Internship Report

Inclusive of Project Report and Training summary

INDIAN MARITIME UNIVERSITY- VISAKHAPTNAM CAMPUS

Internship Duration: 1st June 2012- 27th July 2012 Interns: Ashwin A. Gadgil Dhruv H. Prajapati Ankit Ghosh Roy Thomas Shreya Dutta

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INTRODUCTION
We have undergone summer internship in MDL (Mazagon Dock Limited) situated in Mumbai, a leading Shipbuilding Company of INDIA with ISO 9001:2000 accreditation. It is a profit-making Central Government Schedule A PSU under the Ministry of Defense, Department of Defense Production, engaged primarily in the construction of Warships and Submarines for the Indian Navy. Main activities are ship building, ship repair and fabrication of offshore structures with facilities situated at Mumbai and Nhava. MDL have the capability to built warship, merchant ship, submarines upto 30,000 deadweight and fabrication of wellhead platforms and jack up rigs. For outfitting work the company has a large number of workshops with sophisticated equipments and machines specific to hull fabrication and ship construction work. Our training was mainly conducted in design department. our training schedule is planned as two weeks in structural department (Sdo) , two weeks in outfit department (Odo) , two weeks in forward design group (Fdg), one week in engineering department (Edo) and one week in electrical department (Ldo). We were basically focused on the design aspect of the ships, on which software it is made and how the material flow works etc. We were taken to the ships to study the interior of the engine room of a naval ship of INS KOCHI and MSV II (multipurpose service vessel)

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ABOUT THE AUTHORS

The authors are students of INDIAN MARITIME UNIVERSITY VISAKHAPATNAM CAMPUS. They had finished their 3rd year of B.Tech Naval Architecture & Ocean Engg. and underwent Industrial Training/Internship at Mazagon Docks Limited from the period of 1st June 2012 till 27th July 2012(8weeks). During their 8 week internship they were assigned to the DESIGN DEPT. of MDL and following is the breakup of their time in MDL: 1. 2. 3. 4. 5. Forward Design GroupStructural Dept. Outfitting Dept. Engineering Dept. Electrical Dept. 2 weeks 2 weeks 2 weeks 1 week 1 week

Highlights and Data Collection: SHIPS STUDIED: P15 Alpha Destroyer; P15 Bravo Destroyer; P17 Stealth Frigate; Great Ship Leela (MSV); Hercules (MSV) 1. The students successfully completed the basic design (GENERAL ARRANGEMENT, LINES PLAN) of a 80 pax cruise vessel. 2. The above assignment was assigned to them in the FDG dept. 3. Within the structural dept. the students learnt softwares viz. HYPERMESH, TRIBON M3. Etc. 4. The SCANTLING CALCULATIONS of the 80pax vessel were done under this dept. 5. They visited shop floors conducting the erection of the P15 Alpha destroyer. 6. They also visited the MOULD LOFT section where they got a deeper understanding of the conventional production process applied at MDL. 7. Within their time in the outfitting dept. they visited 2 ships to understand the intricacies of ship out fitting. 8. In the engineering dept. the students conducted a rigorous study of the systems and components of P17 Alpha Frigate. 9. Note: Attached within are the project reports along with the overall internship report.
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ABOUT MDL
Mazagon dock Limited Mumbai is an ISO 9001:2008 company is one of the leading shipbuilding and offshore fabrication yards in India. The yard was established in the 18th century , and over the 200 odd eventful yards , has earned a reputation for quality work and established a tradition of skilled and resourceful service to the shipping world in general and the Indian navy , Coast guard and ONGC in particular. In its varied history MDL passed through varied ownerships like the P&O lines and the British India Steam Navigation Company. It was incorporated as a Public Limited Company in 1934. After its takeover by the government in 1960, Mazagon Dock grew rapidly to become the premier war-shipbuilding yard in India, producing sophisticated warships for the navy and offshore structures for ONGC. It has grown from a single unit, small ship repair Company, into a multi-unit and multi-product company with significant rise in production, use of modern technology and sophistication of products. The companys current portfolio of design spans a wide range of products for both domestic and overseas clients. The company has qualified manpower to implement CAD/CAM/CIM using the latest ship design softwares ,operating from a number of work stations having the latest computer hardware to provide , up to date design and production support, commensurate for the yards capabilities. It manufactures warships and submarines for the Indian Navy, as well as offshore platforms and associated support vessels for offshore oil drilling. It also builds tankers, cargo bulk carriers and passenger ships and ferries. The shipyards of MDL were established in the 18th century. These yards have over two centuries of experience in shipbuilding. Ownership of the yards passed through various entities, including the P&O Lines and the British India Steam Navigation Company. Eventually, MAZAGON DOCK LIMITED was registered as a public company in 1934. The shipyard was nationalized in 1960, and is now a PSU of the Government of India.

