You are on page 1of 26

1.

0 INTRODUCTION
Each project of shipbuilding process needs a planning and management from the
beginning until sea trials and delivered. In this project, a 76M barge has been chosen
for planning in method of block construction. Technical report has been written down in
each part. From the beginning, the construction of ship was carried out based on
reference of Classification Society Rules and specifications under and Bureau Veritas.
Shipbuilding is the construction of ships, which takes place in a specialized
facility known as a shipyard. Shipbuilders, also called shipwrights, are workers which
specialize in vessel construction and repair. The construction of boats is called boat
building. Due to the smaller size and scope of the vessels being produced, boats do not
necessarily require the full services of a shipyard but may be built in a boatyard or even
smaller private facility.

2.0 OBJECTIVE
1. Determine the type of vessel for project.
2. Determine the method of construction in shipbuilding process.
3. To carry out the planning for whole project based on reference of Classification
Society Rules and Regulations and Bureau Veritas.

3.0 CONSTRUCTION
Ship construction is shipbuilding process that needs a planning for whole project.
In this project, method of block construction has been chose. Block construction is a
modern shipbuilding method which involves the assembly of prefabricated sections.
Cross-sections of the superstructure are pre-built in a shipyard, taken to the building
dock (or slipway) and then hoisted into position and attached. Some of the more
equipped shipyards are able to build equipment and utilities into the blocks, preinstalling pipes, plumbing, and electrical cables. The more components that can be built
into the blocks before final assembly, the less effort required once the hull is welded
together.
In this technical report, the whole project was carried out based America Bureau
of Shipping.

4.0 SHIPBUILDING PROCESS

The ship is constructed like a jig saw puzzle, consisting of some blocks including
deck cargo crane and cargo hold plan. To supervise the construction process of the new
vessels, labor as supervisors, and some selected external supervisors hired by the
company to the ship yard. The number of supervisors will be reduced at a later stage
when the majority of ships are delivered.
Ship constructions are carried out based on Gantt chart of shipbuilding process.
All the processes are noted in this Gantt chart, as below:

i)

Pre-Treatment

Steel surface treatment for processing.


1. Oil or grease shall be removed by wiping or scrubbing the steel with clean rags or brushes
wetted in solvent.
2. Corroding salts, such as chlorides and sulphates, etc. on the steels surface shall be rinsed-off
with fresh water. Water and moisture shall be removed by wiping the steel using dry rags or by
drying the steel with hot forced air.
3. All mill-scale, rust, rust scale, paint marks or foreign matter shall be removed by shot-blasting,
grit-blasting, or sandblasting.

4. Before shop primer is applied, dust, sand residue, crushed steel shot or any grit and all other
contaminants must be removed from the surface using a vacuum cleaner, air blower, etc.

ii)

Cutting

Cut the pre-treated steel according to the drawing.


Most of the cutting operation is done using a computerized CNC Cutting technique. In
addition, Laser cutting and Plasma cutting techniques are applied depending on the

thickness of the steel. If the steel is too thick for these techniques, it can be cut by way
of Gas cutting manually.

iii)

Assembly

Assemble the cut & processed steel using step-by-step processes of piece assembly,
sub block assembly and block assembly.
After cutting steel sheets, the cut and processed components are assembled block
by block. In order to maximize manufacturing efficiency, the assembling of blocks is
carried out in a phased manner: small-scale assembly comes first, mid-scale assembly
second, and large-scale assembly last. Each piece is very heavy, so cranes are
used for the assembling. They weld steels to assemble, in other words, they
melt steels and put them together. The melted parts become like adhesive.

iv)

Outfitting
Fitting-out, or "outfitting, is the process in modern shipbuilding that follows the

float-out of a vessel and precedes sea trials. It is the period when all the remaining
construction of the ship is completed and readied for delivery to her owners. Since most
of the fitting-out process is interior work, this stage can overlap with latter stages, such
8

as the sea trials. After launching, the ship is berthed in a fitting-out basin for completion.
The main machinery, together with auxiliaries, piping systems, deck gear, lifeboats,
accommodation equipment, plumbing systems, and rigging are installed on board, along
with whatever insulation and deck coverings are necessary.
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 pre-decided 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.

10

v)

Coating and Painting.

Steel surface treatment using special paint.


