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Cochin Shipyard Training Report PDF
Cochin Shipyard Training Report PDF
LIMITED
Industrial Training Report
2012
NA10B047 Rinshad K
NA10B057 Sayanth V
a) IMS 9001:2008
It is a Quality Management System (QMS). This certification stands for quality
management in productivity and work output of CSL.
b) OHSAS 18001:2007
This is an environmental management system. This certification stands for
fulfillment of environmental policy by CSL.
c) ISO 14001:2004
This certification stands for personnel safety in all working conditions of
employees.
Division Department Section
Hull
BD
SBOC/S & C
Ship Building Outfit
Planning
SSD-Operations
IQC
Hull/ACR
MR
Ship Repair D&P
EE & I
SRP & M
SRC
Materials
U&M
Civil
Hull Structural Design
Services Hull Outfit Design
Design Accommodation Outfit
Design
Machinery Outfit Design
Electrical Outfit Design
Projects
HRD
Finance
Supporting ISD
S&F
Training/METI/FFTC
The basic procedure followed by the shipyard starting from obtaining the contract to
delivering the vessel is shown. The design department deals with the key plans, yard plans,
trial / testing and MLFs.
Design
One of the services provided by CSL is DESIGN. Prior to the construction of a
vessel, detailed drawings concerning the engineering as well as the architectural
aspects of it are to be created. This task is accomplished by the Design Department.
Stages of
Design
Preliminary Detailed
Basic Design
Design Design
1. Basic Design
It is the first step of designing a vessel. It depicts the basic hull form and is
created from lines plan. It concentrates on the stability of the vessel, its
hydrostatic and hydrodynamic particulars and mechanical properties like
section modulus, strength etc.
Any basic design has to undergo various tests to practically calculate its
efficiency and a design is deemed acceptable or not based on the results.
Wooden models are created as per the design and are tested for properties like
resistance in a towing tank. This process requires many facilities and trained
people which as of now are not available in CSL.
In CSL, basic design is available only for tugs of DWT 35-55 tons. So for other
vessels like PSVs, FPVs basic design is purchased from companies like Rolls-
Royce Marine and STX Europe. They have fixed designs (proven) for particular
vessels like PSVs which are modified as per owner’s requirements. Basic Design
package consists of key plans, one line diagram. This Design is a proven design
i.e. economically feasible and meeting owner’s requirements. For a purchased
design, parameters such as hull form, cargo capacity, speed etc. are fixed.
Basic Design is approved by any of the classification societies as specified by
owner.
They give an idea about the various systems, machines in the ship, various
sections and their dimensions.
Steel to be used for construction is to be of Ship Building Quality (SBQ).
e.g.
03KNMDKW3P
03 - Unit number
KN - Knuckling
MDK - Main deck
W - Plate
3 - Plate no.
P - Port side
The Nesting plan is a drawing showing how to fabricate the parts required out of
a steel plate. It is made in a manner to reduce wastage and increase production
rate.
The MLF is very important part of the yard plan. It has details of all the parts
which are to be used while building the unit. The officer in charge can use it as a
checklist of sorts to confirm that all the parts have been accounted for before
outfitting or fabricating. This helps in reducing time taken for production as it
can be ensured that work doesn't stop due to shortage/absence of material
required.
COMPUTERISATION
Before the development of computers, the designing was done manually on paper
using drafters. All the drawings were done in full scale. It was a tedious and time
consuming process.
But since the introduction of computers, the designing process has become much
easier. Many softwares have been introduced to produce 2-D drawings.
TRIBON is a family of programs that create and refer to a common set of databases
containing the design details of the ship. Together, these databases are used to
depict a 3D model of the ship, with embedded information for all of the parts of the
design, from ship structural elements to pipe segments to equipment. Many
common ship design elements, especially equipment, can be downloaded from
databases. The software brings about an increased degree of inter department
cooperation, as each department modifies the same model and we can observe any
collisions and route pipes and cables accordingly.
SECTIONS IN DESIGN DEPARTMENT
The design of a vessel is divided into five sections, with a team of people focusing on
one particular section. The advantages of doing so are in its convenience, greater
detail in designing and increasing the overall efficiency.