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PROJECTS
COMMERCIAL PROJECTS 1. Offshore platforms MDL builds offshore oil drilling platforms. It operates facilities at Alcock, Mumbai and at Nhava Yard for construction of platforms with wellhead, water injection and production separator and glycol process capabilities, as well as jackup rigs, SBMs and other offshore structures. Repair and maintenance jobs on offshore rigs are also undertaken at Alcock, Jackets up to 80 m. length and 2200 T. weight can be constructed. At Nhava, Jackets up to 80 m. length and 2300 T. weight, Main Decks up to 550 T. weight and Helipads of 160 T. weight The yard also builds specialist vessels with capability to clean oil spills and fight fires on offshore drilling platforms. A welding training school develops and maintains welding techniques and procedures to acceptable standards and continuous update of welding techniques.

2. Commercial vessels The yard has built a wide range of vessels for the commercial sector, including offshore supply vessels (OSVs), harbor utility vessels and crafts such as tug boats, dredgers, tankers, passenger ships and cargo ships. It has also built and supplied commercial trawlers and barges, support vessels, a floating jetty and floating cranes.

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Naval Projects
1. Warships
a. Nilgiri class frigate

The first warship built by MDL was the 2,900-ton displacement, INS Nilgiri, the lead ship of her class. She was launched on 15 October 1966 and commissioned on 23 June 1972. Five more frigates of this class were built over the next nine years for the Indian Navy.
b. Godavari class frigate

While construction of the Nilgiri-class was being completed, the Indian Navy proposed requirements for an indigenously designed and built frigate. This new frigate was to be of wholly Indian design and manufacture. To address these requirements, MDL designed and built the Godavari class guided-missile frigates with a 3800 tons diplacement, and ability to embark two helicopters. Three ships of the class were built by MDL - the lead ship, INS Godavari, the INS Ganga and INS Gomati.
c. Khukri class corvettes

MDL designed and built the first two vessels of the Khukri class corvettes for the Indian Navy. The lead vessel of the class was commissioned on 23 August 1989, and the second, INS Kuthar, on 7 June 1990. The remainder of the class were built at Garden Reach Shipbuilders and Engineers (GRSE) following a transfer of technology from MDL, in order to diversify warship building capabilities to other yards, as well as to make room at MDL for the larger projects to follow.[5]
d. Delhi class destroyers

The next class of vessels designed and built by MDL were the Project15 Delhi class guided-missile destroyers. These were powered by gas turbines and displaced 6,200 tonnes. The first of the class, INS Delhi, was launched in February 1991 and commissioned on 15 November 1997. The second, INS Mysore, was commissioned on 2 June 1999 followed by the last ship in the series,INS Mumbai, on 22 January 2001.[6]

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e. Shivalik class frigates

The 6000 tons Shivalik class (Project-17) frigates are the first warships with stealth features to be designed and built in India. These multi-role, guidedmissile frigates have reduced radar signature and are due to enter service starting in 2010. At least 3 of this class are under construction at MDL. The lead vessel of the class commissioned on 29 April 2010.
f. Kolkata class destroyers

