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Hull New Construction

Surveys

Some key points to consider during Hull New


Construction at the BUILDING YARD

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Agenda

Review of LR Responsibilities during a New Construction Project


Project Management and Survey Team
Liaison with Owners Site Team
The Basic Essentials
Data and Document Control
Key Data

Fundamentals of Shipbuilding
Quality Procedures and Standards
New Building Surveys
Construction Monitoring Procedures

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Project Management and Survey Team

Project Manager for each project

Ensures contractual requirements are satisfied

Acts as main point of contact for owners and shipyard

Co-ordinates all survey/inspection activities

Ensures all problems/issues are resolved

Monitor progress and time spent

Arrange deliverable certificates and reports

Team of professionally qualified surveyors

Hull construction surveyors

Machinery construction/installation surveyors

Electrical/control surveyors

NDE specialists & metallurgists

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Liaison with Owners site Team

Start-up meeting with owners team


Technical briefing for owners supervision team
Co-ordinated approach for monitoring and survey activities
Outstanding issue list following sea trials
Issue full term certificates
Close down meeting/follow up actions

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The Basic Essentials

The Request for Services (Form 2500):


Contains what LR is contracted to deliver and is our legal contract.

Key Event Dates (Steel Cutting, Keel Laying, Launch, Delivery):


Impact on stage payments, Statutory Regulations and preparation of
deliverables.

Division of work:
Who does what, (London Office, Local P.A., Site Surveyor, Other LR
Offices) and Extant Instructions, Checklists, Reports, Flag state
authorisations.

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Data and Document Control

Requested plans for approval are submitted on time and any


amendments dealt with - maintain a master lists, up to date checklist.

Design Appraisal Document (DAD)s complied with and any


outstanding items closed.

Correspondence (incoming/outgoing) recorded as necessary dealt


with.

Demonstrate compliance with LRs Quality Procedures (CM 02-04-01)

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Key Data
Special steel locations
- High Tensile, through thickness, forgings, castings

Construction Monitoring Locations for Ship Right Notation.


Structural Details
- Alignment, Gaps and Edge preparations

Welding Details
- Leg-Lengths, Throat, Thickness, Full and Partial Penetration, Spec
Techniques

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Shipyard Procedures & Standards

Building Standards
Shipbuilding Quality Standard
IACS Shipbuilding and Repair Quality Standard

Weld Procedures Specifications (WPS)


Welders Qualified to recognised standards
Approved Welding Procedures different grades & processes
Approved Welding Consumable
Approved Shop Primers being used

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Shipyard Procedures & Standards

Non Destructive Examination


NDE Plan to be approved by surveyor in accordance with the Rule
Requirements for the NDE - based on length of butts and seams
and number of intersections

Usually a mixture of RT, UT & MPI

To be recorded and evaluated

NDE as part of the quality control procedures

Production NDE (usually UT)

Start and end of all submerged arc welding runs

Suitable NDE Qualified operators and procedures


Reviewed NDE Procedures

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Shipyard Procedures & Standards

Tank Testing
Approved Tank Testing Plan
All Tank Boundaries to be tested to confirm that their design and
construction is satisfactory. All pressure gauges to be calibrated.
Air Leak Tests
The application of a protective coatings is not allowed prior
to test excluding the shop primer
Air pressure be raised to 0.2 bar for 1hour and then lowered
to 0.15 bar
Hydrostatic Strength Tests (Structural Testing)
Hose Testing: Max distance of 1.5m (not less than 2.0bar)
Fillet Weld Air Tests
Vacuum Leak Tests
IACS UR-S14 Testing Procedures for Watertight Compartments
IACS Recommendation No. 72 Confined Space Entry

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Tank Testing - Fillet Weld Air Tests

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Tank Testing Vacuum Leak Tests

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Structural Testing

Rules to be complied with - See Part 3 for details


Correct air pressures/hydrostatic test heads applied - Do Not Over
Pressurise - Danger

Gauges calibrated and working correctly


Vacuum Boxes and fillet air testing
Listen and look for BIG and SMALL leaks
Deformation during and after testing

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The New Building Project - Hull Construction

Materials
Forming
Block Surveys
Pre-erection Surveys
Dock Erection joints Surveys
Patrols of work in progress
Construction Monitoring Procedures
Deck house and Accommodation
Anchoring and Mooring Equipment
Other items

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Materials
From stockyard to production, there needs to be clear identification
of different grade of plates and sections: Visible colour coding and
marking

Spot check material scantling during routine patrols and surveys


Insert plates/partial renewals must be correct grade for the locations
Handling of special steels: avoid contamination and damages
stainless steel and aluminium

Identification and Traceability

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Typical Steel stockyard with plates stored in the


as rolled condition.
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Steel plate entering the shotblast and primer


treatment line.
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Steel plate immediately after shotblasting and priming.


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Steel plate marking after blasting and priming.


Marking is done automatically by machine.
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Transferring identification marks and correct


grade manually - just after blasting and priming.
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Forming (Hot & Cold)

Correct procedures need to be applied


Operators need to be properly trained and experienced
Verify that heating is being monitored during the process : Use of
Tempel sticks and/or temperature probe

Use guidance notes and work instructions.


