INTERNSHIP TRAINING REPORT

AT
COCHIN SHIPYARD LIMITED

Submitted For the Partial Fulfillment of Degree in B Tech Naval Architecture and
Offshore Engineering
From
VISTAS, Chennai

Submitted By
MILAN JOSE CYRIAC
(Reg. No. 15613117)

School of Ocean Engineering

Department of Naval Architecture & Offshore Engineering
VISTAS, Pallavaram, Chennai-600117
 CONTENTS

 TABLE OF CONTENTS

 INTRODUCTION

 ABOUT CSL

 SHIP BUILDING

 SHIP BUILDING TECHNOLOGY

 SHIP BUILDING FACILITY

 SHIP REPAIRS

 SHIP REPAIR FACILITY

 SHIP REPAIR EXPERTISE

 PRODUCTION PLANNING AND CONTROL

 VARIOUS MACHINES USED

 INS VIKRANT
 PREFACE
This is the industrial training visit report prepared during the shipyard visit
training undertaken at COCHIN SHIPYARD LTD, & INS VIKRANTH Cochin as part of
the degree in B tech Naval architecture and offshore engineering at Vels
university, Chennai campus.
The theory of an industrial visit is important. The knowledge of engineering is
incomplete without the practical knowledge and practical application. This
industrial visit provides us a golden opportunity to all the students, especially
engineering students who is not familiar with the functioning and the working of
project construction facility under our staff members and faculties. Hence this
report is designed with the objectives to gain practical know-how and is
undertaken at COCHIN SHIPYARD LTD & INS VIKRANTH Cochin.
 ACKNOWLEDGEMENT
Industrial training at COCHIN SHIPYARD LTD, & INS VIKRANTH had been a
great learning experience for me. The theoretical knowledge that I gained during
my three years of study at Vels university, Chennai had been complemented
effectively due to the guidance and support provided by our staff members and
faculties. But some factors while designing a ship cannot be fully covered
theoretically. The practical knowledge can only be guided by handling those cases
yourself or by witnessing the process under guidance.
The shipbuilding process at COCHIN SHIPYARD LTD is a unique one. CSL has
been serving to Indian and international clients with ease. The reason for the file
of one of the largest govt. ship building company in India is plainly visible
As well as the INS VIKRANTH is also a great experience for me. In that the ship
was very realistic and true. The visuals which we viewed in that was very useful
and convincing like how we were live in a navy vessel.
I would like to thank all the members in CSL & the INS VIKRANTH for allowing
me to complete my visit. And also I would like to thank 0our department staff
members and who arranged a visit for us.
 INTRODUCTION
A shipyard is a place where ships are built and repaired. These can be yachts,
military vessels, cruise liners or other cargo or passenger ships. Dockyards are
sometimes more associated with maintenance and basing activities than
shipyards, which are sometimes associated more with initial construction. The
terms are routinely used interchangeably, in part because the evolution of
dockyards and shipyards has often caused them to change or merge roles.
COCHIN SHIPYARD LIMITED
Cochin Shipyard Limited (CSL) is the largest shipbuilding and maintenance
facility in India.[2] It is part of a line of maritime-related facilities in the port-
city of Kochi, in the state of Kerala, India.[3]

Of the services provided by the shipyard are building platform supply vessels
and double-hulled oil tankers. Presently it is building the first range of
indigenous aircraft carriers for the Indian Navy, the Vikrant-class aircraft
carriers.

Cochin Shipyard was incorporated in 1972 as a Government of India company,

with the first phase of facilities coming online in 1982. The company
has Miniratna status.[4] The yard has facilities to build vessels up to 1.1 million
tons and repair vessels up to 1.25 million tons, the largest such facilities
in India. In August 2012, the Government of India announced plans
of divestment to raise capital of Rs. 15 billion (15,000 million Rupees) for
further expansion through an Initial Public Offering (IPO) towards the end of
the fiscal year.[5]However, this did not materialize until August 2017, when the
company conducted its IPO and listed its shares on the BSE and NSE.[4]

The government finalized the decision of stake sale on 18 November 2015.

33.9 million (33.9 million) shares of face value Rs. 10 Each will be sold, out of
which the government is holding 113,000 shares while the others are fresh
equity.

