Professional Documents
Culture Documents
Copy to: 1. DGM (HRD) 2. GM (Q. C) 3. D.Sp (S. B Hall) 4. Chairman (IND Department)
Acknowledgment:
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 belief 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:
Contents
S. No. #
1.
Department #
Introduction to KS&EW
Page No. #
4 to 6
2.
Quality Control
7 to 22
Quality Assurance
3.
23 to 25
4.
Conclusion
26
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.
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 wellequipped 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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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.
requirements of the personnels as well by providing training whenever required). 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)
18th century perspective: 148 ship parts, 18 labeled hull sections (From Cyclopedia, Volume 2, 1728)
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.
In all the above production departments of KS&EW, Quality is checked with the help of the following two main methods: 1. Destructive Testing (DT) 2. Non Destructive Testing (NDT)
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.
3. Dye penetrant Test (DPT): Dye Penetrant Test (DPT), also called Liquid Penetrant Test (LPT) or Penetrant Testing (PT), is a widely applied and low-cost inspection method used to locate surfacebreaking defects in all non-porous materials (metals, plastics, or ceramics). The penetrant may be applied to all non-ferrous materials and ferrous materials, but for inspection of ferrous components magnetic-particle inspection is also preferred for its subsurface detection capability. LPI is used to detect casting, forging and welding surface defects such as cracks, surface porosities, and leaks in new products, and fatigue cracks on in-service components. First the surface to be test is cleaned with a dry cloth or cotton piece to remove the dust particles. The penetrant usually red in color is applied and allowed to set. The particles of the penetrant get into the cracks on the surface. The surface is cleaned again this putting a small quantity of cleaner on a piece of cloth or cotton and then smoothly cleaning the surface with it. The contrast color usually white is applied on the surface and allowed to
dry out. This material brings out penetrant red particle from with-in cracks and the white contrast makes it easy to observe.
1. 1. Penetrant application to the Section of material with a surface-breaking crack that is not visible to the naked eye. 2. Excess penetrant is removed. 3. Developer is applied to the surface. 4. Inspection for the presence of discontinuities.
Advantages:
1. The main advantages of DPI are the speed of the test and the low cost. 2. Limited training is required for the operator although experience is quite valuable.
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. 2. Proper cleaning is necessary to assure that surface contaminants have been removed and any defects present are clean and dry. Some cleaning methods have been shown to be detrimental to test sensitivity, so acid etching to remove metal smearing and re-open the defect may be necessary.
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 XRays 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 industry or within hospitals.
Weld Position: Material: Weld Process: Radiography: Type of Discontinuity: 5. Ultrasonic Test (UT):
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 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. 2. 3. 4. High penetrating power, which allows the detection of flaws deep in the part. High sensitivity, permitting the detection of extremely small flaws. Only one surface need be accessible. 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.
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. Customers 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. The company-wide quality approach places an emphasis on four aspects:i. ii. iii. iv. Elements such as controls, job management, adequate processes, performance and integrity criteria and identification of records Competence such as knowledge, skills, experience, qualifications Soft elements, such as personnel integrity, confidence, organizational culture, motivation, team spirit and quality relationships. 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 nonbusiness activity:
It comprises a quality improvement process, which is generic in the sense it can be applied to any of these activities and it establishes a behavior pattern, which supports the achievement of quality. This in turn is supported by quality management practices which can include a number of business systems and which are usually specific to the activities of the business unit concerned. In manufacturing and construction activities, these business practices can be equated to the models for quality assurance defined by the International Standards contained in the ISO 9000 series and the specified Specifications for quality systems. In the system of Company Quality, the work being carried out was shop floor inspection which did not reveal the major quality problems. This led to quality assurance or total quality control, which has come into being recently.
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 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.
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.
Level IV: Applicable Standards, Products Drawings, Technical Specifications, Forms, Check Sheets and Quality Records:
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. ***** *****
1.
This is also known as short blast plant. Drawings are issued from the design office through planning department. According to the drawings material is taken from the main store. The materials (i-e steel plates) are brought from the steel-yard situated at the corner of the SBH. Electromagnets or mobile cranes move the materials directly from one end to other, or materials are moved through conveyer belts. The materials are first moved to the short blast plant where steel plates (materials) are forcefully hit through mild steel balls, this remove and cleans all the contaminants (usually rust) from the metal plates. After short blasting worker coat the sheets with primer to protect it from decay.