They develop the basic design to suit the requirements of the contractor i.e. the ship
dimensions, number of decks, number and types of cargo tanks etc. The main focus
if this section is on the stability and strength of the vessel.
All these various systems have piping which comes under outfitting. The seats of
machinery, ladders, anchor design, the mooring bollards, the chocks etc all come
under outfitting and they are designed under this section.
CSL follows the IHOP system for outfitting. Integrated Hull Outfit and Painting is a
system which reduces production time and increases ease of access while outfitting.
Each of the units is outfitted with pipes and other parts before the grand assembly
to the maximum extent possible. This is possible because of the accuracy of design
plans generated by TRIBON. All the parts of each unit are joined together by various
means after the grand assembly. But the major setback being faced currently while
following this system, is the availability of all the outfit parts required.
Accommodation outfit Design (AOD)
AOD
Structures: Accomodation:
Piping Ladders,Equipment Insulation,Panelling,Deck
Seats,Masts Covering,HVAC system
This section in design is responsible for all the outfitting in the accommodation
section of the ship like piping system, sanitary system, water supply, discharge,
drain system, fire fighting system, rescue boats, HVAC, the navigation and
communication systems etc.
Insulation
Insulation is another major aspect. The decks above the main deck are used for
accommodation purposes and as per regulations; they are required to be insulated
from sound, heat and fire.
Types of insulations:
Fire
Thermal and sounding
Fire Insulation
According to SOLAS rules by IMO “A” class Divisions and “B” class divisions are
defined as follows:
‘‘A’’ class divisions are those divisions formed by bulkheads and decks which
comply with the following criteria:
‘‘B’’ class divisions are those divisions formed by bulkheads, decks, ceilings or
linings which comply with the following criteria:
Cabins are prefabricated with optimum space use (Modular systems). Components
of cabin are as follows:
i. Wall Panel
ii. Ceiling Panel
iii. Marine Door
iv. Unit toilet
v. Interior Furnishing
Fire and Safety Equipment plan is to comply with the requirements as per SOLAS.
Power
- Generation
- Transmission
- Distribution
Lighting
Fire Alarm and Detection
Navigation, Radio Communication
Control and Monitoring
e.g.
C-BA 14
EOD has to play a coordinated role with the other design departments. The EOD
designs the location and position of the cable trays. The cable trays contain the all
the cables attached to it by a tightening band. The cable trays are designed to
minimize the usage of cables. There is a main cable tray which runs from the
forward to the aft of the ship. This has some trays which branch out and reach all
the necessary areas. The cabling schedule is done manually by the EOD team. The
scheduling decides how much length of wire has to be drawn from cylinder and for
which connection. This is done keeping in mind, the aim to have minimum wastage
of cable.
Propellers, bow thrusters also come under this section. Companies like BMW, MAC,
Rolls Royce and Caterpillar provide the engines, generators etc.
• Preparation
• Sub assembly
• Assembly
The preparation section is situated next to the steel stock yard. Since the
preparation section uses steel plates and frames as the raw materials, it works along
with the material department of the yard. The location of this section is in
accordance with availability of cranes and other such facilities for easy handling of
plates.
The plates and frames procured by the yard is stored in the steel yard which
is then taken into the preparation section for mangling, blasting, painting, marking,
cutting and forming as per the requirements of the design section.
Plate preparation
The steel plates from the stockyard are taken into the preparation section
using electromagnetic cranes. Maximum lifting capacity of cranes is 50 tons. A semi-
automatic roller conveyer system is used for moving the plates through the
machineries.
Mangling: The steel plates are first fed into the mangling machine for straightening
the plates. During the mangling process the internal stresses of the steel plates are
relieved. For mangling process altogether five rollers are used as shown in the
figure below.
Plates with thickness between 6-30 mm can be treated this way. For plates with
thickness greater than 30mm mangling is not necessary and for plates with
thickness less than 6mm additional stiffeners are welded along the length. The gap
between upper and lower rollers will be 1 or 2mm less than that the thickness of the
plate. The speed of the machine is 6000 mm/min.
Blasting: After mangling; the steel plates are fed into blasting machine to remove
the rust, dirt on the surface and also for roughening of the surface. While plates pass
through the blasting machine small pellets of iron (approximate diameter 2mm) are
shot from guns situated inside the upper and lower side of the blasting machine.
