Professional Documents
Culture Documents
Copy to:
1. DGM (HRD)
2. GM (Q. C)
3. D.Sp (S. B Hall)
4. College (Chairman IND Department)
1
cknowledgment
By the Grace of Almighty Allah, We have been able to complete our INTERNSHIP at
Karachi Shipyard and Engineering Works. All this become possible only due to the
support of the following employees. They help us in understanding the different work
being carried out in KS & EW, to enhance our technical skills. We really believe that our
internship at KS & EW would never be possible without the support of all these people.
We also appreciate the cordial co-operation from all our concern Managers in all
departments; Especially:
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S. No. # Department # Page No. #
1. Introduction to KS&EW 4 to 6
2. Quality Control
Quality Assurance
4. Conclusion 26
3
4
Introduction to K S & E W:
The Karachi Shipyard & Engineering Works Limited (KSEW), is Situated at West
Wharf in Karachi, Sindh Pakistan. KSEW was established in early 1950's as a project of
PIDC. It was incorporated as a public limited company in 1957. The shipyard spread over
an area of 29 hectares (71 acres).
Karachi Shipyard is the oldest Heavy Engineering Works of Pakistan which is catering
for its Ship Building, Ship Repairing, Submarine/Warship Construction and
Heavy/General Engineering requirements. KSEW has a large Ship Building Hall, three
Ship Building Berths, two Dry Docks, three Foundries (Iron, Steel & Non-Ferrous),
Fabrication Shops, one machine shop and other supporting facilities like Carpentry, Pipe
Fitting and Light Steel Fabrication Shop. KSEW is working as an autonomous
commercial organization under the Ministry of Defense, Government of Pakistan.
Karachi Shipyard is the only shipbuilding company in Pakistan. It has built numerous
cargo ships, tugboats and support vessels, naval vesselsand submarines.
It has played a historical role in transferring of technologies and broadening the industrial
base of the country. KSEW is the only shipyard in Pakistan and has two dry docks of
18,000 TDW (Tons Dead Weight) and 26,000 TDW capacities respectively. It has the
capability for building large vessels including Cargo Ships, Oil Carriers, Bulk Carriers
and Warships, and Marine Craft including Tugs, Barges, Ferries, Fishing Trawlers,
Dredgers and Special Crafts. Furthermore, KSEW has the facilities to produce a wide
range of heavy engineering products including Heavy Steel Structures, Pressure Vessels,
LPG Storage Tanks, Industrial Boilers, Overhead and Portal Cranes, complete Sugar and
Cement Plants, etc.
Since 1957 when it commenced its commercial production, it has built over 430 vessels
of different types and sizes for different nations. KSEW possesses an elaborate Ship
Repair setup where it has so far repaired over 5000 Vessels, both of national as well as
foreign origin. Many renowned Navies of the world including Pakistan Navy and various
Shipping lines and Port authorities are KSEW's regular customers.
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KSEW has experience in handling a wide variety of steel construction work. Power house
building / Boiler structure, pedestrian overhead bridge, steel frame buildings, platforms,
gantries for cranes, bridges, girders, towers for power transmission, broadcasting and
telecommunication etc. are some of the examples. Similarly hydraulic steel work such as
sluice, radial, flap, regulator gates, tunnel shafts, penstocks etc. for dams, barrage and
headwork is also carried out.
KSEW offers complete sugar plants on turnkey basis. So far KSEW has manufactured
various plants in the range of capacities from 2000 to 500 TCD which are based on
FIVES-CAIL BABCOCK (FCB) FRANCE design. These plants are fully automatic and
have the latest technology. KSEW is a major source of supply of steel structures,
conveyors, hoppers; bucket elevators, piping, and manganese steel lining plate and cast
steel components for kiln, ball mills etc. for the cement factories.
KSEW can rightly be called “the first major steel industry of Pakistan ". Although it is
designed for series production of ocean going vessels, its role in the support of industry
and developmental engineering is very well known and prominent. It has a long record of
service to industry and during slump in the shipping industry, has promoted further
diversification of its General Engineering activities. It has one of the largest and well-
equipped engineering workshops of the country, the foundry (15 metric ton a piece) Steel
Foundry (3 metric ton a piece) and Non-Ferrous Foundry (750 Kg. a piece) are working
in conformity to ASTM, BSS and DIN norms.