Kolkata class vessels are the next-generation of guided-missile destroyers in the 6,800 tonnes range to be designed and built at MDL. They incorporate stealth features. The lead vessel of the class was launched on 30 March 2006. At least three vessels of the class are planned. 2. Coast Guard vessels The yard also builds offshore patrol vessels (OPVs) for the Indian Coast Guard. These vessels are specialized ships built for patrolling, policing, search and rescue operations in India's Exclusive Economic Zone. Each of these ships carries a helicopter on board. Seven such ships have been delivered to the Coast Guard. 3. Floating police stations Based on the order by the BSF the yard started construction of floating Border Out Posts (BOPs). Essentially these BOPs are floating police stations, each with four high-speed boats. The yard has delivered 9 out of an order for 14 BOPs. 4. Other vessels Among other ships, the yard has built three fast missile boats, a cadet training ship, and various other utility ships for the Indian Navy.
Submarines
Shishumar class submarine

The Shishumar class submarines are a variant of the Type 209 diesel-electric submarine designed by Howaldtswerke-Deutsche Werft. Two vessels of this class were constructed at MDL. These were the first two indigenously built submarines in India. INS Shalki was commissioned on 7 February 1992 and INS Shankul was commissioned on 28 May 1994.

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Scorpne class submarine

MDL is presently building six diesel-electric submarines of the Scorpne class under a technology-transfer agreement with DCNS.

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DESIGN DEPARTMENT
Shipbuilding is an activity that requires integration of all forms of technology known to man into a vessel that floats in water. It has evolved greatly over the centuries and become more and more sophisticated with every passing century. Today, it is the realm of the professional naval Architect to design and to ensure

that its manufacture conforms to the various specifications and the need of the user. Every shipbuilder in the world requires a ship designer and that is what the Design Department at MDL basically functions towards. All the sophistication and detailing that is required to manufacture is provided by the Design Department. Each section in the Design Department has its own role to play. Apart from the various sections of mentioned below, there is an electrical department that takes care of the various electrical wiring throughout the ship. These are as follows: 1. Forward Design Group (FDG) 2. Structural Department (SDO) 3. Outfit Department (ODO) 4. Engineering Department (EDO) 5. Electrical Department (LDO)

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FORWARD DESIGN GROUP

The forward design group can be sub divided into 3 sections: 1. Basic Design Group 2. Cost Estimation Cell 3. Contract and Marketing Cell The general progression of any typical order follows the following sequence: THE PRE CONTRACT STAGE:

The owner (NAVY/Private) gives a basic briefing about the required product consisting of the following documents: 1. 2. 3. 4. 5. Naval Architecture Specifications Basic Drawings Electrical and Other requirements General Arrangement (If Available) Machinery Specifications The first threshold within the pre contract stage consists of THE TECHNICAL SPECIFICATION BID it consists of the technical specifications the yard is able to provide the owner including the speed, dead weight, etc. This bid is formed by taking inputs from the STRUCTURAL, OUTFIT AND ENGINEERING DEPTs.
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It is then simultaneously forwarded to the owner and the cost estimation cell. The cost estimation cell with the help of past records, vendors/OEMs and other methods estimates the cost of the ship. It also estimates the PROFIT MARGIN, MANPOWER, MATERIAL, LABOR, TIME etc. All the above terms including the final cost constitute the final FINANCIAL BID which is also then submitted to the owner. THE ORDER STAGE: Once the financial and technical bids are approved by the owner the legal dept and the marketing cell form the final contract which includes even the minutest details of the ship required. THE POST CONTRACT STAGE:

This stage is primarily concerned with the detailed design of the ship and is taken care by the structural, engineering depts. Etc. Once the bare hull is made the FDG dept. once again comes into picture. It conducts the following activities:
1. 2. 3. 4. THE INCLINING EXPERIMENT LAUNCHING AND DOCKING CALCULATIONS TRIM STABILITY BOOKLET WEIGHT MONITERING etc.

