Ship Production - 2

Hull and Machinery Outfitting Shops Infrastructure, Layout and Management

Ebin Joseph
Goutham Venkatesh K.
P. Akshay Kumar
Vineesh K
Semester 7
Department of Ship Technology

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Introduction ..................................................................................................................... 3
Outfitting ......................................................................................................................... 4
Fitting Out Ships.............................................................................................................4
Traditional Practice ........................................................................................................5
Disadvantages with Traditional Practice........................................................................6
Concept of Unitisation: ..................................................................................................6
Block Outfitting Concept:...............................................................................................7
Group Technology / Concept of Workstations / Product-Work-Breakdown-Structure:7
Concept of Zone-Outfitting:...........................................................................................8
Management in Outfit Shops .......................................................................................... 10
Typical Responsibilities for College-Educated Staff People Assigned to an Outfitting
Fabrication Shop (e.g., for manufacturing pipe pieces) ..................................................10
Special Activities ..............................................................................................10
Routine Activities .............................................................................................11
Typical Responsibilities for College-Educated Staff People Assigned to an Outfitting
Assembly Shop (e.g., deck, accommodation, machinery and electrical) ........................11
Special Activities ..........................................................................................................11
Pipe Outfitting................................................................................................................ 13
Pipe Shop: Case Study - Cochin Shipyard Ltd. .....................................................................13
Outfit Warehouse at Cochin Shipyard Ltd. ..............................................................14
Work Flow In A Pipe Shop........................................................................................16
Infrastructure ...........................................................................................................16
Layout Sequence of Machinery ...............................................................................18
Location of piping shop............................................................................................19
Storage of piping......................................................................................................20
Advanced Outfitting Practices in a Shipyard ...........................................................21
Machinery Outfitting ...................................................................................................... 28
Main Engine Installation ......................................................................................................29
Deck and Cargo Space Equipment ................................................................................... 31
Deck Crane Installation ................................................................................................31
Crane Pedestal Installation ..........................................................................................32
Accommodation Outfitting ............................................................................................. 33

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Electrical Outfitting ........................................................................................................ 36
Electrical Repair Shop ..................................................................................................36
Electrical Shop Plan......................................................................................................37
Vote of Thanks ............................................................................................................... 38
References ..................................................................................................................... 38

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Introduction
In conventional shipbuilding, the ships hull structure is fabricated and erected on the berth
or dock and the outfitting is started only after launching the hull from the berth. As a result,
it has been found that the process of first fabricating and completing the hull structure
followed by outfitting the hull after launching takes longer time. Hence, to reduce the cycle
time and improve the productivity of the shipyards, the concept of advanced outfitting has
been developed.

All the modern day shipyards across the world have now identified that by adopting the
concept of advance outfitting the vessel building cycle time can be reduced and a substantial
saving of costs, along with other benefits, depending on the availability of infrastructure in
the yards can be achieved. Different concepts have been developed for the completion of
outfitting in block stage to derive the benefits of this methods. Where previously outfitting
was done entirely after the ship was launched from the slipway or the dry-dock, modern
concept facilitates the outfitting work to be started even before the launch; i.e. within the
block erection stage.

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Outfitting
Outfit includes all non-structural parts of a ship.
Among these items are:
1.
2.
3.
4.
5.
6.
7.

Main propulsion systems and auxiliary machinery

Pumps and piping systems
Heating, ventilation, and air-conditioning machinery and systems (HVAC)
Electrical systems
Accommodations and hotel services
Deck and cargo space equipment
Weapons and combat systems for naval vessels

Organization of and responsibility for outfit work may vary from shipyard to shipyard,
subject to local traditions, union jurisdictions, subcontractor arrangements, and other
considerations.