After outfitting process finished, they are painted in one of two ways:
1) As soon as possible after assembly, partially or completely (the block painting or
paint-then weld method), in which each block is painted prior to welding of the blocks
to form the ship structure, or
2) After a long period, e.g., after erection on the slipway (the building in the shop coat
or weld then-paint method), in which the shop-coated blocks are welded into the ship
structure and painted later. The main advantages of block painting are that premature
corrosion and weathering of the shop primed surfaces are avoided and that the final
coating systems can be applied under cover. In theory, block painting allows
shipbuilders to take control of their environment and to handle advanced solvent-free
and water-borne systems, even in winter

11

vi)

Erection

Erect the assembled block


The construction process is divided into 3 stages:
1.

The block stage

2.

The pre-erection stage

3.

The erection stage

Stage 1

Cut and formed steel plates and steel beams are welded together to form the block
portion of the vessel. The blocks are not completed until the supervisors are called for
sub-assembly and final block inspection and accept them.

Stage 2

12

Blocks are joined/ welded together at a suitable weight within the capacity of the
shipyards crane to carry. This is also the stage where the machineries for engine room
blocks, forward blocks for deck machinery and bow thruster etc. equipment in deck
houses and other outfitting are installed. During this stage, the keel of the vessel will be
ready to be laid in the slipway.

Stage 3

Blocks are now joined together in the dock and seated on the dock keel blocks which
are arranged according to hull form or docking plan and then welded. Cargo deck
cranes are erected, the hull markings such as draft marks, freeboard marks, bottom
markings, anchor chain markings etc. are confirmed to be correctly installed. The
principal dimension of the ship i.e LOA, LBP, depth, breadth and level of keel are
measured. The erection from keel laying until set to float takes approximately 20 days.

13

14

Shipbuilding and Ship Repair


Minimum Manpower

Large

Medium

Small

Registered Naval Architect


and Shipbuilding Eng

Licensed marine Engineer

Licensed Mechanical
Engineer

1*

1*

Licensed Mechanical
Engineer

1*

1*

Safety Officer

Draftsman

Mold Loftman

Foreman /QC

Welder

1*

Cutter

1*

Pipe Fitter

1*

Ship Fitter

1*

Carpenter

Licensed Master
Electrician

Heavy Equipment
Operator

Mechanic

Painter

Blacksmith

1
15

Foundry man

Sandblaster

Diver

Rigger

THE EQUIPMENT
Major equipment
The diversity of materials used in shipbuilding is conditioned by diversity of requirements to operating
characteristics of mechanisms and structural components of the vessel. This major components is to
ensure the process being smooth and excellent production.
1 unit of CNC Fusion Plasma Underwater Cutting Machine
Thermal cutting processes that can produce beveled edges are not new. In fact, they probably have been
around nearly as long as oxyfuel cutting. Their use has been popular in the shipbuilding industry for many
16

years. However, until recently, the high capital investment and the trial-and-error nature of their
application have limited their use.
Under water CNC plasma cutting actually submerges the plate below 2 to 4 of water, so the torch tip and
the entire arc are submerged.

plasma cutting

underwater plasma cutting

When plasma cutting under water, the water will absorb the vast majority of the plasma smoke. Instead
of billowing clouds of smoke that have to be captured by an expensive dust collector, a water table will
usually emit an occasion little puff that quickly dissipates.

Emission of fume when plasma cutting mild and stainless steel


Material

Thickness

Dry Cutting (lb/hr)

Under Water Cutting (lb/hr)

Mild Steel

5/16

2.65 - 3.44

.01 - .05

Stainless Steel

5/16"

3.97 - 5.29

.03 - .07

Stainless Steel

1-3/8"

.24 - .45

0.003

1 unit of Fuji 500 Ton Press


17

This ton press made from Japan company co. Able to press the steel within range 500 ton

1 unit of Roundo Plate Bending & Rolling PS 600


ROUNDO machines are always more powerful and more heavily proportioned in terms of frame, roll
size, bearings and drive torque than machines from other suppliers. The result is higher reliability, higher
precision and longer service life.
The ROUNDO PS rolls provide a large opening between the upper and the lower rolls, permitting heavy
bars and even such unusual items as stair stringers for spiral staircases to be rolled. Versatility can be
further expanded by the addition of attachments to roll flat bar on edge and on many models angle iron, Tbar, channel pipe and other sections. RLC controls and a wide range of options are available for all
models. This Labuan ship shipyard using roundo ps 600.