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Structural Department
Structural design group mainly deals with the modelling of the ship in the software tribon. However the whole department is being upgraded to aveva marine for detailing of the modelling and the structural details. Basic requirement of Navy are met with a basic design. After approval from the navy detail designs are drawn. Tribon M3 modelling is carried for hull detailing and sheeting, bulkheads, stiffeners, etc. based on the lifting capacity of assembly units available in the shop, until erection plan is prepared. Erection plan consists of typical unit drawings. Optical section will prepare nesting and cutting plans using faired hull surface designs and curvature requirements. Planning section prepares the part list and cutting document to be sent to material requisition store and production shops. Plate Preparation Plates are subjected to shot blasting and various and various layers of coat are painted on to prevent rusting while storing. The store will provide required plates and stiffeners and welding and cutting starts at the production and assembly shops (P&A) Production and Assembly Shop (P & A SHOP) Pressing, bending, rolling, bevelling and cutting are the major activities carried out in the production shop of the shipyard. Assembly carries out welding, hammering, grinding and bolting. Production Machinery Cutting CNC Cutting Machine Plasma of 2-30 m thickness Plasma Cutting Gases used include oxygen hydrogen and air Gas Cutting machine Pug machine Plates up-to 8 inches thickness Semi automatic Uses acetylene and(C2H2) and oxygen Plano Shear Machine (bevelling) Bevelling is used for plate preparation in the case of welding together plates of different thickness Employs mechanical cutting Hydraulic jacks are used to hold the plate in position
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Roller shears the plate Rolling 300t rolling machine Small plates 600t rolling machine Larger plates Pressing / Bending 350t and 600t pressing machines Manually done Experienced labour force required to obtain required shape of plates Templates made of wood to compare and assist Blocks and support prices used to assist Folding Machine 300t Knuckles 90 deg bends and wedges Chalk /marker used markline to be bend Heavy weight used to put pressure on plate and bend it according to need Assembly Major activity in assembly is welding together components to make sub assembly units and assembly units. Welding major activity Arc for steel plate Plasma for aluminium plates Bolting Huge nuts and plates used to join Grinding Preparing edges of plate for welding without defects arising from impurities Hammering Bends may arise due to temperature variation and thermal stresses arising due to welding Hammering flattens those ends

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Unit assembly at dry dock Unit installation starts from amidships and extends both ways .To compensate for losses and expansion during welding green material is employed. Standard Structural Details (SSD) Detail design about each unit like with structural component like bulkhead, transverse and longitudinal, collision, minor, WT and NWT, compartments, decks, side shells, stiffeners, pads, collars and plates.

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OUTFIT DEPARTMENT
To start with the hull outfit, first drawing should be prepared is an Access Plan of the whole ship. Access means to enter /move through openings. So, key plan of Hatches, Manholes, emergency Escape Scuttles (EES) and various types of Ladders, Doors, Windows and Side Scuttles are finalised. These are prepared based upon the General Arrangement Plan (GA) of a particular ship. Next, the detail production drawings of individual items covering above systems are prepared. Hull outfit section is also design and specifies the location of the various equipments that are fitted in the ship. The outfitting items which remain on the deck and inside of the ship are mainly as follows: 1) 2) 3) 4) SHIPS FITTINGS (excluding machinery and electrical) BOLLARDS FAIRLEADS ACCESS DOORS, HATCHES ,MANHOLES AND EES STAIRS AND LADDERS BROW AND GANGWAY 5) BOOMS & DAVITS 6) WINDOWS AND SIDE SCUTTLES 7) DECK EQUIPMENTS ANCHOR Different types of anchors are used in ship : a. BOWER ANCHOR A ships main anchor are called bower anchor used for anchoring the ship and stowed on both sides of the bow. b. STERN ANCHOR This anchor is used by some ships as a stern anchor, stowed in a stern region. These are mainly used for beaching purpose. LSTL is having one stern anchor and two bower anchors. ANCHOR CAPSTAN ANCHOR CUM GENERAL PURPOSE WINCH
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CRANES VEHICLE LASHING ARRANGEMENT 8) LIGHT & SOUND SIGNAL ARRANGEMENTS 9) FIRE FIGHTING ARRANGEMENT 10) MOORING AND BERTHING ARRANGEMENT 11) CARGO ACCESS EQUIPMENT such as BOW RAMP BOW DOOR VEHICLE RAMP WETHER DECK HATCH COVER INNER BOW DOOR HYDRAULIC EQUIPMENT (including pipes, fittings, flexible hoses etc.)