Fitting Out Ships

This includes a large number of operations of which the main components are hull, machinery
and electrical fitting out. Work carried out under these categories includes:
Hull:

Deck equipment

WINDLASS/WINCHES/BOATS/DAVITS

Accommodation Spaces

JOINERY/ELECTRICAL /PLUMBING/VENTILATION

Piping

FUEL/BALLAST/CARGO MAINS

Miscellaneous

LADDERS,WALKWAYS, GRATINGS, ETC.

Machinery:

STERN TUBE, MAIN AND TAIL SHAFTS, PROPELLER

RUDDER/STOCK

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MAIN ENGINES
AUXILIARY MACHINERY/EQUIPMENT
PIPING

Electrical:
Engine Room
Hull main services.

Traditional Practice
In the past, the tendency has been to separate various trades and to commence outfitting
only after a significant proportion has been erected. The principal features is this mode of
work where the ship spending a relatively short time at the assembly/fabrication stage and
comparatively long periods on the building berth and in the basin.

Typical steps for accommodation work following approximate completion of steelwork as

listed below:

1. Make pipe/trunk/electrical penetrations

2. Fair buckled plate
3. Install airports/windows
4. Perform hose testing
5. Paint steelwork
6. Fit insulation/wiring/ducts pipes
7. Fit joiner partitions/bulkheads
8. Install plumping fixtures
9. Lay floor covering
10. Install built-in furniture/doors/fixtures
11. Complete painting
12. Fit carpets/curtains
13. Install portable furniture.

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Traditional sequence of Production Event

Disadvantages with Traditional Practice

Although it appears simple, this manner of work has a number of disadvantages associated
with it:
(1) Longer build time
(2) Uneven labour requirement
(3) Larger space requirements
(4) Extensive re-work
(5) Uncomfortable work environment
(6) Difficult to plan
(7) Access problems

Concept of Unitisation:
Even before the hull block is made, the outfit components (machinery, piping, seating
structures, etc.) which are supposed to be located in a particular small area in the ship are
fully assembled into a small unit and when the hull block is made, this unit is then directly
installed at the required position in the block. Hence you see, in this process, the steel
structure and the machinery outfit units are developed simultaneously instead of a traditional
process wherein the machinery and outfit are installed only after complete erection of the

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ships hull. This process actually helps in reducing the cycle time required to build the ship.
Remember, in ship-building too, time is money.

Block Outfitting Concept:

Block outfitting involves erection of units of assembled components (a component may be a
unit of a pump with its seating and associated piping) and also heavy machinery (for example:
boilers) on large blocks of the hull before the blocks are erected and welded to each other.
However, consideration is always given to the limitation of the total weight that can be
handled by the carnage facilities of the yard. The size of the hull blocks are accordingly predecided by the design department of the yard, keeping this factor in mind.
By this process, the yards have managed to prefer down-hand welding because, the hull
blocks can be inverted and the outfit can be installed before erection of the blocks. As a result,
the components requiring overhead welding (for example: exhaust lines, ventilation trunks,
etc.) can be welded by down-hand welding. This is actually very fruitful because down-hand
welding is not only easier than overhead welding but also a safer option for the welders in
the shipyard.
Also, open-sky access for erection of machinery, makes it easier for the production
department to erect larger machinery.

Group Technology / Concept of Workstations / Product-WorkBreakdown-Structure:

The basic principle of Group Technology is that it involves identifying the subdivisions of a
product, which although may not be necessarily identical are produced by the same process
and set of operations. For example; in the engine room area of a ship, a unit can be considered
as a machinery component along with its seat and connected piping. The kind of work
required to erect such a unit, will be similar to that required to erect many similar units in the
engine room area. Therefore, Group Technology involves identification of the interim
products or so called units, which can be handled by the same type of processes.
The application of Group Technology to ship-building results in dividing entire ship into subdivisions based on the kind of work required to build and erect each division. Each division
can now be assigned to different manufacturing groups who are specialised to build those
particular units effectively. Such categorisation of the components required to build the ship
is known as Product Work Breakdown Structure (PWBS). Now, each type of component is to
be manufactured in separate and specialised locations in the shipyard called workstations.

