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Fabrication Shop •Erection Department •Engineering Department .CONTENTS •Introduction •Basic Design Office •Hull Shop •Pre.
•The various departments located in this shipyard are as follows Project cell Basic Design Office Hull division Mini loft Drawing office Material estimate steel Hull outfit drawing office Machinery Division Electrical division Production Departments .INTRODUCTION •The shipyard in which we undergone the industrial training deals with construction and repair of ships.
Departments in outfit Complex: Blacksmith department Joiners and Carpentry Sheet Metal Rigging department Painting department Steel outfit Departments in Engineering complex: Engineering department Plumbing department Electrical Department .
coefficients of form . powering to achieve the required speed. • Design calculations such as hydrostatic characteristics. design of propeller to provide the required thrust to overcome the resistance. . arrangement of keel blocks and bilge blocks. • Comparison of model test results with the results obtained during sea trials to evaluate the performance of ship. • Stability calculations .BASIC DESIGN OFFICE •Preparation of geometry of ship defining L. launching calculations . •Determination of light weight of ship and center of gravity by conducting inclining experiment.capacity plans. weight estimation. T. B. D.
Hull form design lines/surface Use hull form Compartmentation Release hull form SHIP DATABASE Release design Release calculation geometry Steel work definition Basic design/hull Use Design Use calculation geometry Hydrostatics and hydrodynamics .Now a days the hull design is done using Tribon software.
Preparation of steel plates and sections 2.Gas cutting 4.HULL SHOP This is the first department in the production process of a ship.Marking 3.Forming . The various jobs involved in hull shop are 1.
CNC: (Numerically controlled flame cutting machines using NC tapes): NC implies control of machines by means of tapes on which they record the co-ordination points of profile. Marking Lines to be cut –pink line –blue Completion of cutting –red line . The following colors are displayed on computer to indicate the process. The CNC machine has a capacity to cut about 100m per day. as AUTOKON (NORWAY) earlier and TRIBON at present is being used the preparation of plates.
The normal cutting speed for 12mm (1/2in) plate is about 3 times the speed of oxyacetylene cutting. The speed advantage decreases with the increase of plate thickness. Substantial reduction in the amount of fumes and noises result when cutting is done over a water surface.Plasma arc cutting: Plasma arc cutting is also used with N/C burning machines. The plasma arc process has been used for cutting aluminum and stainless steel with argon mixtures. . Plasma arc nozzle is bulky and is therefore used primary for machine cutting.
blasting chamber(shot blasting).• Captivator lifts the plates from the top of stacking using magnetic pickups and transfers it to a roller conveyor. spray painting and drying chamber. • Mangles is the name given to a heavy set of plate straightening rolls through which the plate is passed prior to its being worked Plate treatment plant: It consists of heating chamber. . This is for the treatment of plates to remove rust and dust particles thereby spraying primer to prevent the further formation of iron oxide.
MACHINES IN HULL SHOP •2000 tones press cum rolling machine. •Cambering machine. •Gilton/Shearing machine to cut the plates by shearing.320-ton press. •Frame bending machine. •Robotic profile cutting machine. 800-ton press.250-ton press. •Hammering block. 500ton press. . •Pugg machine. •Plasma cutting machine. •Nicol bending machine.
Sub assemblies are fabricated from plates and sections UNIT ERECTION: All the sub-assemblies are joined to form a unit.Unit Erection 3. .Sub Assemblies 2. In the erection of the ship units it is important to employ the correct welding sequences.Testing Of The Compartments SUB ASSEMBLIES: Sub assembly is an element which is placed in the unit erection.PRE-FABRICATION SHOP The following are done in the prefabrication shop 1.
•First unit erection is done in the region of the machinery spaces. the tanks are tested by filling up with air to required pressure and find out leaks by applying soap solution to the welded joints. •Next the stern sections are being completed . •Bow sections are often the last to be fitted. obviously working from the bottom to upwards. and also aft and forward. . are installed prior to launch. TESTING OF THE COMPARTMENTS All watertight and oil tight compartments below the water lines are tested before the ship is launched by filling them with water and applying a head of specified height as per the requirement of the Classification Societies. The tail shaft etc. Generally pressure test is done by fresh water. Alternatively.
•Construction of panels. •Erection of panels. •Alignment of panels. •Survey. There are seven stages of hull construction at hull berth •Preparation of berth/ building dock. .ERECTION DEPARTMENT It is also called ship hull construction at hull berth. •Marking of reference lines. •Placement of blocks.
Process map of Hull construction at Hull Berth Drawings &schedule from production planning(pp) and production management (pm) Quality plan Panels/blocks from Prefabrication Department Erection of panels/ blocks Arrangement of keel blocks and bilge blocks Alignment of panels/blocks Quality control check Quality control check Fit up of master joints for welding clearance Class/owner survey Progress status to pp & pm Dry survey of master joints/ spaces/ tanks QC/class /owners survey .
planers.ENGINEERING DEPARTMENT It consists of: •Machine Shop •Works-before launching or float out. •Commissioning of all auxillaries and equipment. Works-before launching or float out: Finalization of centerline of shaft line and rudderstock is done primarily. drilling machines. Machine Shop: It consists of lathes. erection of rudder stock and rudder. turners. •Works-after launching. . Preliminary alignment of propeller shaft and other shafting erection and fixation of propeller. Overhauling of machinery and testing before erection onboard the ship is done is here.
steering gear arrangement etc. bilge and ballast system. the working condition of the auxillaries like boilers. After the launching or float out. lubricating oil system etc are checked so that they are in good condition. Commissioning of all auxillaries and equipment: Maintenanence of machinery and equipment from day of receipt into the yard until they are drawn for installation onboard of the ship. erection of underwater discharge valves and sea chests works are done prior to float out of the ship. testing of all machinery.Machining of tank top of engine room double bottom. . deck cranes. pumps. air conditioning system. Works-after launching: Erection alignment. anchoring-arrangement.