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7
Quality Control:
Quality control is a process by which entities review the quality of all factors involved
in production. This approach places an emphasis on three aspects:
Elements such as controls, job management, defined and well managed processes,
performance and integrity criteria, and identification of records.
Competence, such as knowledge, skills, experience, and qualifications
Soft elements, such as personnel integrity, confidence, organizational
culture, motivation, team spirit, and quality relationships.
The quality of the outputs is at risk if any of these three aspects is deficient in any way.
Quality control emphasizes testing of products to uncover defects, and reporting to
management who make the decision to allow or deny the release, whereas quality
assurance attempts to improve and stabilize production, and associated processes, to
avoid, or at least minimize, issues that led to the defects in the first place. For contract
work, particularly work awarded by government agencies, quality control issues are
among the top reasons for not renewing a contract.
The Quality control department of KS&EW ensures the quality of work done, weather it
is ship building, ship repairing, or other engineering project.
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Quality control department of KS&EW has to maintain the quality of work at the
following sections:
Shipbuilding Quality Control (SQC)
Ship Repair Quality Control (SRQC)
Engineering Quality Control (EQC)
In the 20th century, shipbuilding (which encompasses the shipyards, the marine
equipment manufacturers, and many related service and knowledge providers) grew as an
important and strategic industry in a number of countries around the world. This
importance stems from:
The large number of skilled workers required directly by the shipyard, along with
supporting industries such as steel mills and engine manufacturers;
And
A nation's need to manufacture and repair its own navy and vessels that support
its primary industries.
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Modern shipbuilding manufacturing techniques:
Modern shipbuilding makes considerable use of prefabricated. Entire multi-deck
segments of the hull or superstructure will be built elsewhere in the yard, transported to
the building dock or slipway, and then lifted into place. This is known as "block
construction". The most modern shipyards pre-install equipment, pipes, electrical cables,
and any other components within the blocks, to minimize the effort needed to assemble
or install components deep within the hull once it is welded together. This was first
introduced by Alstom Chantiers de l'Atlantique when they built the largest Ocean Liner
in the world Cunard's RMS Queen Mary 2.
Ship design work, also called naval architecture, may be conducted using a ship model
basin. Modern ships, since roughly 1940, have been produced almost exclusively
of welded steel. Early welded steel ships used steels with inadequate fracture toughness,
which resulted in some ships suffering catastrophic brittle fracture structural cracks
(see problems of the Liberty ship). Since roughly 1950, specialized steels such as ABS
Steels with good properties for ship construction have been used. Although it is
commonly accepted that modern steel has eliminated brittle fracture in ships, some
controversy still exists.[15] Brittle fracture of modern vessels continues to occur from time
to time as the use of grade A and grade B steel of unknown toughness or fracture
appearance transition temperature (FATT) in way of ships' side shells can be less than
adequate for all ambient conditions.
Shipbuilding department of KS&EW work continuously to develop and build new ships
keeping in view of the requirements of the country and the private firms, giving
independent orders. Currently KS&EW are developing or working on a new Ship (F22
Frigate) for Pakistan Navy, with the cooperation of China.
The main aim of Shipbuilding Quality Control (SQC) is to check and control the different
processes or procedures carry out in the manufacturing of a ship, As shipbuilding demand
an accurate, precise and accident free work, so that to minimize the wastages of
materials, instruments and tools. QC put efforts to make possible efficient working by
proper inspection of equipments, tools, and various tests for materials, so that to use high
quality of materials during manufacturing.
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Some important terminologies regarding F22 Frigate ship are:
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Ship Repair Quality Control (SRQC):
All ships need maintenance and repairs. A part of these jobs must be carried out under the
supervision of the Classification Society. A lot of maintenance it is carried out while at
sea or in port by ship's staff. However a large number of repair and maintenance works
can only be carried out while the ship is out of commercial operation, in a Shiprepair
Yard. Prior to undergoing repairs, tankers must dock at a Deballasting Station for if
necessary completing the tank cleaning operations and pumping ashore its slops (dirty
cleaning water and hydrocarbon residues) ashore.
Modern and well-planned facilities exist in KSEW for undertaking above water & under
water repairs of Ships and off shore Drilling Rigs. The ancillary facilities include Shore
electric supply, Compressed air, Oxygen, Acetylene gas and Natural gas in pipelines and
cylinders as well as Fresh and Sea water supply lines and Fire fighting system. The well-
equipped Machine Shop is in attendance besides other readily available facilities for
supporting Ship repairs of all kind.