The shipyard also trains graduate engineers in marine engineering.[6] Around

one hundred students are trained each year.
 SHIP BUILDING

The first ship to roll out of the Cochin Shipyard was the MV Rani Padmini in
1981.[7]
The yard has delivered two of India's largest double-
hull Aframax tankers each of 95,000 DWT.
CSL has secured shipbuilding orders from internationally renowned
companies from Europe and the Middle East. The shipyard is building six
30,000 DWT bulk carriers for Clipper Group of the Bahamas and the first
three vessels have been launched.[8]
Eight platform supply vessels for the Norwegian Sea tankers Management
Company, are also under construction.[citation needed]
Cochin Shipyard is currently building India's first indigenous aircraft carrier.
The Vikrant-class aircraft carriers (formerly, the Project 71 "Air Defense Ship"
(ADS)) are the first aircraft carriers of the Indian Navy to be designed and
built in India. The carriers will be the largest warships built by CSL. As of
March 2016, it has nearly completed the construction of the first Vikrant-class
carrier, the INS Vikrant.

SHIP BUILDING TECHNOLOGY

Advance Out-fitting and Painting

CSL has introduced the latest Japanese Integrated Material Management

concept in which at the basic design stage itself not only all high value and
long lead items that go into the ships are identified, but also the method of
outfitting viz. Unit/On block/On board is also finalized. Portable painting
sheds are used for efficient and fast painting of the hull blocks.

Tie ups

The tie-up with the renowned shipbuilder M/s Ishikawajima Harima Heavy
Industries (IHI), Japan and with Shipping Research Services (SRS), Norway for
building Crude Oil Tankers have provided exposure to the latest ship building
technology adopted in Japan and Europe and hence the confidence to take up
more challenging jobs.

Trigon based in house capabilities

CSL uses the 'state of the art' TRIBON shipbuilding package for undertaking
basic design, structural, machinery and electrical design. With over 80
workstations, and fully trained personnel, CSL has world class capabilities to
undertake ship designs. 3D hull, piping and electrical models are created
leading to error free and optimum ship designs. Information for various NC
equipment are also generated on these systems.

Quality Control and Testing Laboratory

From the very inception of the yard itself, strict quality control techniques had
been adopted. As a result, quality of the ships constructed at CSL have been
very good and lauded by ship owners and classification societies. CSL has in
its premises a well-equipped laboratory capable of undertaking all NDT tests.
The laboratory is approved by various classification societies.

Marine Coating Shop

Four Nos. Blast / Paint Shops of size 20 x 20 x 11 m are equipped for blasting
and painting of fabricated units in controlled and favorable ambient
conditions. Blasting using graded copper slag and Painting using modern air-
less spray painting machines are carried out to provide the most effective
coatings on steel structures. The entire methodology, process and finished
surface are checked and vetted by well qualified and experienced personnel
from CSL and the paint manufacturer.
SHIP BUILDING FACILITY
Dock No 2

The Dock No.2 of 255 x 43 x 9 M is available for building ships up to 1,10,000

DWT. This dock and the grand assembly area are served by two Gantry crane
(300 T and 150 T) and two LLTT cranes (50 T).

Steel Stock Yard

The steel stockyard has an area of 13,000 Sq.M. aided with two gantry cranes
of 25T each and one semi-gantry crane of 25 T. It is directly linked to the rail
lines as well as to the waterfront, in addition to road connections. This enables
steel to be brought in through wagons, barges or trucks.
 Hull Shop

The Hull Shop is self-contained with infrastructure required for fabrication of

hull blocks up to 50 T. The shop is provided with EOT cranes (50 T) for along
the bay movements and gantry crane (20 T) and trailers for across the bay
transfer of materials.

Other Major equipment’s/facilities

 C.N.C. Cutting Machine

 Plasma Cutting Machine
 Shot Blasting Machine<
 Automatic Painting Machine
 1200 T Hydraulic Press
 Line Heating Techniques for curved shell formation
 F.C.B. One side welding for large panels
 Semi-automatic CO2, Gravity welding machines
 Semi-automatic CO2, Gravity welding machines
 Electro Slag welding
  150mm Pipe Bending Machine
 Pipe Coaster (1.2 m dia capacity)
 150 tons transporter

Assembly Shop

This shop has telescopic sliding roof with gantry cranes of 300 T and 150 T
which spans over it and building dock. Hull blocks up to 450 T can be
jumboized here and erected in the building dock using the gantry crane. In
addition, two 20 T capacity EOT cranes are there in the shop.

Pipe and Sheet Metal Shop

The pipe shop is provided with all the necessary equipment for bending,
cutting, welding and pickling of pipes. The sheet metal shop handles all the
light steel fabrications, trunking etc.

Quays

CSL has totally three Quays having almost a length of 1 KM.