Capacity of plate blasting machine:
Thickness= 6mm to 50 mm
Painting: After blasting, the plate is fed into painting and drying machine, where
zinc primer coat of approximate 100 micron thickness is sprayed on to the plates by
the four spraying units inside the painting machine with a pressure of 2 kg/cm2 by a
pneumatic pump and compressor. The heat generated here dries the paint there
itself.
Drying: Most of the paint dries as soon as it is sprayed, and the plates are passed
through a dryer which completes the drying and absorbs the paint fumes from the
plates.
Cutting
The plates are then taken for the cutting and marking. Plasma cutting and gas
cutting are the two types of cuttings used in the shop. Plasma cutting is four times
faster than the gas cutting however the maximum thickness of plate that can be cut
by the plasma machine is much less compared to gas cutting.
Gas cutting: In gas cutting, high pressure oxygen is pumped at high temperature
which oxidizes the region to be cut. For maintaining the temperature acetylene and
CO 2 are used. Marking of the plate for cutting is done by burning zinc powder which
leaves a mark on the plate without an impression. The program (generated by
TRIBON) for cutting the plate, is then fed into the machine and the tip is accordingly
positioned over the plate. Once the cutting is done the parts are marked manually
and carried by cranes to the sub assembly section.
Plasma cutting: In plasma cutting, tungsten electrode is used as the filament. When
high electric potential is provided between electrode tip and nozzle tip, it ionizes
oxygen atoms around it which collides with each other to release heat. The high
temperature melts the steel and removes it along a thin region where the marking is
made and thus cutting it. Nitrogen gas is provided as a shield in plasma cutting.
Marking is done using zinc powder as in gas cutting. Program is then fed into the
machine and initial coordinates set to perform the cutting.
Shear cutting: Shear cutting is the simplest form of cutting. Its action is similar to a
scissors. The metal piece is properly positioned along the high carbon steel and
manually using legs the other half of the blade is lowered to cut the plate. The
method is faster and pollution free but needs more effort with limited cutting
possibilities.
Forming
In forming, roller bending and hydraulic bending are used.
In roller bending, plate is rolled over two rollers with a third one on top arranged
in accordance with the radius of curvature required. Plates are passed through the
rollers in such a way that the line drawn on the plate is parallel to it as shown in the
figure below.
Once the bending is done, the plate is checked using the wooden templates provided
by the mould loft section based on the design.
SECTION PREPARATION
Inverse Line Technique: In inverse line bending technique, first the section is
straightened with the help of beam bender. Then a line, known as the inverse line, is
drawn manually on the section according to the data given by the design section.
Then this frame is fed into the frame bending machine. Once the bending is done,
the inverse line is checked. When the bend is right the line becomes straight.
MOULD LOFT
It is here, the templates for the forming section are made. From design
section, film containing the shape of section of the plate is given in a 1: 10 scaled
ratio. This is then projected to actual size and the templates are made accordingly
using wood. In sheet bending and frame bending, these templates are used for
checking the accuracy of the bend. Minimum number of templates required to
define the shape of a plate arr provided by mould loft .For complicated 3d shapes
such as bulbous bow, complete template is made.
SUB ASSEMBLY
Gas welding: In gas welding LPG, oxygen and compressed air is used .LPG gas
welding can be used only for ferrous materials. For the shielding either CO 2 or argon
gas or mixture of both is used. A welding torch is used to weld metals. Welded metal
results when two pieces are heated to a temperature that produces a shared pool of
molten metal. The molten pool is generally supplied with additional metal called
filler.
Submerged arc welding is the strongest followed by CO 2 gas welding and manual.