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The question arises as to why do we need such a grouping? The answer lies in the fact that
this method of grouping offers considerable potential for the improvement of the
manufacturing efficiency of the shipyard. Because each workstation is now specialized in
efficiently manufacturing its designated units, since it is equipped with the suitable tools,
machinery and workforce required for the same. This not only allows easier planning of work
but also maintains a steady work load with increased performance of operators.
One very notable aspect that we must take note of is that this method can now be applicable
to develop and manufacture the interim products of units for all types of ships that the yard
will be building in the future. Thus, the advantage of repeated work can be obtained in
utilising the workstation concept in shipbuilding industry.

Concept of Zone-Outfitting:
Before we start understanding this concept of advanced outfitting, it is necessary to
understand what a Zone is when we are speaking in terms of shipbuilding. A zone may
correspond to a compartment or even any integral part of a compartment of a ship, such as
a cargo hold or a machinery space and its sub-divisions. It completely depends on the yard as
to how they define the zones in a ship to be built. Even an entire superstructure or just one
level (deck) of a superstructure could be considered to be a zone. Hence, in a nutshell, a zone
is a sub-division of a ship that is selected for the convenience of outfitting either on units of
hull block or on larger hull blocks or directly on-board the whole ship after all the blocks are
joined.
There are three types of zone outfitting practices, mainly dependent on the scale on which it
is applied.
1. On-Unit
2. On-Block Installation:
3. On board (either on berth or afloat):

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Advanced Outfitting - Sequence of Production Events

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Management in Outfit Shops

Typical Responsibilities for College-Educated Staff People Assigned to
an Outfitting Fabrication Shop (e.g., for manufacturing pipe pieces)
Special Activities
1. For each building contract, budget man-hours and materials allocated to the shop to
the various flow lanes based on records of efficiency achieved and also based on
planned improvements in work methods, e.g., automatic welding, and better jigs and
tools.
2. Maintain a long-term (1 year) shop loading plan and revise it in response to every
change in the shipyards master schedule.
3. Manage the use of subcontractors and the use of overtime to offset work-load
fluctuations.
4. Negotiate with subcontractors and settle on volumes of work and unit prices that are
to apply for a one-year period.
5. Estimate work associated with drawings, material lists and other information provided
by designers.
6. Develop intermediate-term (3 months) schedules to meet pallet required dates using
feedback, i.e., man-hours per unit weight, per-piece, per electric-cable lengths, etc.
7. Maintain man-hour control graphs per ship by the parameters used for feedback.
8. Maintain the data bank for computer processing of information.
e.g., lot number and serial number for control during fabrication vs. ship
number, part number and pallet number needed for control during assembly
on-unit, on-block and on-board.
9. Plan facilities improvements.
10. Implement special projects, e.g., how to make the shop more vivid.

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Routine Activities
1. Preside over weekly meetings attended by the shop manager, flow lane foremen and
their assistants and other staff assistants to:
a. ascertain the number of components completed per week relative to planned
output per flow lane,
b. establish the amounts of work to be accomplished next week, including
overtime work and work to be subcontracted, and
c. Establish a manning plan per flow lane for next weeks work.

2. Once each month, prepare the shop managers report to the department manager
presenting the actual trend of production (difference between what was planned and
scheduled and final results) and presenting recommendations for improvement.
3. Maintain the accuracy control system.
4. Attend safety control meetings which are held twice per month.

Typical Responsibilities for College-Educated Staff People

Assigned to an Outfitting Assembly Shop (e.g., deck,
accommodation, machinery and electrical)
Special Activities
1. Participate in the study of each preliminary design, before contract design starts, and
contribute to a basic build strategy
2. Participate in meetings for hull block definition.
3. Prepare the strategy for zone outfitting by designating zones and stages for outfitting
unit , on block, on grand block and on board and when necessary advising designers
of changes in arrangements that would improve productivity without inhibiting owner
requirements.
4. Designate special material required dates such as for a main engine and check for such
material availability.