SHIP REPAIR
The shipyard started offering ship repair services in 1982 and has undertaken
upgrades and repairs for all types of ships including ships for the oil
exploration industry as well as scheduled maintenance and life extension for
ships of the Indian Navy, Indian Coast Guard, the Union
territory of Lakshadweep, Fisheries and Cochin Port Trust, SCI and the Oil and
Natural Gas Corporation (ONGC). It has performed major overhauls for
the aircraft carrier, INS Viraat.
Recently CSL was awarded major maintenance and upgrade orders
from ONGC. This included major overhaul of three rigs, Mobile Offshore
Drilling Unit (MODU) Sagar Vijay, Mobile Offshore Drilling Unit Sagar
Bhushan and Jackup rig Sagar Kiran.

Some major repair projects

 Major up gradation of Mobile Offshore Drilling Unit ‘Sagar Vijay’ of
ONGC. The up gradation increased the drilling capacity of the vessel
from 300 M to 900 M

 Maintenance and repairs to the Aircraft Carrier "INS Viraat" of Indian

Navy

 Repair and maintenance of tankers and bulk carriers of Shipping

Corporation of India.

SHIP REPAIR FACILITY

Dock No. 1

The repair dock of 270 x 45 x 12 M can accommodate ships up to 1,25,000

DWT. The dock has high capacity discharge pumps to drain it in less than
three hours. It is served by three LLTT cranes, one of 40 T and two 10T
capacity.

Quays
There are three quays of 280 M length with 15 T carnage, 208 M length with
10 T & 5 T carnage and 460 M length with 20 T carnage. The quays have
adequate service lines of oxygen, acetylene, compressed air and power
connections.

Engine and Machine Shop

This shop is equipped with modern machine tools like Plano miller (up to 30
T) Bar Boring equipment (up to 300 mm dia), Inside Grinding machine (up to
300 mm dia), Heavy Duty Lathes (up to 12M length), Horizontal Drilling
machine ( up to 100 mm boring & 600 mm drilling), Shrinkage equipment (up
to 6 M x 900 mm O.D), Cylindrical Grinding machine (630 mm dia x 2 T),
Horizontal Boring machine (up to 560 mm dia), Dynamic Balancing machine
(up to 3 T) etc.

Other Facilities

 Hauling Carriage for safe docking and un-docking of ships.

 High Pressure Water Jet for hull cleaning.
 Blasting and Painting of conventional, epoxy and SPC systems.
 Hauling Carriage for safe docking and un-docking of ships.
 Facility for Boiler re-tubing.
 Facility for Tank Coating.
 Electric shop for overhauling of motors and testing.
 Pipeline supply of compressed air, oxygen and acetylene.

SHIP REPAIR EXPERTISE

Afloat Repairs
The yard has a team of experienced Engineers and skilled workmen
exclusively for undertaking afloat repair jobs.

Afloat Repairs Availability of Sub-Contractors

A captive pool of competent sub-contractors are readily available and can be

engaged for various jobs at very short notice.

Workmanship

The quality of workmanship is of very high order and the owners on many
occasions have gone on record, appreciating the quality work done in CSL.
Many vessels have been repaired and handed over, ahead of schedule.

Experience

CSL has successfully undertaken repairs to more than a thousand ships

belonging to a wide variety of clients including Shipping Corporation of India,
Indian Navy, ONGC, Dredging Corporation of India, Union Territory of
Lakshadweep Administration, Fisheries Survey of India, Ethiopian Shipping
Lines, Transocean Offshore Deep water Drilling Inc. and vessels belonging to
various ports of India.

PRODUCTION PLANNING AND CONTROL

Ship construction is a complex and lengthy process that demands careful planning
and timely decision-making. Plan, optimize and validate ship construction
processes before building. Use a broad range of tools to streamline your process
planning workflows, automate non-value-added planning tasks and validate the
best shipbuilding plan. These tools facilitate process design and sequencing,
production BOM and BOP management, time management, 3D shipyard layout and
ergonomic analysis. Control ship and production lifecycles from process planning
and detailed engineering to full production by connecting the entire value chain to
realize the best production strategy.

Demands on shipbuilders continue to increase ship and process complexity

with increased regulations, the need for global construction and sourcing to
meet local demands and competitive pressures that result in reduced margins.
Today’s shipbuilders need to ensure rapid delivery of highly reliable, high
quality and safe ships. To accomplish this, they must move construction
process planning and simulation upstream. If not, increasing complexity
results in most issues and changes being caught in the final steps of ship
development and delivery, when they are the most costly to fix. Shipbuilders
must improve collaboration between engineering and production to control
all aspects of the ship development process so that shipyards can build their
ships right the first time – reducing rework during sea trials and final
acceptance testing.
Shipbuilders must employ advanced, process-driven techniques to build ships
that meet or exceed customer expectations and ensure that constraints are
considered during the early stages of ship development. Our solutions allow
shipbuilders to digitalize the shipbuilding process and shipyards to maximize
productivity, increase profitability and realize the best ships.
VARIOUS MACHINES USED IN COCHIN SHIPYARD
 Plate Bending Roll
 Plano Miller
 Horizontal Boring Machine
 Horizontal Drilling Machine
 Lathes
 Dynamic Balancing Machines
 Drilling Machines
 Grinding Machines
 Shaping Machine
 Slotting Machine
 Vertical Milling Machine