For above-water repairs of Vessels, Quay Walls of 500 meter on the northern side and
165 meter on the southern side are available. Above water repairs for Vessels of any size
and dead weight can be undertaken not only at KSEW premises but also in Karachi
Harbour and even at outer anchorage. Similarly any alteration/conversion on hull/ super
structure can be undertaken. For marine boilers, insulation, lagging, flooring, brickwork
can be carried out at the yard. Facilities also exist for repairs of Steam and Motor Vessels,
both Main and Auxiliary machinery and all types of marine and stationary Boilers. Ships
having draught of about 20 feet can be accommodated in graving docks, while vessels
with draught of up-to 15 feet can be berthed at the quay walls.
In the repair or replacement of parts or materials in a ship, QC tries to use high quality
materials, therefore reducing risk to a high percent.
In all the above production departments of KS&EW, Quality is checked with the
help of the following two main methods:
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1. Destructive Testing (DT):
In Destructive Testing, tests are carried out to the specimen's failure, in order to
understand a specimen's structural performance or material behavior under different
loads. These tests are generally much easier to carry out, yield more information, and are
easier to interpret than nondestructive testing.
Destructive testing is most suitable, and economic, for objects which will be mass
produced, as the cost of destroying a small number of specimens is negligible. It is
usually not economical to do destructive testing where only one or very few items are to
be produced (for example, in the case of a building).
Some types of destructive testing:
Stress tests
Crash tests
Hardness tests
Metallographic tests
1. Visual Inspection:
Often overlooked in any listing of NDT methods, Visual Testing inspection is one of the
most common and most powerful means of non destructive testing. It is done by
observing the test material by naked eye or under a magnifying glass. Other NDT
methods such as MPT and DPT are indeed simply scientific ways of enhancing the
indication to make it more visible to naked eye.
Visual Inspection cannot deduct defects under the surface that’s way other methods/tests
are performed to ensure the quality of test piece or material.
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2. Magnetic-particle Test (MPT):
Magnetic particle inspection (MPI) is a non-destructive testing (NDT) process for
detecting surface and subsurface discontinuities in ferroelectric materials such as iron,
nickel, cobalt, and some of their alloys. This method is capable of detecting open source
or just below the surface flaws.
The process puts a magnetic field into the part. The piece can be magnetized by direct or
indirect magnetization. Direct magnetization occurs when the electric current is passed
through the test object and a magnetic field is formed in the material. Indirect
magnetization occurs when no electric current is passed through the test object, but a
magnetic field is applied from an outside source. The magnetic lines of force are
perpendicular to the direction of the electric current which may be either alternating
current (AC) or some form of direct current (DC).
The presence of a surface or subsurface discontinuity in the material allows the magnetic
flux to leak. Ferrous iron particles are applied to the part. The particles may be dry or in a
wet suspension. If an area of flux leakage is present the particles will be attracted to this
area. The particles will build up at the area of leakage and form what is known as an
indication. The indication can then be evaluated to determine what it is, what may have
caused it, and what action should be taken if any.
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dry out. This material brings out penetrant red particle from with-in cracks and the white
contrast makes it easy to observe.
Advantages:
1. The main advantages of DPI are the speed of the test and the low cost.
Disadvantages:
1. The main disadvantages are that it only detects surface flaws and it does not work
on very rough surfaces. Also, on certain surfaces a great enough color contrast
cannot be achieved or the dye will stain the work piece.
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4. Radiographic Test (RT):
Radiographic Testing (RT), or Industrial Radiography (IR), is a Non-Destructive
Testing (NDT) method of inspecting materials for hidden flaws by using the ability of
short wavelength electromagnetic radiation (high energy photons) to penetrate various
materials.
Either an X-ray machine or a radioactive source (Ir-192, Co-60, or in rare cases Cs-137)
can be used as a source of photons. Neutron radiographic testing (NR) is a variant of
radiographic testing which uses neutrons instead of photons to penetrate materials. This
can see very different things from X-rays, because neutrons can pass with ease through
lead and steel but are stopped by plastics, water and oils.
Since the amount of radiation emerging from the opposite side of the material can be
detected and measured, variations in this amount (or intensity) of radiation are used to
determine thickness or composition of material. Penetrating radiations are those restricted
to that part of the electromagnetic spectrum of wavelength less than about 10 nanometers.