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5. Prepare 3-months and l-month schedules using the design outputs per pallet and manhour rates associated with fitting specific materials.
6. Continue to contribute to further definition of a build strategy as subsequent design
phases evolve and eventually inputting information needed to facilitate work, e.g.,
check points, reference lines, means for air testing welds , so that the output of detail
design is, literally, work instructions.
7. Document the outfitting strategy and establish targets taking into account new ideas
for reducing costs.
8. Prepare the zone-outfitting schedule insuring that it is compatible with the design
schedule for preparation of work instructions corresponding to pallets (MLF).
9. Prepare a staging plan.
10. Specify access and routes from a safety point of view.
11. For each building contract, budget man-hours and materials allocated to the shop to
the various flow lanes based on records of efficiency achieved and also based on
planned improvements in work methods, e.g., automatic welding, and better jigs and
tools.
12. Plan relocations of on-board cranes to anticipate erection progress.
13. Prepare plans such as for main engine installation, propulsion system alignment,
flushing completed pipe systems, etc.

Routine Activities
1. Attend the brief meeting of electric shop foremen each morning.
2. Preside over the weekly meeting for finalizing next weeks work load specifically by:
a. Checking monthly schedules proposed by foremen and weekly schedules
proposed by assistant foremen,
b. Conveying policy conceived by the shop staff for how work is to proceed.
c. Discussing and adjusting the distribution of workers with the foremen, and
3. Resolve owners and surveyors reports of unsatisfactory items and process feedback
reports.

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Pipe Outfitting
Pipe Shop: Case Study - Cochin Shipyard Ltd.
At the Cochin Shipyard Ltd., the Outfit department takes over the ship from the Hull Erection
department. The hull erection department assembles the blocks and the basic structure is
laid. Now the ship needs to be stuffed with all the equipment, machinery and comfort. This is
done in the outfit department. There is outfitting of machineries, piping, electrical outfitting
and accommodation outfitting.

Software used in Cochin Shipyard Ltd. for Pipe modelling

Ship Constructor
FORAN
TRIBON

Pipe Layout example in AVEVA TRIBON

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Outfit Warehouse at Cochin Shipyard Ltd.

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Piping is divided into:

1. Engine Room Piping

2. Piping used by crew and passengers
3. Piping for machinery support and safety
4. Ship specific piping system

1. Engine Room Piping

Compressed Air pipe

Fuel oil pipe
Lube oil pipe
Cooling water pipe
Exhaust Gas Piping
Bilge piping

2. Piping used by crew and passengers

Fresh water pipe

Grey water pipe
Black water pipe
Scupper

3. Machinery support and safety

Steam piping
Ballast piping system
Ventilation pipes
Refrigeration pipe
Sounding pipe
Air pipe

4. Ship specific piping system

Cargo Handling piping
Firefighting pipes
Inert Gas Pipes

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Work Flow In A Pipe Shop

1. Pipe Design Process

2. CAD Drafting

3. Cutting Process

4. Edge Preparation

5. Hole And Contour cutting Flange

Fitting and welding

9. Bending

8. Hole Punching

7. Stress Relieving

6. Testing

10. Surface Preparation

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Infrastructure
Machinery Items in Pipe Shop:

MACHINE

SPECIFICATION

Pipe Coaster

350NB

CNC Pipe Coaster

80NB to 1200 OD pipe

2 Pipe Bending Machine

10NB 50NB (2D & 3D)

6 Pipe Bending Machine

65NB 150NB (2D & 3D)

2 Yogi Pipe Bending Machine

10NB 50NB

Wallace Coast Bending Machine

50Nb 150NB (2D & 3D)

Portable Pipe Bender

15NB 25NB

Threading Machine

Rems Uni upto 2

Threading Machine

Rems 773 upto 4

Winch

5T

High Speed Cutting Machine

upto 80NB

High Speed Cutting Machine (Roller Type)

upto 175NB

Sand Filling Machine

Manual Metal arc Welding (AC & DC)
CO2 Welding

15V 50V (Megatronic)