Indigenous Aircraft Carrier

The company is constructing the most prestigious and largest warship for the
Indian Navy viz the Indigenous Aircraft Carrier (IAC). The IAC is being
designed by the Indian Navy, with the detailed engineering, material
procurement and ship construction being carried out by Cochin Shipyard. The
contract for the ship was signed in May 2007 and the Phase-I, comprising of
15000 Tonnes of hull construction and over 2500 tonnes of outfitting was
completed on 12 August 2013. The ship was launched on 12 August 2013 by
Smt Elizabeth Antony wife of Shri A K Antony, the then Hon’ble Raksha
Mantri.

INS VIKRANT

INS Vikrant (víkrānta "courageous"[8]) (IAC-I) is the first aircraft carrier built
in India and the first Vikrant-class aircraft carrier built by Cochin Shipyard
(CSL) in Kochi, Kerala for the Indian Navy. The motto of the ship is Jayema
Sam Yudhi Sprdhah, which is taken from Rigveda 1.8.3 and can be translated
as "I defeat those who fight against me".
Work on the ship's design began in 1999, and the keel was laid in February
2009. The carrier was floated out of its dry dock on 29 December 2011[9] and
was launched in 2013. As of 2018, the ship is expected to be completed by
December 2018, after which it will be handed over to the Navy and undergo
two years of sea trials before its expected commissioning in October
2020.[1] The project cost has escalated dramatically to ₹19,341
crore (US$2.7 billion) as of 2014.[10]

Design

INS Vikrant is the first ship of the Vikrant class of aircraft carriers. The
name Vikrant (Sanskrit vikrānta, literally "stepping beyond") means
"courageous" or "bold". It is 262 metres (860 ft) long and 60 metres (200 ft)
wide, and displaces about 40,000 metric tons (39,000 long tons). It features
a Short Take-Off But Arrested Recovery (STOBAR)[11] configuration with a ski-
jump. The deck is designed to enable aircraft such as the MiG-29K to operate
from the carrier. It is expected to carry an air group of up to thirty aircraft,
which will include up to 24–26 fixed-wing combat aircraft,[12] primarily
the Mikoyan MiG-29K . The naval variant of the HAL Tejas was rejected by the
navy on Dec 2, 2016 for being overweight.[13] Besides carrying 10 Kamov Ka-
31 or Westland Sea King helicopters. The Ka-31 will fulfill the airborne early
warning (AEW) role and the Sea King will provide anti-submarine
warfare (ASW) capability.

Vikrant is powered by four General Electric LM2500+ gas turbines on two

shafts, generating over 80 megawatts (110,000 hp) of power. The gearboxes
for the carriers were designed and supplied by Elecon Engineering.[9][16][17]