The Radiographic Testing (RT) method is used for the detection of internal flaws in many
different materials (especially in joints between materials i-e welding). An appropriate
radiographic film is placed behind a test specimen and is exposed by passing either X-
Rays or Gamma-Rays through it. The intensity of the X-Rays or Gamma-Rays while
passing through the product is modified according to the internal structure and thickness
of the specimen and thus exposed film, after processing, reveals the shadow picture,
known as Radiograph of the product. It is then interpreted to obtain data about the flaws
present in the specimen. This method is used on wide variety of products such as
forgings, castings and weld-ments.
Safety:
Industrial radiography appears to have one of the worst safety profiles of the radiation
professions, possibly because there are many operators using strong gamma sources (> 2
Ci) in remote sites with little supervision when compared with workers within
the nuclear indu
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Weld Position: Flat
Material: Steel
Weld Process: Arc Welding
Radiography: ≤145 KV
Type of Discontinuity: Slag inclusion
In Ultrasonic Testing (UT) a high frequency sound waves are introduced into the
material being inspected. Most ultrasonic inspection is done at frequencies between 0.5
and 20 MHz, Well above the range of human hearing which is about 20 to 20,000 KHz.
The sound waves travel through the material with some attendant loss of energy
(attenuation) due to material characteristics. The intensity of sound waves is either
measured, after reflection (Pulse Echo) at intensities (or Flaws) or is measured at opposite
surface of the specimen (Pulse transmission). The reflected beam is detected and
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analyzed to define the presence and location of flaws. The degree of reflection depends
largely on the physical state of matter on the opposite side of the interface, and to a lesser
extent on specific physical properties of that matter, for instance, sound waves are almost
completely reflected at metal-gas interfaces. Partial reflection occurs at metal liquid or
metal solid interfaces.
Ultrasonic testing has a superior penetrating power than radiography and can detect flaws
deep in the specimen, almost up to 6 to 7 meters of steel. It is quite sensitive to small
flaws and allows the precise determination of the location and size of the flaws.
Ultrasonic testing is often performed on steel and other metals and alloys, though it can
also be used on concrete, wood and composites, albeit with less resolution. It is a form
of non-destructive testing used in many industries including aerospace, automotive and
other transportation sectors.
Advantages:
1. High penetrating power, which allows the detection of flaws deep in the part.
2. High sensitivity, permitting the detection of extremely small flaws.
3. Only one surface need be accessible.
4. Greater accuracy than other nondestructive methods in determining the depth of
internal flaws and the thickness of parts with parallel surfaces.
5. Some capability of estimating the size, orientation, shape and nature of defects.
6. Nonhazardous to operations or to nearby personnel and has no effect on
equipment and materials in the vicinity.
7. Capable of portable or highly automated operation.
Disadvantages:
1. Manual operation requires careful attention by experienced technicians
2. Extensive technical knowledge is required for the development of inspection
procedures.
3. Parts those are rough, irregular in shape, very small or thin or not homogeneous
are difficult to inspect.
4. Surface must be prepared by cleaning and removing loose scale, paint, etc.,
although paint that is properly bonded to a surface need not be removed.
5. Inspected items must be water resistant, when using water based couplants that do
not contain rust inhibitors.
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Quality Assurance:
Quality assurance, or QA for short, is the systematic monitoring and evaluation of the
various aspects of a project, service or facility to maximize the probability that minimum
standards of quality are being attained by the production process. QA cannot absolutely
guarantee the production of quality products.
Two principles included in QA are: "Fit for purpose" - the product should be suitable for
the intended purpose; and "Right first time" - mistakes should be eliminated. QA includes
regulation of the quality of raw materials, assemblies, products and components, services
related to production, and management, production and inspection processes.
Works Of QA:
1. The QA department does the following:
2. Monitoring the implementation of Quality Management System through out the
organization.
3. Planning and scheduling of internal and external audits.
4. Initializing NCR IQA (Non Conformity Report of Internal Quality Audit).
5. Arranging follow up audit through auditors to verify the implementation and
correctiveness of the corrective actions.
6. Planning and scheduling the Quality Council meeting to review.
7. Customer’s feedback.
8. Follow up of previous management review.
9. Changes that could affect the Quality Management System
And
10. Weak areas and recommendations for improvement.
Company Quality:
During the 1980s, the concept of “company quality” with the focus
on management and people came to the fore. It was realized that, if
all departments approached quality with an open mind, success was possible if the
management led the quality improvement process.
