INDUSTRIAL TRAINING IN HINDUSTHAN SHIPYARD LTD

CONTENTS

Introduction Basic Design Office Hull Shop Pre- Fabrication Shop Erection Department Engineering Department

INTRODUCTION The shipyard in which we undergone the industrial training deals with construction and repair of ships. 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

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

BASIC DESIGN OFFICE Preparation of geometry of ship defining L, B, D, T, coefficients of form . Design calculations such as hydrostatic characteristics, weight estimation, powering to achieve the required speed, design of propeller to provide the required thrust to overcome the resistance.

Stability calculations ,capacity plans, arrangement of keel blocks and bilge blocks, launching calculations .
Determination of light weight of ship and center of gravity by conducting inclining experiment. Comparison of model test results with the results obtained during sea trials to evaluate the performance of ship.

Now a days the hull design is done using Tribon software.

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

HULL SHOP This is the first department in the production process of a ship. The various jobs involved in hull shop are 1.Preparation of steel plates and sections 2.Marking 3.Gas cutting 4.Forming

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, as AUTOKON (NORWAY) earlier and TRIBON at present is being used the preparation of plates. The CNC machine has a capacity to cut about 100m per day. The following colors are displayed on computer to indicate the process.

Marking
Lines to be cut

pink line
blue

Completion of cutting red line

Plasma arc cutting:

Plasma arc cutting is also used with N/C burning machines. 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. Plasma arc nozzle is bulky and is therefore used primary for machine cutting. Substantial reduction in the amount of fumes and noises result when cutting is done over a water surface. The plasma arc process has been used for cutting aluminum and stainless steel with argon mixtures.

 Captivator lifts the plates from the top of stacking using magnetic pickups and transfers it to a roller conveyor. 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, blasting chamber(shot blasting), spray painting and drying 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, 800-ton press,250-ton press, 500ton press,320-ton press. Gilton/Shearing machine to cut the plates by shearing. Plasma cutting machine. Robotic profile cutting machine. Hammering block. Cambering machine. Pugg machine. Nicol bending machine. Frame bending machine.

PRE-FABRICATION SHOP The following are done in the prefabrication shop 1.Sub Assemblies 2.Unit Erection 3.Testing Of The Compartments SUB ASSEMBLIES: Sub assembly is an element which is placed in the unit erection. Sub assemblies are fabricated from plates and sections UNIT ERECTION: All the sub-assemblies are joined to form a unit. In the erection of the ship units it is important to employ the correct welding sequences.

First unit erection is done in the region of the machinery spaces, obviously working from the bottom to upwards, and also aft and forward. Next the stern sections are being completed . Bow sections are often the last to be fitted. The tail shaft etc. 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. Generally pressure test is done by fresh water. Alternatively, the tanks are tested by filling up with air to required pressure and find out leaks by applying soap solution to the welded joints.

ERECTION DEPARTMENT It is also called ship hull construction at hull berth. There are seven stages of hull construction at hull berth Preparation of berth/ building dock. Marking of reference lines. Placement of blocks. Erection of panels. Alignment of panels. Construction of panels. Survey.

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

ENGINEERING DEPARTMENT

It consists of: Machine Shop Works-before launching or float out. Works-after launching. Commissioning of all auxillaries and equipment.
Machine Shop: It consists of lathes, planers, turners, drilling machines. Overhauling of machinery and testing before erection onboard the ship is done is here. Works-before launching or float out: Finalization of centerline of shaft line and rudderstock is done primarily. Preliminary alignment of propeller shaft and other shafting erection and fixation of propeller, erection of rudder stock and rudder.

Machining of tank top of engine room double bottom, erection of underwater discharge valves and sea chests works are done prior to float out of the ship. Works-after launching: Erection alignment, testing of all machinery, pumps, deck cranes, anchoring-arrangement, steering gear arrangement etc. 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. After the launching or float out, the working condition of the auxillaries like boilers, air conditioning system, bilge and ballast system, lubricating oil system etc are checked so that they are in good condition.