INTERNSHIP AT CSL

INTRODUCTION
Cochin Shipyard Ltd was incorporated in the year 1972 as a fully owned Government
of India company. In the last three decades the company has emerged as a fore runner in the
Indian ship building and ship repair industry. This yard can build up to 110,000 DWI and
repair ships up to 125000 DWT. India’s first indigenous Air defence ship is being built here.

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. 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. The shipyard also trains graduate engineers
in marine engineering.[5] Around one hundred students are trained each year.

The shipyard commenced ship repair operations in the year 1982 and has undertaken
repairs of all types of ship including up gradation of oil exploration industry as well as the
periodical layup repairs and life extension of ships of navy, UTL coast guards, fisheries and
pod trust besides merchant ships of SCI and ONGC. The yard has over years developed
adequate capabilities to handle complex and sophisticated repair works.

The main services offered here are:

 Ship building
 Ship repairing
 Marine training

Dept. of AE&I, ASIET

 INTERNSHIP AT CSL

TRAINING INSTITUTE:

We spend our first two days at the training institute where we were allowed to explore
the entire CSL operations through various interactions and presentations.

On the second day itself we received the schedule and we all were parted into several groups.

The students dealing with the instrumentation engineering joined in our group.

IT DEPARTMENT:

We were directed to visit the ship repair section in the IT department.

CHSL 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, Fisheries survey of India…

The IT department has a very small part in the ship repairing department. They only provide
a software support which includes networking operations, ERP operations, managing control
signals, and various other miscellaneous operations.

Some major projects are:

 Major up gradation of Mobile offshore drilling unit ‘Sagar Vijay’ of ONGC. The up
gradation increased the drilling capacity of the vessel from 300m 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 REPAIRING SECTION:

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.

Dept. of AE&I, ASIET

 INTERNSHIP AT CSL

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.

INSTRUMENTATION SECTION:

The Instrumentation section handles the calibrations and the flow meters required.
The calibration activities cover the different types of meters and gauges such as temperature,
pressure, level, speed, electrical power, salinity, viscosity…

 PRESSURE GAUGE:

Instruments used to measure and display pressure in an integral unit are called pressure
gauges. Bourdon tube pressure gauges are the most frequently used mechanical pressure
measuring instruments.

Working principle: The pressure gauge is designed to be mounted directly with bottom
entry. C-type bourdon tubes gauge are used for pressure measurement. The bourdon tubes are
made

Out of an elliptically flattened tube bent in such a way as to produce the C shape/spiral
shape/twisted shape or helical shape. One end of the tube is sealed or closed. The other end is
open for the fluid to enter. When the fluid whose pressure is to be measured enters the tube,
the tube tends to straighten out on account of the pressure applied. This causes a movement at
the free end and the displacement of this end is amplified through mechanical linkages. The
amplified displacement to the free end may be used to move a pointer on a scale calibrated in
terms of pressure.

Dept. of AE&I, ASIET

 INTERNSHIP AT CSL

Calibration procedure: the pressure gauges are calibrated with reference to a standard
master gauge certified by international agencies using dead weight tester.

 PRESSURESWITCH:

This is a device designed to monitor a process pressure and provide an output when a set
pressure (set point) is reached. A pressure switch is used to detect the presence of fluid
pressure. They make use a diaphragm as the sensing element. The movement of this sensing
element is used to actuate one or more switch contacts to indicate an alarm or initiate a
control action.

Working principle: Pressure enters through the connection port and acts on the diaphragm.
This diaphragm is forced upwards by the inlet pressure against the range spring.

The tension of the range spring can be adjusted so that it is compressed at a certain pressure
or set point. When this pressure is reached, the operating pin will hit the trip button on the
micro switch and change it over. The normally open contacts will become closed and
normally closed contact will open. The pressure at which the micro switch changes over is set
by adjusting the trip setting nut. This nut adjust the tension of the range spring.

 LEVEL SWITCH:

Level switch is a device used to detect the level of a liquid with in a tank or sump.

Dept. of AE&I, ASIET

 INTERNSHIP AT CSL

Operating principle: The level switches are of displacer type. The sensor is a displacer
heavier than liquid, which is suspended by a spring. When liquid contacts the displacer, a
buoyancy force is produced, which causes the effective weight of the displacer to change, this
cause the spring to retract slightly to a new equilibrium position. When the spring retracts the
attraction sleeve also move upward into the field of the external magnet, thus overcoming the
force of the bias spring and actuating the switching element.

 PIG SIGNALLER

The pig signaler is used to indicate the pig has left the launcher, arrived in a receiver or
passed a certain point in the pipeline. They are positioned at the pig launching and pig
receiving stations and at key points along a pipeline.

Operating principle: Pig signalers are bi-directional type and has pivot less tumbler
mechanism and laminated trigger blades. A bi-directional trigger protrudes into the pipeline
operating the visual or electrical indicators. The signaler indicates the passage of a pig
through the pipeline in either or both of the following ways.

Dept. of AE&I, ASIET

 INTERNSHIP AT CSL

Visual flag unit: when the pig passes, the flag is flipped from a position perpendicular to the
axis of the signaller .The flag is rest manually.

Electrical switch: The proximity switch is actuated when the pig passes, the switch
automatically resets at the control panel.

 PRESSURE TRANSMITTER:

Pressure transmitter/differential pressure transmitter is used for the measurement, transmit

and indication of pressure/differential pressure in pipeline at terminals and SV stations.

Operating principle:

1. Pressure transmitter: The smart pressure transmitter used for pressure measurement are
of variable capacitance type. The pressure applied to the external diaphragm compress silicon
oil along the ceramic channels which in turn deform capacitor plates. The deformation is
relative to the compression of diaphragm due to the applied pressure and the change in
capacitance is sensed electronically.