General Welding Defects
• Lack of fusion
o Possible Causes
o Corrective Action
Weld vertical up
• Porosity
o Possible Causes
Contaminated material
o Corrective Action
o Possible Causes
o Corrective Action
• Undercut
o Possible Causes
o Corrective Action
Change/tighten technique
o Corrective Action
o Possible Causes
o Corrective Action
• Excessive penetration
o Possible Causes
o Corrective Action
Reduce welding power
• Lack of penetration
o Possible Causes
o Corrective Action
Increase power
• Linear misalignment
o Possible Causes
o Corrective Action
o Possible Causes
o Corrective Action
• Spatter
o Possible Causes
o Corrective Action
Change polarity
o Possible Causes
Welding tests:
Non destructive testing (NDT) of welds
These are test methods to examine an object, material or system without impairing
its future usefulness. Non-destructive testing is often required to verify the quality
of a product or a system. Commonly used techniques are
• ET - Electromagnetic Testing
• LT - Leak Testing
• RT - Radiographic Testing
• UT - Ultrasonic Testing
Acoustic Emission Testing takes advantage of the sharp sound that PCCP emits
when it breaks or slips to identify areas of active distress within a construction. AET
can be used to verify the structural integrity of pressure vessels, spheres, high
temperature reactors and piping, coke drums, above ground storage tanks,
cryogenic storage tanks and more. The inspection is executed externally and shut-
down of the process may often not be necessary.
ET - Electromagnetic Testing
LT - Leak Testing
Techniques used to detect and locate leaks in pressure containment parts, pressure
vessels, and structures. Leaks can be detected by using liquid and gas penetrant
techniques, electronic listening devices, pressure gauge measurements or soap-
bubble tests.
RT - Radiographic Testing
UT - Ultrasonic Testing
Ultrasonic testing uses high frequency sound energy to conduct examinations and
make measurements. Ultrasonic inspection can be used for flaw
detection/evaluation, dimensional measurements, material characterization, and
more.
Visual testing or inspection offers a wide range of options to secure proper system
or product quality.
Destructive weld testing, as the name suggests, involves the physical destruction of
the completed weld in order to evaluate its characteristics. This method of testing is
used frequently for a number of applications. Some of these applications include
welding procedure qualification and welder performance qualification testing,
sampling inspection of production welds, research inspection, and failure analysis
work. A number of destructive weld testing methods are used to determine weld
integrity or performance. Typically they involve sectioning and/or breaking the
welded component and evaluating various mechanical and/or physical
characteristics. We shall briefly examine some of the more common methods of this
type of welding inspection. We shall consider the macro etch test, the fillet weld
break test, the transverse tension test, and the guided bend test. We shall consider
how they are used, and what types of weld characteristics they are designed to
determine. We shall examine their advantages over other inspection methods and
their limitations.
Macro Etch Testing – This method of testing typically involves the removal of small
samples of the welded joint. These samples are polished across their cross-section
and then etched using some type of mild acid mixture, dependent on the base
material used. The acid etch provides a clear visual appearance of the internal
structure of the weld. Particular interest is often shown at the fusion line, this being
the transition between the weld and the base material. Such items as depth of
penetration, lack of fusion, inadequate root penetration, internal porosity, cracking
and inclusions can be detected during inspection of the etched sample. This type of
inspection is obviously a snapshot of the overall weld length quality when used for
sampling inspection of production welds. This type of testing is often used
extremely successfully to pinpoint welding problems such as crack initiation, when
used for failure analyses.
Fillet Weld Break Test – This type of testing involves breaking a sample fillet
weld that is welded on one side only. The sample has load applied to its unwelded
side, transverse to the weld and directed to its unwelded side (typically in a
press). The load is increased until the weld has failed. The failed sample is then
inspected to establish the presence and extent of any welding discontinuities. This
test will provide a good indication as to the extent of discontinuities within the
entire length of weld tested (normally 6 to 12 inches) rather that a cross-sectional
snapspot like the macro etch test. This type of weld inspection can detect such
items as lack of fusion, internal porosity and slag inclusions. This testing method is
often used in conjunction with the macro etch test. These two testing methods
complement each other by providing information on similar characteristics in
different detail and in different ways.
Guided Bend Test – This is a test method in which a specimen is bent to a specified
bend radius. Various types of bend tests are used to evaluate the ductility and
soundness of welded joints. Guided bend tests are usually taken transverse to the
weld axis and may be bent in plunger type test machines or in wrap-around bend
test jigs. Face bend tests are made with the weld face in tension, and root bend tests
are made with the weld root in tension. When bend testing thick plates, side bend
test specimens are usually cut from the welded joint and bent with the weld cross
section in tension. The guided bend test is most commonly used in welding
procedure and welder performance qualification tests. This type of testing is
particularly good at finding liner fusion defects, which will often open up in the plate
surface during the testing procedure
ASSEMBLY
In assembly shop; the materials are received from the sub assembly as well as
the preparation section. The units are combined through welding in the assembly
shop to form the blocks.