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The company-wide quality approach places an emphasis on four aspects:-
i. Elements such as controls, job management, adequate processes, performance and
integrity criteria and identification of records
ii. Competence such as knowledge, skills, experience, qualifications
iii. Soft elements, such as personnel integrity, confidence, organizational
culture, motivation, team spirit and quality relationships.
iv. Infrastructure (as it enhances or limits functionality)
The quality of the outputs is at risk if any of these aspects is deficient.
QA is not limited to the manufacturing, and can be applied to any business or non-
business activity:
Design work
Administrative services
Consulting
Banking
Insurance
Computer software development
Retailing
Transportation
Education
ISO 9000:
KS&EW has pioneered implementation of Quality Management System ISO 9000 in
Pakistani industry. The decision of ministry of defense to build AGOSTA 90B submarine
in Pakistan with the collaboration of French shipyard encouraged KS&EW management
to obtain ISO 9000 International Quality Standard Certification for SWCD, which has
now merged with Ship-Building (SB) division. After effective implementation of ISO
9000 Quality Management System in SWC Division which was certified in 1997,
KS&EW Management decided to extend the coverage of ISO 9000 QMS scope to other
division of KS&EW.
Therefore the next divisions which qualified for ISO certification were GED (General
Engineering Division) certified in 1999, SBD (Ship-Building Division) in 2000, and
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finally SRD (Ship-Repair Division) in February 2002. Now the ISO 9001:2008
certification for all above division has been renewed in November 2008.
Certification:
ISO does not itself certify organizations. Many countries have formed accreditation
bodies to authorize certification bodies, which audit organizations applying for ISO 9001
compliance certification. Although commonly referred to as ISO 9000:2000
certifications, the actual standard to which an organization's quality management can be
certified is ISO 9001:2008. Both the accreditation bodies and the certification bodies
charge fees for their services. The various accreditation bodies have mutual agreements
with each other to ensure that certificates issued by one of the Accredited Certification
Bodies (CB) are accepted worldwide.
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Level I: Quality System Manual:
1. The Quality System Manual is a first level document outlining the Quality Policy,
Quality Objectives and Structure & general principles of operation of Quality
System.
2. The Quality System Manual shows how KS&EW intends to meet the
requirements of ISO 9001:2000 and now the ISO 9001:2008 standards.
3. The Quality System Manual is a controlled document and is issued through
Quality Assurance (QA) department to relevant departments/sections.
1. KS&EW has developed more detailed second level document i-e System Element
Procedures.
2. The Quality Management System Procedures specify what has to be done, by
whom, how and when will it be done with-in the scope of the Quality
Management System.
3. All Quality Management System Procedures have a common format which
includes purpose of the procedure, scope and the detailed step by step instruction
in accordance with the ISO 9001:2008 standard. A list of all forms and
appendices are included at the end of these procedures.
KS&EW has forth level documents to support Quality System Procedures and the Work
Instruction.
Due to the high effectiveness of the ISO 9000, and ISO 9001:2000 Quality
Management System, KS&EW Management has now achieved certification
against ISO 9001:2008 version. This new version of KS&EW ‘Quality
Management System Manual’ has been prepared which outlined the Quality
Management System in KS&EW based on ‘Process Approach’.
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Ship Building Hall:
Ship-Building Hall (SBH) is the 1st important part of the
ship building process. It is the place where construction of
Ship-Building starts. Ship-Building is also known as
Feeding Shop.
This hall is divided into four sections, namely;
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3. CC-523 (Marking Section):
After all the work is done on metal sheets as required, then it is marked with number, size
and other vital information, now the sheet part is ready and sent to the cutting and
bending where the cutting and bending of these sheet are carried out as required.
This portion is also called cutting and bending shop. Here the sheets are cut and bent
according to the issued drawings, and marking done in Marking Section in this section
cutting usually done by gas cutting process known as oxy-cutting for which a mixture of
oxygen, methane and acetylene is used.
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Conclusion:
As for trainees, we don’t think that any organization is better than KS&EW
because each person from worker to management is too much trained and
cooperative. We gain a lot of technical knowledge from KS&EW which we
will never forget and also this will help us a lot in our professional life.
***** *****
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