Template to be used to verify the shape of curvature to steel
plate and structural members

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Hot Forming Line Heating

Plates being Line heated prior to application of water


to shape and form the plate to the required curvature .
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Hot Forming Line Heating

Wooden template being used to check the shape


of a side shell plate during Line heating .
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Cold Forming Mechanical forming

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Cold Forming Mechanical forming

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Block Surveys

Verify structural details against approved plans to ensure:

the working drawings comply with approved Plans


welding details and quality visual, leg-length & throat
plate and section edge preparations for fit to next unit
W.T. /O.T. Boundaries for penetrations missing members collars, bkt, etc.
Positions of air and drain holes should not in high stress areas and placed
in correct places for drainage and pressure relief

alignment, deformation, unsupported structure

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Numerical Control steel cutting. This is the first


stage of the block where the piece parts are cut
from the parent plates.
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Piece parts from parent plate now arranged ready


for sub assembly of block sections.
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Automatic fillet welding of stiffeners for sub assembly.

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Submerged Arc Welding for plate joints.


Note run off plate at the end of the weld.
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Transportation of sub-assembly to the block


construction shop
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Typical double bottom block


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Pre-erection Survey

Alignment, deformation, any unsupported structure and welding


Lifting lug positions and removal - MPI testing of areas effected to
verify possible cracks due to stress and notches.

Structural testing in way of outfitting is completed or noted for later


- before insulation, pipe, cable, machinery equipment and etc are
fitted and access to weld is not possible

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Pre-erection of fore
body section
Four individual units
brought together to
form one single
block
Lifting lugs will also
be removed after
erection

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Typical Pre-erection for Aft body / Machinery space


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Typical pre-erection for side shell


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Pre - erection
of a very large
section of
main hull and
LPG tank

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Erection joints Survey


Alignment, deformation, unsupported structure welding and missing
members

Fairing aid positions Not on stress areas


Bad workmanship/practices - wide gaps, excessive force, Backing plates
Adverse environmental conditions
Welding in rain
Wind blowing away shielding gas
Steel temperature too low in winter

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Typical erection of double bottom blocks being


placed in the building dock (Oil Tanker) .
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Typical erection of double bottom blocks (Oil tanker)


laid out in the dock bottom ready for fairing .
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Typical lower hopper joint to double bottom


(Oil Tanker). This is a Critical location
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Typical erection joint of double bottom to longitudinal


and transverse bulkheads (Oil Tanker).
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Typical erection joints forward - Longitudinal bulkhead


and lower hoppers to double bottom (Oil Tanker) .
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Typical erection joint of forward side shell to


double bottom (Container Ship)
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Patrols of work in progress

Carry out regularly, daily if possible


Tell the yard and owners that you do patrols
Vary your routine, time and places
Mark up with chalk or paint any problems you find and report
them to QC

Follow up any problems identified

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Ceramic baking strip fitted at the root of a full


penetration weld
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Ceramic backing strip viewed from the root side


of the weld .
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Poor root weld after removal of the ceramic backing


strip .
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Arc air gouging of a shell butt prior the root sealing


run
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Shell butt weld after arc air gouging

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After repairing of shell butt weld

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Construction Monitoring Procedures

LR ShipRight Procedure
ShipRight (CM) assigned as a class notation

Mandatory Part of ShipRight procedures involving

Materials
Alignment
Welding
Construction procedures

Objective
To ensure that special attention is given to critical joints
to avoid stress concentrations

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Construction Monitoring Procedures

Construction Monitoring Plan Approved - by PAS


Critical locations identified at design approval stage tolerances
for fit up, gap, etc

Enhanced alignment tolerances specified by LR


Shipyard develops working procedures to control fit-up at these
locations

Shipyard controls checked by the surveyor at the critical locations


by monitoring & direct inspection

This procedure is unique to LR

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Construction Monitoring Procedures

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Construction Monitoring Procedures

Midship
Section Plan
showing location
of Critical Areas

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Construction Monitoring Procedures


Midship Section Critical Areas

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Surveyor confirming that the 100mm reference


mark (to indicate position of girder under)
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Close up of same location as previous slide

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Same reference
mark (100mm)
for hopper joints
alignment to
double bottom
girder

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Another typical
example of a
Critical joint at
the connection
of the tank top
with the
longitudinal
bulkhead
transverse web
brackets

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Typical transverse end bracket toe or side shell


frame lower bracket toe at the connection to the
double bottom tank top or lower hopper plating
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Deckhouse and Accommodation

Fire protection and detection as per approved plans


Crew Accommodation (as per Flag State)
Routing of cables and pipes
Structural compensation

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Typical complete
Deckhouse being
erected as single
unit.
Theses units are
often constructed
outside the
shipyard at a
specialist
contractor.

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Anchoring and Mooring Equipment

Verify supplied anchors and cables against approved equipment plan


Anchors and cables from approved works with LR Certificates
Certificates verified with the marking on the equipment
Check Rule requirements for Mooring lines

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Anchoring and Mooring Equipment

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Anchoring and Mooring Equipment

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Other Items

Keel Sights (Especially on slipways )


Principal Dimensions (L.B.D.) , Draft Marks (FWD and AFT for
Tonnage, Midships not required)

Non-LR certified materials (other IACS members) Should not


exceed 10% of lightship

Outfitting (pipe supports in tanks and on deck)


Bilge Keels and their attachments

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If all goes well with the Project then LR is the


winner and the Client comes back

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Building better business

Working together to improve


business performance

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