GRAND ASSEMBLY
In grand assembly; the blocks fabricated in the assembly shop are combined by
welding. They are first positioned using cranes. Weight of each block is less than 50
tons which is maximum lifting capacity of cranes.
PAINTING
The huge blocks are then painted according to the paint scheme, which
includes blasting, primer, coal tar, tie coat, anti-fouling etc.
HULL ERECTION
After painting the Grand assembly units are placed one by one in the dry dock
according to the dry dock plan provided by the design section. Grand assembly units
are thus welded to finish the hull of the ship.
After welding, various tests are performed to ensure quality of welding in presence
of owner and classification society surveyor.
At last, staging is removed and vessel is ready for launching and further outfitting.
Ship Outfitting
Ship outfitting involves fitting of pipes, machinery,carpentary and electrical equipments
etc. on to the ship hull as per the design. The entire structure is divided into smaller
units, blocks and bigger grand assemblies for organizing the outfitting work.
Each unit to be outfitted has an associated MLF (Material List of Fittings). An MLF is a
list indicating the item number, description like diameter, schedule, material, pallet,
availability and quantity etc. CAD drawings are passed n to the Pipe Shop and the Sheet
Metal Shop and they prepare the pipes, ducts, supports and other outfits accordingly.
The pipe shop receives the CAD drawings for manufacturing the different kinds of pipes
required for outfitting process. The pipe shop has the capability to bend, cut, weld and
paint pipes to get to the desired structure. Galvanisation of pipes is outsourced. There
are semi-automatic and fully automatic CNC bending and cutting machines. Welding
facilities include Tungsten Inert Gas welding, Metal Inert Gas welding, Metal Active Gas
welding, Manual Metal Arc welding, CO 2 welding and Submerged Welding. Submerged
welding is not used these days.
1) Cutting
2) Bending
3) Fabrication and,
4) Pickling
PIPE CUTTING
PIPE BENDING
FABRICATION
Usually 900 elbow bend or 450 elbow bend is commonly available. For other type
of elbows, we cut using elbow cutting machine.
Ost-Large thickness pipe, Pst-Low thickness pipe
Steps for obtaining a 300 elbow from a 900 long radius elbow is as follows:
• Mark the central lines on both inner & outer side.
• Measure the outer length of tube (L1).
• Now find (L1/90)*30. Mark that length on other side.
• Measure the inner length of tube (L2).
• Find (L2/90)*30.Mark that length on inner side.
• Put Right Square & mark & cut it using plasma cutting.
Tig welding & X-Ray welding is used to join two cut sections of pipe.
While welding a small gap should be given by providing a thin rod there so that
uniform gap will be there throughout the section & welding can be done
properly.
PALLETISATION
Other stuff manufactured there – hand grips, ladder + steps, grating for sea chest
and bow thrusters .
Smoothening of the sharp edges should be done so as to avoid the loss of paint
from that site and thus prevent corrosion – New Safety Requirement.
USE : Cargo supply (Fresh Water , methanol ,cement ,mud ,base oil, fuel oil to rig )
The detailed design is given by design department. Various outfitting is done according
to the different MLFs. The significant parts in the PSV in the outfitting point of view are-
• PSV has three major bulkheads dividing the ship into bow part, engine room and
deck hull part.
• Tugger winch - It is used to move heavy objects along the deck.
• Workshop - This consists of lathe machine, drilling machine provided with vices
for emergency purposes.
• Control room:- In this room, major controls like ballast level control,
pneumatically and hydraulically operated valves and other parameters like pitch
can be monitored and controlled.
