacture of machines and their parts like engines etc.
This department consists of two EOT cranes and it also
includes all kinds of manufacturing machines like

1. Milling

2. Boring

3. Drilling

4. Lathe

5. Grinding

6. Engraving

7. Planer

1. MILLING: A milling machine is a machine tool used for

the shaping of metal and other solid materials. Milling
machines exists in two forms-Horizontal and Vertical
which terms refer to the orientation of the cutting tool
spindle. Milling involves the movement of workpiece
against the rotating cutter, the later of which is able to cut
on its flanks as well as its tip. Workpiece and cutter
movement are precisely controlled to less than 0.001
inches usually by precision ground slides and lead screws
or analogous technology. Milling machines may be
manually operated, mechanically automated or digitally
automated via Computer Numerical Control (CNC).
2. BORING: In machining, Boring is a process of enlarging a
hole that has been drilled (or cast), by means of a single
point cutting tool (or of a boring head containing several
such tools), for example as in a boring cannon barrel. Boring
is used to achieve greater accuracy of the diameter of a hole
and can be used to cut tapered hole.

Generally the boring is done on a Lathe

machine for small works and on a large machine for large or
big works.

3. DRILLING: Drilling is a hole making process and is a multi

point cutting process. The process of drilling requires either
the drill piece or the object being drilled to be rotated.
Drilling can either create a new hole or enlarge an existing
one.

On most workpieces it is vitally important

that the hole be drilled precisely in X, Y, Z axes. When
possible drilled holes should be located to the workpiece
surface, this is due to the large length to diameter ratio
which causes the drill bit to be easily deflected which can
cause the hole to be misplaced or the drill bit to break or
fatigue.

4. LATHE: A Lathe is a machine tool which rotates the

workpiece while the tool is stationary. It performs various
actions such as cutting, tapering, drilling, knurling or
deformation with tools that are applied to the workpiece to
create an object which has symmetry about an axis of
rotation.

In Ship industry, metal is removed from the

workpiece using a hardened cutting tool, which is usually
fixed to the solid movable mounting, either a tool post or a
turret, which is then moved against the workpiece using
hand wheels or computer controlled motors. These tools
come in wide range of shapes and sizes, some of these are
diamond, round, square, triangular.

5. GRINDING: The grinding machine consists of power

driven grinding wheel spinning at the required speed and a
bed with a fixture to guide and hold the workpiece. The
grinding head can be controlled to travel across a fixed work
piece or the workpiece can be moved whilst the grind head
stays in a fixed position. Very fine control of the grinding
head or table’s position is possible using a vernier calibrated
handwheel or using the features of a NC or CNC controls.

6. ENGRAVING: Engraving is the practice of incising a

design on to a hard, usually a flat surface by cutting grooves
into it. The result may be a decorated object in itself, as
when silver, god, steel or glass are engraved, or may provide
an intaglio printing plate, of copper or another metal, for
printing images on paper as prints or illustrations; these
images are also called ENGRAVING.
 Engravers use hardened steel too; called a
BURIN to cut the design into surface, most traditionally a
copper plate. Gravers come in a variety of shapes and sizes
that yield different line types. The burin produces a unique
and recognizable quality of a line that is characterized by its
steady, deliberate appearance and clean edges. The angle
tint tool has a slightly curves tip that is commonly used in
print making. Florentine liners are flat bottomed tools with
multiple lines incised into them, used to do fill work on larger
areas. Flat gravers are used for doing fill work on letters, as
well as most musical instrument engraving work. Round
gravers are commonly used on silver to create bright cuts
(also called bright cut engraving), as well as other hard to
cut metals such as nickel and steel. Burins are either square
or diamond shaped used for cutting straight lines. Other
tools such as mezzotint rockers, roulets and burnishers are
used for texturing effects.

7. PLANER: A Planer is a type of metal working machine

tool that is analogous to a shaper, but larger and with the
entire workpiece moving beneath the cutter, instead of the
cutter moving above a stationary workpiece. The work table
is moved back and forth on the bed beneath the cutting
head either by mechanical means such as rack and pinion
gear or a hydraulic cylinder.
 PLUMBING DEPARTMENT

All the pipe work in ship construction is carried

out by the plumbing department. The workman and
technicians working in this department are called
PLUMBERS. Mild steel pipes from the stock yard are brought
to the section and bent cut to the required shape and size
respectively.

The plumbing department consists of two shops:

1. Pipe cutting, Bending and Testing section.

2. Welding Section

TIG, MIG and Manual welding.