12) Guard Rails, Stanchions, Storm Rails, Helo Safety: mainly deals with guard rails(exposed decks), Storm Rails(weather exposed), HeloSafety(helicopter landing deck). Accommodation arrangement plan: deals with Accommodation facilities. Tonnage Measurement Plan: deals with tonnage measurement calculations. Life Saving Appliances: mainly deals with Life Saving Appliances such as 1. 2. 3. 4. 5. Inflatable Life Rafts Life Rafts Lifebuoys Rocket Parachute Distress Flares Line Throwing Appliances

1. Surface Preparation and Painting: mainly deals with Surface Preparation and Painting 2. Anticorrosive Paint(Water Ballast Tanks and Fresh Water Tanks) 3. Antifouling Paint(External Underwater Hull) 4. Heavy Duty Non Skid Paint with Primer(Exposed Decks) 5. Painting as per Paint Scheme(Above Waterline)
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Cathodic Protection System: mainly deals with three methods such as 1. Sacrificial Magnesium hanging type of anodes to protect Underwater Hull at the time of Launch till Sea Trials. 2. Sacrificial Aluminium Alloy anodes for Water Ballast Tanks and Sea Chests. 3. ICCP System for Underwater Hull Insulation: There are three types of insulation 1. Fire Class Insulation ( Bulkheads and Deck Heads) 2. Thermal Insulation (Internal Sides, Bulkheads, Deck heads exposed to weather) and then insulated with Marine Fibre Mineral Board (MFMB). 3. Acoustic Insulation (Compartments where Noise Originates) and then insulated with Marine Fibre Resin Board (MFRB). 4. Cold Room Insulation (Compartments and Doors for cold and Refrigerated rooms) and then insulated with MFRB.

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ENGINEERING DEPARTMENT
This Engineering Design group deals with various mechanical systems fitted in a ship, such as: 1. PROPULSION AND POWER GENERATION SYSTEM 2. ENGINE FITTINGS AND ACCESSORIES 3. REFRIGERATION SYSTEM 4. FIRE MAIN SYSTEM 5. BILGE AND BALLAST SYSTEM 6. FRESH WATER SYSTEM 7. FILLING AND LUBRICANT SYSTEM 8. SEA WATER COOLING SYSTEM 9. CIRCULATING WATER SYSTEM 10. AVCAT SYSTEM 11. FIRE AND DECK WASHING SYSTEM 12. SCUPPER DRAINAGE & SANITARY SYSTEM 13. SEWAGE TREATMENT PLANT WITH VACCUUM TOILET SYSTEMS 1. AIR ESCAPE & SOUNDING 2. EMERGENCY DG EXHAUST SYSTEM 3. STEERING GEAR SYSTEM 4. FIN STABILIZER SYSTEM 5. CO2 SYSTEM 6. SHIPS COMPRESSED AIR SYSTEM 7. COMPRESSED AIR SYSTEM IN MAIN & AUX. ENGINE ROOM 8. DD COMPRESSOR SYSTEM 9. A/C AND VENTILLATION SYSTEM 10.DOMESTIC ARRANGEMENT 11.LAUNDRY 12.LOGISTIC ARRANGEMENT 13.HOT AND COLD FRESH WATER SYSTEM 14.DRAINAGE ARRANGEMENT 15.FLOODING AND SPRAYING