TIG Welding Machine

(AC & DC)

Radial Drilling Machine

RM62

Centre Lathe

HMT H26

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Pedestal Grinder

Heavy Duty

Tool Grinder

Light Duty

Hyd. Pressure Testing Equipment

250Kg/cm2

Plasma Cutting Machine

plates upto 2 thick

Power Hack Saw

upto 250NB

EOT Crane

5T & 2T

Post Crane

1T

Layout Sequence of Machinery

1. CUTTING
.

2. BENDING

3. SPOT WELDING

4. WELDING

5. GRINDING

6. BLASTING

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Location of piping shop

1. Closely related to outfitting bay

Largest outfit tasks in shipbuilding

Easy handling, saving time as well as cheap cost makes it near to the outfitting
bay
2. Readily accessible to the ware house
The pipe piece fabrication is very important to connect all the pipes by small
pieces.
Easy handling, saving time as well as cheap cost makes it near to the outfitting
bay
3. Flow of work not interrupted
No interrupt of flow of work
Separated from hull, block assembly, block storage, the building berth and the
steel stockyard.

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Storage of piping
In the storage of pipes in shop before fabrication or after fabrication one should
consider the following

Space occupation

Retrieval of the material

Flow of work

Minimum apparatus

Least time should be spend

Recommended should be obeyed

In pipe shop pipes are kept in racks with recommended height and proper
accessibility with minimum space available for the handling of pipes

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Advanced Outfitting Practices in a Shipyard

On-Unit Outfitting
Outfitting on unit is the assembly of a unit of machinery or component or an already
manufactured product (which can also be purchased by the shipyard). But this unit is not a
part of the steel structure of the hull. For example: a unit can be a boiler mounted on its seat,
along with its connected piping, flanges, valves. This unit is first completely assembled, and
then transported to the site where the hull block is previously erected. The unit is then
erected on the hull block as a single unit. This is again similar to the application of the
Unitisation Concept that we discussed previously. But the point to be noted is that in zone
outfitting, we are focussing on the zone of the ship where the unit is erected.

Step: 1

Seawater Service Pump and an Air-conditioning Water Pump

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Shown in previous image is a machinery unit which will contain both a Seawater
Service Pump and an Air-Conditioning Water Pump.

Vertical Seawater Service Pump is fitted to the subcontractor-furnished painted

foundation which was built according to a shipyard-provided detail drawing.

A pipe support, to be subsequently fitted, is included. The horizontal Air-Conditioning

Water Pump is on the platen alongside are scheduled to be fitted on block.

Step: 2

A strainer has been fitted to the Seawater Service Pump, the Air-Conditioning Water Pump
has been fitted and a valve is being lifted into position

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Step: 3

A pipe piece is being lifted by the shop's bridge crane for bolting to the Seawater Service Pump

Step: 4

A second worker temporarily assists by guiding a strainer to its final position while the
gasket and a few bolts are secured

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Step: 5

Pipe piece supports are being fitted

Step: 6

The completed unit is being transported for fitting on-block

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On-Block Outfitting
Outfitting on block is the installation of outfit components (machinery with seats, piping,
electrical cables, ventilation trunks, etc.) after an entire hull block is completed. The units are
installed either as separate components or after unitising them (similar to what is described
above)

On Block Advanced Outfitting

Advanced Outfitted Grand Block

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Outfitting components, units, and grand units are sometimes fitted in a block zone
defined for hull construction.

However, when they are to be fitted to ceilings, blocks should be inverted because
fitting down-hand enhances safety and efficiency.

Following block turnover, the outfit zone encompasses the components, units, and/or
grand units fitted to the floor.

Forecastle Upside Down

Forecastle Deck Right Upside Up

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Double Bottom On-block Outfitting

Outfit items should be fitted in the zone of a double bottom block before its tank top
panel is installed.