• Engine room:- This is present in the forward region of the PSV. There are four
generators mainly for propulsion, machinery, HVAC, thrusters and a harbour
generator for usage in ports and in case of emergency. There are two starting air
compressors to compress air and feed it to the engines. There are instrument air
compressors for controlling pneumatically operated valves. Hydrofore system to
provide fresh water to hull region. In this 75% of the tank will be water and rest
will be compressed air to pump water to top. There are UV sterilizers and
Calorifiers to heat. Calorifier or hot water tank is used to supply hot water to
kitchen (galley), accommodation area and for bathing. All the leakage water/oil
will be collected at the bilge pit which will be then separated by Oily- Bilge Water
Separator and pumped out. For cooling purpose there are heat exchangers and
box coolers. In heat exchangers sea water and hot fresh water are passed
parallelly causing heat transfer. Box coolers are immersed in the sea water and
hot water is passed though them. Every engine has two box coolers. This avoids
the need for pumping sea water into the ship but it’s maintenance is possible
only while dry docking.
• It has an emergency generator , 2 tunnel thrusters of 700- 800 KW capacity, one
electric propulsion motor of 1600 KW. Each main generator has a capacity of
1200 KW & has 1800 rpm.Generator produces a voltage of 690 V .It has phase to
phase connection & there is no neutral connection.
• It has DP2 system for dynamic positioning. Bow thrusters are provided for this.
• There are three fuel oil tanks comprising of two service tanks and a settlement
tank. There is a fuel oil separator to test the purity of oil and similarly for
lubricating oil. A flow meter is used to measure the amount of oil used by engine.
• A sewage treatment plant:- the sludge is taken to incinerator which burns
(oxidation) the sludge and fumes are let out by exhaust pipes.
• There are turbo chargers attached to the engine which use energy from exhaust
gases.
• There are eight mud tanks and six cement tanks. To pump out the cement, hot
compressed air is used.
• Caging:- Exhaust pipes from incinerators and emergency generators pass
through caging from deck to top.
• Thrusters are used for dynamic positioning while unloading the cargo near the
platforms. These are used to arrest the motion in the transverse direction. In
emergency conditions swing up thrusters can be used to propel the ship.
• Two azimuthal propellers are present in the aft region.
• It has cargo rail from which cargo (fuel, chemicals,brine,mud, fresh
water,cement) is transferred to the rigs.
• There is Hydraulic Power Pack to control flow oil,lubricant flow in hydaulic
elements.
• Insulation is done by using mineral wool pads & over that Al foil is used as
covering. Types of insulation used are
- Comfort Insulation
BY86
Dimensions
• Length = 78.7m
• Breadth = 16m
• Depth = 6m
• D.W.T = 3060 Tonnes
• Name : S.C.I YAMUNA
• Owner : S.C.I
Specifications
Dimensions
Specifications
• Hull Repair
• Accommodation repair
• Machinery repair
• Electrical repair
• Underwater painting
DRY DOCKING
A dry dock is a narrow basin or vessel that can be flooded to allow a load to be
floated in, and then drained to allow that load to come to rest on a dry platform.
Dry docks are used for the construction, maintenance, and repair of ships, boats,
and other watercraft
DOCKING REQUIREMENTS :
Docking Plan.
Flooding.
Mooring crew.
Winches
Hauling carriage
Docking plan- it’s a plan issued by the designer, in which the positioning of the
blocks is explained. There is more than one docking plan for each ship. Once it is
docked according to one docking plan, next time will be docked with another plan.
So the places where the blocks were placed at last time will be repaired.
Block settings and markings- arranging of the blocks on the dock floor based
on docking plan. They should not be placed under hull plates where there are no
stiffeners. Likewise only docking plan will indicates the block arrangement. If a
block placed on a part where there is no stiffener that plate will be buckled and
damaged. So it is very important to arrange the blocks as per docking plan. Usually
blocks are made by concrete, iron and wood which can adjust their height according
to the shape of the ship. Reference lines will be marked on the dock to indicate the
exact position of the fore and aft of the ship while docking. Bow line is one of the
lines which helps for the positioning of the ship, which is the line at which bow of
the ship should be aligned such that the ship will seat exactly on the blocks.
Centering point is another marking where the bow of the ship is to be aligned.
Ropes : Head rope, Spring rope, Breast rope, Stern rope, Steel
DP-50:
Discharge -720m3/hr , power -37KW, Rpm -600,
DP-75:
o Putting Gangways
o Fresh water lines
o Fire lines
o Cooling lines
o Galley garbage removal
o Placing and clearing the pallets from repair vessels.