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ELECTRICAL DEPARTMENT
Electrical group designs the electrical, electronics and weaponry systems of ships. The Various systems which are being dealt by them are as follows: 1. POWER GENERATION & DISTRIBUTION 2. LIGHTING SYSTEM 3. NAVIGATION SYSTEM 4. SIGNAL AND COMMUNICATION SYSTEM 5. INTERNAL COMMUNICATION SYSTEM 6. EXTERNAL COMMUNICATION SYSTEM 7. ARMAMENT SYSTEM 8. AVIATION SYSTEM 9. ALARM, MONITORING & CONTROL SYSTEM 10.GENERAL a) LOAD CHART b) MAIN CABLE ROUTE PLAN (WITH GLAND LIST) c) SEPARATE CABLE ROUTE PLAN (WITH GLAND LIST) d) AERIAL LOCATION PLAN e) BOOK OF JUNCTION BOXES Load chart is a table for calculating electrical power requirements for operating various systems used in a ship. On the basis of the same the capacity of power outputs for generators is determined.

MAJOR ELECTRICAL SYSTEMS 1. 2. 3. 4. 5. 6. 7. Automated Power Management Systems (APMS) Integrated Machinery Control Systems (IMCS) ATM Based Integrated Ship Data Network (AISON) Lighting Systems Navigational Aids Internal Communication System External Communication System

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OTHER ELECTRICAL SYSTEMS 1. LAN Systems 2. VCS 3. MK-III 4. SICADS 5. Upper Air Sounding 6. V-UHF 7. Auto plotter 8. ACS 9. ICCP 10.Steering Gear 11.Degaussing System

WEAPONS DEPARTMENT The weapons and the weapons system also come under the electrical department. The procurement of the systems and their installation also carried out under the supervision of the electrical department. MAJOR WEAPON SYSTEMS 1. 2. 3. 4. 5. Surveillance System Close IN Weapon System Surface To Surface MISSILE System Surface To Air MISSILE System Under Water Weapon System WEAPONS

1. Surface To Surface Missile 2. Surface To Air Missile 3. Close IN Weapon System UNDER WATER SENORS 1. SONAR ATAS 2. SONAR HUMSA UNDER WATER WEAPONS 1. Rocket Launcher RBU 6000 2. PURGA
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ACKNOWLEDGEMENTS
This summer training has given us an opportunity to have an overall idea of vast shipbuilding activities. We would like to convey our gratitude to MDL Personnel with high regards for their co-operation and guidance received from the design department. Firstly we want to thank the MDC dept of MDL for allowing us to be a part of this organisation of the 8weeks of our internship. Mr. A.B.Oval & Mr. Mohite have been instrument to this internship and their assistance was invaluable. We would like to thank Mr.A.J.Das (GM-design dept) for guiding us through the FDG dept and also expertly supervising our projects with tremendous interest. We also appreciate the invaluable assistance given by Mr. N Faisal & Mr. Nidhil within the FDG dept and the project. Within the structural dept we were greatly helped and led expertly by Mr. Shailendra singh Tomar, Mr. Pandey. Mr. Arun Joseph has been a absolute mentor during the entire period of the internship. Mr. Sadanand was kind enough as to explain to us the basics of scantling and strength calculations along with the use of Hypermesh. We would like to thank Mr.Mehta, Mr. Pai & Mr. Deep for helping us throughout the Outfit section. Mr. Deep was our mentor throughout the dept. He accompanied us on a lot of yard visits explaining even the minutest of details on board the ships. We would like to thank Mr. Kavade for his expert guidance in the engineering dept. We would also thank Mr. Verma for his support during the week at Electrical dept. Lastly we would like to thank out college and Mr. DSP Vidyasagar in particular for facilitating this deeply informative & fruitful internship. We would like to thank our campus Director Prof.S.C.Misra for allowing us to do this internship.

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CONCLUSION
The overall knowledge gathered during the 8 weeks(1st june-27th July 2012) on practical Shipbuilding &design will definitely become an asset in our lives. This practical knowledge gathered from here will be whole heartedly utilised in our future service. The amount of experience gained on practical design issues is unparalleled & and we have definitely benefitted for this once in a life time opportunity.

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