2. Differential pressure transmitter: They are installed across the booster pump strainer for
denoting the pressure difference of the upstream and downstream of strainer so the blockages
if any can be identified. The instrument is piped with impulse lines running from upstream
and downstream sides of booster pump strainer. The process pressure from the respective
lines are transmitted through an isolating diaphragm and silicone oil fill fluid to sensing
diaphragm in the center of the capsule. The capacitance plates on both sides of the sensing
diaphragm detect the position of the diaphragm and convert the differential pressure into 4-20
mA signal.

Dept. of AE&I, ASIET

 INTERNSHIP AT CSL

 DIFFERENTIAL PRESSURE GAUGE:

Differential pressure gauge is used for the measurement of differential pressure for local
indication in pcckl pipeline carrying HSD, KSO and MS.

Operating principle: These gauges are intended for measuring the pressure differential
existing across two media or two parts of a system. The pressure element separates the two
pressurized media, and deflects proportional to the difference in pressure between the media,
irrespective of the absolute pressure applied. The absolute value of either of pressure is not
usually indicated. The pressure element for differential pressure gauge is SS 316
diaphragm.an over range protection up to 130% of maximum range is present.

 TEMPERATURE ELEMENTS:

Temperature instrument RTD (Resistance Temperature Detector) is used for the measurement
transmit and indication of temperature in pipeline carrying HSD, SKO and MS.

Operating principle: Temperature is the degree of hotness or coldness measured on a

definite scale. It is the driving force for heat flow. The resistance of conductor changes when
its temperature is changed. This property is utilized for measurement of temperature. The
variation of resistance with temperature can be represented as,

R=R0 (1+K1T+K2T2+…+KNTN)

R0=Resistance at temperature T= 0 and K1, K2….KN are constants.

Platinum is especially used for temperature measurements as it can withstand high

temperatures while maintaining excellent stability.

Dept. of AE&I, ASIET

 INTERNSHIP AT CSL

 LEVEL TRANSMITTER:

A level transmitter is simply an instrument that provides continuous level measurement.

Operating principle: Anybody immersed into a liquid is subject to Archimedian buoyancy

force which depend on the density. This is exploited to determine liquid level, density and
interface level by suspending a displacer with a constant cylindrical shape into a liquid,
changes in buoyancy forces are proportional to liquid level changes and are converted to a
measuring signal. The buoyancy force of the displacer is transferred via transmission lever
and torque to operating rod of the sensor where it acts on free end of sensor element .Four
thin film metal string gauge elements are supported onto sensor elements which change their
resistance in the ratio of the tensile or pressure tension .This four film metal string gauge
elements are connected as a wheat stone full bridge supplied from amplifier. The voltage ta
the diagonal bridge section which is proportional to the effective weight is fed to the
electronic amplifier as an input signal.

 HYDROCARBON GAS DETECTOR:

The hydrocarbon gas detector is designed to be mounted directly on wall /surface.IR type
hydrocarbon gas detectors is used to detect and measure the percentage of hydrocarbon gas
present at place where the equipment is installed.

Operating principle: It consist of a chamber in which the sample gas is passed through. At
one end of the chamber there is an IR source which is a bulb or a heater which produces IR
energy .At the other end of the chamber is an IR detector element, this IR detector measures
the amount of IR energy that reaches it and produces a signal output proportional to the
amount of energy .Generally there is an IR filter in the IR path which allows the detector only
to look at a particular wavelength region of IR energy. If gas which absorbs this particular
wavelength or IR energy by sample flowing through the detection chamber it will produce the
amount of IR energy that reaches to the detector. The measuring circuit compares this IR
energy to the energy that is present when fresh air is in the chamber and interpret the signal
and process it as a measured reading of the detected gas.

Dept. of AE&I, ASIET

 INTERNSHIP AT CSL

INS VIKRAANT

INS Vikrant is the first aircraft carrier built in India and the first Vikrant-class aircraft

carrier built by 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 2023, after which it will be handed
over to the Navy and undergo two years of sea trials. The project cost has escalated
dramatically to ₹19,341 core. CSL has offered repeatedly to build a second Aircraft carrier
project 71 Indigenous Aircraft Carrier while the navy finalizes plans for the configurations of
its larger and likely nuclear powered next carrier.

SHIP DESIHNING

The ship designing process starts with deciding the mission requirements. These are
usually specified by the ship owners who based on the current and future market scenario and
expectations, define the parameters and features of the ship. The process goes through
various phases-

 Concept design phase: The key objective is to arrive at the feasibility of the project.
 Contract design phase: The key objective is to plan the project.
 Detailed design phase: The key objective is to construct the vessel.
The design process can be seen as a sequence of the following steps:
 Analysis: A process of decomposing any system into its sub systems and component
parts to determine their separate and collective nature.
 Synthesis: A process of integrating a collection of subsystems so as to create a system
with emergent properties.

Dept. of AE&I, ASIET

 INTERNSHIP AT CSL

 Evaluation: A process of assessing the degree to which a solution satisfies the goals
that were originally stated.

THE U AND M DEPARTMENT:

The U and M department supplies the required machineries to the yard. It includes
heavy machines, plasma short plasting machines, servo motors… The different types of
weldings used in the ship building process are:

 Shield metal arc welding

 Submerged arc welding
 Gas metal arc welding
 Gas tungsten arc welding
 Oxyaceliflene welding
 Ceramic welding
 Robotic welding

Dept. of AE&I, ASIET