Storing/disposal of dirty oil
Hull repair
Hull repair is the most extensive of all the ship repair processes. The process includes the
following steps:
Survey& Identification
Ship will be taken under different types of surveys like:
• Annual survey- will be done in the interval of one year. It includes examination
of ship side shell plating above water line, ballast tanks, openings on free board,
water tight bulkhead penetrations etc.
• Special survey-
Examination of
Preparatory jobs
They include both before and after docking jobs. Before the ship arrives grade of
steel is identified, material positioning is done in Co-Ordination with SRM, blasting
and priming of steel plates & sections, welding procedure and pre-fabrication.
Once the ship arrives and is docked, lofting and scaffolding is to be done.
Blasting is the surface preparing process of spraying solids like copper slag,
iron grit, granules, etc. with high pressure, dry air which helps expose the surface and
gives it the surface required roughness for painting.
Safety precaution
Liasoning with Safety Dept for obtaining Man Entry & Hot-Work
Permits
Deployment of Firewatchmen
Cropping- cutting out the defective plate sections which have been identified. It
can be either mechanical or manual.
o by CSL QC
Visual inspection
o by Class
Visual inspection
NDT
After Welding, the Welding joint and inner defects are tested.
1. Magnetic particle test: In this iron solution is sprayed on the weld joints.
Electromagnetic machines magnetize the required part. Various contours are
observed if there is any defect. Test is to be done by instrument called yoke, for
magnetizing the material. Field indicator is tested before testing the portion as a
reference. We can use this for surfaces, subsurface, interior portions etc.
2. X-ray test: Photograph of weld joint (especially pipe junction) is taken with a
camera. The photograph is observed in X-ray machine in the dark room. The defects
are clearly visible.
3. Ultrasound test: Ultrasound (having frequency more than 2000Hz) is passed
through the plate. The echo is observed in receiver meter. The variation in echo
shows the depth at which defect is present. The location can be found even in three-
dimensional space.
4. Radiography test: In this gamma-rays are passed through material. The gamma-
rays are allowed to fall on silver-bromide plated. A photochemical reaction takes
place over this plate. If any defect is present, the reaction will be more; means the
product (Ag) formed is more than expected. So the location in the plate where it is
dark after the reaction corresponds to the defect location after development
ACCOMODATION REPAIR
Accommodation includes:
Wheel House
Cabins
Offices
Hospital
Mess & Galley
Game & Lobby
INSULATION
Insulation is important as it
Reduces Heat Transfer
Provides Fire Protection
Helps in Moisture Condensation
Helps in Noise Reduction
Insulation Materials:
Glass wool
Rock wool
Panelling
Some common paneling materials that are used are: stainless steel,
Aluminum sheet, Melamine faced pre-laminated board , Marine Plywood
with Sunmica, Melamine Plastic Laminated Board (MPL), Sandwich type
Board.
For paneling generally we have to fix channels first. Then fix the paneling
then gaps should be filled with beadings. Aluminium and wood are
commonly used beadings.
Flooring
There are four kinds of flooring involved: Macrotech, ceramic tiles, PVC tiles,
wooden tiles.
In Macrotech the work involved are: surface preparation,primer apply, underlay,
top coat, sealer coat.
Piping
I. Sea Water System- these are the pipes for deck washing and
toilet washing. for this cupronickel, copper or Aluminium –brass
alloys are used
II. Fresh Water System- these are used for Mess & Galley, Toilets,
Laundry etc. For this GI or copper pipes are used
III. Scupper Lines- used in deck and toilets. For this piping GI pipes
are used
IV. Soil Lines
Miscellaneous Works
Deck Sheathing
Cold Repair
Carpentry Works
Upholstery Works
Awnigs
MACHINERY REPAIR
Procedures for over hauling of main engine or auxiliary engines are given as
follows:
Decarbonising.
Remove Cylinder heads
Remove Pistons
Remove Liners
Cleaning
Calibration
Inspection and Survey
Remove Bearings
Clean and calibration
Present for Survey
Renewal if Required
Shaft and propeller repair is also included in this department, and this includes
Fixed pitch propeller (can be keyed or keyless propeller) and Controllable pitch
propeller, etc. For propeller maintenance propeller blades and hub should be
removed and refit by manual push up, by pilgrim nut or by hydraulic system after
maintenance and cavitation prevention. For controllable pitch propeller, blades and
hubshould be removed. Blade seals should be renewed. After filling oil, hub should
be refitted with blades.