Construction
Vikrant is the first aircraft carrier to be designed by the Directorate of Naval
Design of the Indian Navy and the first warship to be built by Cochin Shipyard.
Its construction involved participation of a large number of private and public
firms. The keel for Vikrantwas laid by Defence Minister A.K. Antony at the
Cochin Shipyard on 28 February 2009.[18][19]
The AB/A grade steel which was supposed to be supplied from Russia faced
problems in delivery. To resolve this, the Defence Metallurgical Research
Laboratory (DMRL) and Steel Authority of India Limited (SAIL) created
facilities to manufacture the steel in India.[9][14] Reportedly, three types of
special steel for the hull, flight deck and floor compartments were
manufactured at the Bhilai Steel Plant, Chhattisgarh and Rourkela Steel
Plant, Odisha. Due to this, this is the first ship of the Indian navy to be built
completely using domestically-produced steel.[20] The main switch board,
steering gear and water tight hatches have been manufactured by Larsen &
Toubro in Mumbai and Talegaon; high-capacity air conditioning and
refrigeration systems have been manufactured in Kirloskar Group’s plants
in Pune; most pumps have been supplied by Best and Crompton; Bharat
Heavy Electricals (BHEL) supplied the Integrated Platform Management
System (IPMS), which is being installed by Avio, an Italiancompany; the gear
box was supplied by Elecon Engineering; and the electrical cables are being
supplied by Nicco Industries.[21]. Fincantieri provided consultancy for the
propulsion package while Russia's Nevskoye Design Bureau designed the
aviation complex [22]
The ship uses modular construction, with 874 blocks joined together for the
hull. By the time the keel was laid, 423 blocks weighing over 8,000 tons had
been completed.[23] The construction plan called for the carrier to be launched
in 2010, when it would displace some 20,000 tonnes, as a larger displacement
could not be accommodated in the building bay. It was planned that after
about a year's development in the refit dock, the carrier would be launched
when all the major components, including underwater systems, would be in
place. Outfitting would then be carried out after launch. As per the Cabinet
Committee on Security (CCS), sea trials were initially planned to commence in
2013, with the ship to be commissioned in 2014.[24][25]
In March 2012, it was reported that the project had been affected by the delay
in the delivery of the main gearboxes for the carrier. The supplier, Elecon,
attributed it to having to work around a number of technical complexities due
to the length of the propulsion shafts.[26] Other issues resulting in delays
included an accident with a diesel generator and an issue with its
alignment.[27] In August 2011, the Defence Ministry reported to the Lok
Sabha that 75% of the construction work for the hull of the lead carrier had
been completed and the carrier would be first launched in December 2011,
following which further works would be completed until
commissioning. [28][29] On 29 December 2011, the completed hull of the carrier
was first floated out of its dry dock at CSL, with its displacement at over
14,000 tonnes.[16] Interior works and fittings on the hull would be carried out
until the second half of 2012, when it would again be dry-docked for
integration with its propulsion and power generation systems.[2][9]
In July 2012, The Times of India reported that construction of Vikrant has been
delayed by three years, and the ship would be ready for commissioning by
2018.[30] Later, in November 2012, Indian English-language news
channel NDTV reported that cost of the aircraft carrier had increased and the
delivery has been delayed by at least five years and is expected to be with the
Indian Navy only after 2018 as against the scheduled date of delivery of
2014.[31] Work then commenced for the next stage of construction, which
included the installation of the integrated propulsion system, the
superstructure, the upper decks, the cabling, sensors and weapons.[32]
Launch
In July 2013, the Defence Minister A. K. Antony announced that Vikrant would
be launched on 12 August at the Cochin Shipyard. The ship was launched by
his wife, Elizabeth Antony, on 12 August 2013.[33] Extensive sea trials are
expected to begin in mid of 2017 and the ship will be inducted into the navy
by late 2018.[30]
According to Admiral Robin Dhowan, about 83% of the fabrication work and
75% of the construction work had been completed at the time of launching.
He said that 90% of the body work of the aircraft carrier had been designed
and made in India, about 50% of the propulsion system, and about 30% of its
weaponry. He also said that the ship would be equipped with a long range
missile system with multi-function radar and a close-in weapon
system (CIWS).[34] After the launch, Vikrant was re-docked for the second
phase of construction, in which the ship will be fitted with various weapons
and sensors, and the propulsion system, flight deck and the aircraft complex
will be integrated.[21] In December 2014 it was reported that Vikrant will be
commissioned by 2018.
Undocking and fitting-out phase
Vikrant was undocked on 10 June 2015 after the completion of structural
work. Cabling, piping, heat and ventilation works will be completed by 2017;
sea trials will begin thereafter.[35] By October 2015, the construction of the
hull was close to 98 percent complete, with flight deck construction
underway.[36] The installation of machinery, piping and the propeller shafts
was in progress by January 2016; it was reported, however, that there were
delays in the delivery of equipment from Russia for the carrier's aviation
complex.[37] By May 2017, the procurement delays had been resolved and the
carrier's fitting-out was 62% complete, with trials of the auxiliary systems
scheduled by late 2017.[3]
According to the Chief of Naval Staff, the ship is expected to be commissioned
by the end of 2020.[38] In January 2018, the Navy announced the remaining
procurement delays stalling Vikrant 's construction had been resolved, and
that the carrier would be completed and delivered by December 2018; it
would then undergo two years of sea trials before its expected commissioning
in October 2020.[1]
CONCLUSION

I can honestly say that my time spent interning with COCHIN SHIPYARD
LIMITED resulted in one of the best summers of my life. Not only did I gain
practical skills but I also had the opportunity to meet many fantastic people.
The atmosphere at the shipyard campus was always welcoming which made
me feel right at home. Additionally, I felt like I was able to contribute to the
shipyard by assisting and working on projects throughout the summer. For
example, I assisted one of the partners with several PowerPoint presentations
for clients of the shipyard.

Overall, my internship at CSL has been a success. I was able to gain practical
skills, work in a fantastic environment, and make connections that will last a
lifetime. I could not be more thankful.