At a later stage, a different outfit zone encompasses everything to be fitted to the

tank top.

The primary goals of this manufacturing level are to outfit ceilings and double
bottoms when blocks can be manipulated to provide ideal access.

Engine room tank top unit

Engine room tank top components fitted on-block

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Machinery Outfitting
On-Board Outfitting
Conventional method of outfitting - It can be defined as all the outfitting work that is done
after the hull blocks are completed and erected in the slipway or docks.
Ideally, assembly and painting work are left for accomplishment on-board.
These works are limited to:
1. Fitting of components that are too large to fit on block like main engine,
diesel generators etc.
2. Connecting distributive systems at block butts and seams
3. Pulling only the ends of electric cables that were fitted on block
4. Pulling electric cables that could not be pulled on block
5. Connecting electric cables
6. Clean up
7. Painting touch up
8. Installation of the main drive line
9. Finish painting

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Main Engine Installation

STEP 1:

Preparing the engine for installation,

attaching it to the lifting equipment

STEP 2:

Lifting the engine

using the crane
safely and moving it
towards the engine
rooms position

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STEP 3:

Lowering the engine

into the engine room

STEP 4:

Checking for proper

alignment and finally
setting the engine on
the engine mount
foundation

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Deck and Cargo Space Equipment

Deck Crane Installation
This is a highly precise and skilled activity taking place post erection of a vessel
Mainly done by specialized set of workers specially skilled at handling such heavy and
large system on a confined deck space.
Usually for large cranes, the various components are erected one by one
Thus alignment of the units becomes an important consideration in this operation.

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Crane Pedestal Installation

Post erection deck crane installation

Figure showing unit-wise erection of the deck crane structure

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Accommodation Outfitting
Accommodation spaces are available as pre-outfitted modules. These are installed on the ship
as On-block installations. Depending on the space availability in the unit of installation,
modularised accommodation units are ordered.

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Modules lifted into ship using Cranes

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Accommodation Units Before, During and After Installation

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Electrical Outfitting
Electrical equipment installations in ships:
1. D.C. Generators
2. D.C. Switchgear
3. A.C. Generators
4. Automatic Voltage Regulators
5. A.C. Switchgear
6. Distribution Box Main Switch Board, Sub-Switch Boards.
7. Electric Cables
8. Insulation and Temperature rating of Machinery
9. Motors
10. Motor Control Gear

Electrical Repair Shop

The electrical shop in a ship repair yard should be equipped and capable of undertaking
repairs and rewinding of full range of motors and generators of ships and overhaul of
electrical apparatus and switch gears. List of major equipments here are:1.
2.
3.
4.
5.
6.

Electric Coil Winding machines

Industrial Furnaces
Dimmer stats
Quick way Armature winding machine with counter
Coil winding machinery with counter
Testing panel with dimmer status

The potential for electrical shock hazards is greater in shipbuilding and repair than in other
industries, because workers stand on metal decks and often work in a wet environment. Work
on or around energized electrical equipment can expose workers to electrocution, burns, or
electrical shock. Before work is performed, energized equipment must be guarded, deenergized, or appropriate PPE used to prevent worker exposure.

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Electrical Shop Plan

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Vote of Thanks
We would like to take this opportunity to express our sincere thanks to the following persons
who have helped us in completing this assignment.

Mr. Arjun Jacob (Oshima Shipyard Ltd.)

Mr. Akhil Augustine (Cochin Shipyard Ltd.)
Mr. Tomy Joseph Praful (Goa Shipyard Ltd.)

References

Ship Production Technology Part-I and Part-II, Prof. R.A. Shenoi, University of
Southampton
i.T.. Faculty of Naval Architecture and Ocean Engineering Shipyard Organization
GEM 412-E
Shipyard Management - Design, Planning & Operations: Event Brochure
o BC Asia website@ibcasia.com.sg
Ship Production Storch Lee
Marine Insight Website www.marineinsight.com