Ps 600 roundo machine

plates being rolling in the machine

1 unit of 400 Ton Hugh Smith Frame bender

18

For forming all types of stiffener sections, rolled and welded 'T' sections. Rolled equal and unequal
angles and bulb flat sections singly or in pairs, flat/round bar. Frame dimensions from 100 to 1200mm
deep. This machine is to Bilge turns/bow flairs at single pass (port & starboard together). In this Labuan
shipyard using 400 ton fixed with adjustable bending centers for increased capacity.

this frame bender also high capacity adjustable side & centre clamping for distortion control and
Vertical straightening feature to correct lateral distortion.

Huge smith 400 ton frame bender

after the process

1 unit of OTC Plasma D-12000

Transistor Controlled Super Plasma Cutting Machine\

High Speed Cutting (Cutting of a 16 mm plate 4 times faster)

Surface finish resembles those which are produced by gas cutting

The new Cooling System design allows parts change without fluid leakage

Operating Area increased 9 times

Higher benefit, better security

Max. cutting capacity: up to 60 mm

19

Built in "Torch Guard" function

THE MAIN TECHNICAL SPECIFICATIONS AT A GLANCE:

Super Plasma D-12000


Model

Input Voltage

380 V

Frequency

50/60 Hz

Number of Phases

Rated Input

28,3 KVA (27,5 kW)

Rated Output Current

120 A

Maximum No-Load Voltage

270 V

Output Current Range

30-120 A

Duty Cycle

100%

Dimensions B x T x H
450 x 780 x 775

Weight

176 kg

20

D-12000 super plasma cutting machine

Lifting Equipment
The cranes will be used to unload break bulk cargo, including steel and forest products, and will also be
used in heavy lift and project cargoes, for example, wind turbines.
1 unit of 50 tonnes dockside/lifting crane

Dockside lifting crane


2 units of 70 tonnes grove mobile crane

21

Grove mobile crane

1 unit of 250 tonnes Manitowoc M250 crawler crane

The Manitowoc M250 is a powerful liftcrane. It has a max lift capacity of 300 tons (272 t), a max jib
length of 120 ft. (37 m), and a main boom max length of 330 ft. (101 m). Its powered by a Cummins
N14-C450 diesel engine that is capable of producing up to 450 hp (335 kW), and it also comes standard
with an independent swing system which is driven by a fixed-displacement hydraulic motor that is paired
up with an internal brake.

1 unit of 320 tonnes Manitowoc M4600 ringer crane

22

The Manitowoc ringer crane is able to lift 680 Te and can have a main boom configuration of up to
122.0m and attachments of luffing and fixed jibs can add a further 79.2m to its reach.The ringer
configuration means that the crane has to be set up in position on site. The increase of lift capacity this
attachment offers comes at a loss of mobility.

Above: Lampson Manitowoc M460


2 unit if 15 tonnes forklift
Fork lift trucks in the 10-18 ton range are known for their excellent maneuverability, thanks to their short
wheelbase, and for their excellent stability

3 unit of 7 tonnes forklift


This product is available in a pneumatic tyre configuration to suit your individual application. These lift
trucks provide a careful mix of enhanced technology, increased operator comfort levels and easier
serviceability that combine to offer the operator higher levels of productivity and lower operating costs.
23

1 unit of 10 tonnes side forklift

The mast rails are structured for maximized visibility while the hydraulics are configured with both
mechanical and human error safeguards to provide a more secure work environment.

Electrical & Auxiliary Support

Welding sets consist of Miller MK VIII-2 DC (SMAW), Esab LCF1200-DC,RC500 (SMAW), Esab
A2 Multiwoc 1000 Amps.(SAW), Miller Syncrowave 350 Amps.(GTAW) and many more

24

Miller syncrowave
Generators equipment consist of 1000 KVA Portable Cummins Diesel Generator G21, 1875 KVA
Portable Caterpillar Diesel Generator G20 and many more

1000KVA Portable Cummins


Air compressors equipment consist of 750 CFM Air Compressor Ingersoll Rand (Model: HP750/Diesel
Driven. Potable type), 674 CFM Air Compressor IR/Motor EP150/50. Fixed type.
And many more

25

Air compressor Ingerson Rand


Blasting and Painting equipment consist of Air Dryer 750 CFM. IR Model: DXR-750EE, Auto Blasting
Machine 550 m/day. and many more

Air dryer 750 CFM

26

You might also like