Tail shaft repair is done along with propeller maintenance. For this, the tail shaft
and propeller is removed. Stern tube oil is drained and forward and aft seals are
removed. After that, Intermediate shaft and fitted bolts are removed. The internal
shaft is then lowered .Tail Shaft and Stern tube Bushes are cleaned and calibrated.
After presenting for survey, stern tube brushes and shaft seals are renewed as per
requirement.
ELECTRICAL REPAIR
Each ship contains different electrical based plans and diagrams such as block
diagram, system diagram, circuit diagram, wiring diagram and connection diagram.
Electrical repair includes various tests like tests for Insulation resistance (using
megger), current (clam meter), voltage, resistance, and continuity (multimeter).
There are different classes for the protection and insulation of materials. The
insulation class includes: class Y: 90, class A: 105, class E: 120, class B: 130. The
protection class is denoted by “IP XY”. The major equipment on-board a ship that
requires electrical repair include motors, lights, switchboards, wiring, etc. For
motors, its rotor resistance, drive and frequency are checked.
Different types of lamps used are Incandescent lamps, high or low pressure vapour
lamps (mercury or sodium), metal halide lamps, etc. They are used in
accommodation areas, machinery area or for navigational light purpose like mast
lights (fore mast or main mast), port and starboard side lights (red and green), stern
light (white), anchor lights (fore and aft) or Morse code flashing lights.
The electrical repair work is also dependent on the area of activity and the hazard
classification due to presence of gas- air mixture in certain parts.
Prior to the electrical repair, survey is taken. Some of the equipment a typical
electrical survey would require includes:
PAINTING
• Corrosion prevention
• Aesthetic
• Frictional resistance reduction –by keeping hull as smooth
In ship repair the blasting is done under painting department. Blasting is done to
make surface profile. Surface profile is done, so that the paint can easily stick to the
surface of the material. Before blasting, surface should be cleaned to remove
deposits. Iron shorts or copper slag are blasted with high pressure over the surface.
Quality of blasting is depends on standard abrasive (SA) like SA1, SA2 etc. the
following are the blast cleaning techniques which can be used
Centrifugal blasting
Sand injected water blasting
Slurry blast
Wet abrasive blast
Dry grit blast cleaning etc.
air supply hose, blast abrasive hose, copper slag tank, coupling part.
Pressurized air will be supplied from main compressor area at 6Kg/m3.copper slag
will be supplied from tank. Both will couple and ejected through blast abrasive hose
with high force.
1 coat of primer should be applied after blasting to avoid sudden corrosion. After
completing the repair, the painting procedure is as follows
Primer-50 microns
Anticorrosive -150 microns- 2 coats
Tie coat- 100 microns
Antifouling-150 microne-6 coats
After these coatings we will give sacrificial anodes (Zn)for preventing corrosion
of the plates.
Protective coatings
There are three types of protective coatings to prevent the corrosion by contact of
sea water
Sacrificial coating-they are rich in Zn content. They will be oxidized instead of plates
Barrier coatings-these coatings will keep the surface as moisture free
Inhibitive coatings-it is used only as primers
Coatings can be done by either by conventional spray or by airless spray in which hot
spray, electrostatic spray, centrifugal spray etc. methods are used as required.
Types of the paints in different parts of the ship will be different according to the
use and environmental conditions. for example paints which applies at ballast tank
will be different from paint at fuel oil tank.
There are mainly two types of defects which have to try to avoid as much as possible
to prevent fast corrosion they are
MACHINE SHOP
Machining Operations
TURNING
PLANING
DRILLING
MILLING
BORING
ENGRAVING
CUTTING
GRINDING
Machines Available
LATHES – 9 Nos
PLANO MILLER
HORIZONTAL DRILLING MACHINE
HORIZONTAL BORING MACHINE
DRILLING MACHINES
BAR BORING EQUIPMENT
CUTTING MACHINE
GRINDING MACHINE
PORTABLE FINE BORING MACHINES
BALANCING MACHINE