INDIAN MARITIME UNIVERSITY

Chennai

INDUSTRIAL TRAINING REPORT

Ship building process
(Yard- 158 MT ANDAMAN)
(Yard -159 MT BHEEM)
At
TEBMA SHIPYARDS LIMITED MALPE

HIND INSTITUTE OF NAUTICAL SCIENCE &

ENGINEERING, SIKANDRA RAO
Under the guidance of
Mr. Paul Lincoln
Training coordinator
Prepared by- Guddu Singh
Roll No. 1435712007
Submitted To
Department of Shipbuilding
Hind institute of nautical science and engineering

Guddu Singh
 DECLARATION

I hereby declare that the project work described in this thesis as

INDUSTRIAL TRAINING REPORT has been carried out entirely by me
in the TEBMA SHIPYARDS LIMITED MALPE UDUPI KARNATAKA, and
further state that it has not been submitted earlier wholly or in part to
any other University or Institution for the Subject Shipyard Attachment.

GUDDU SINGH

IMU Reg. No. 1435712007

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 CERTIFICATE
This is to certify that the thesis entitled SHIPYARD INTERNSHIP TRAINING
REPORT submitted by GUDDU SINGH to the College for Subject Shipyard
Attachment in 5th semester work carried out by his/her under my supervision. The
contents of this thesis, in full or in parts have not been submitted to any other
institute or University for Subject Shipyard attachment. . In our opinion, the
Internship training is up to the standard of fulfilling the requirements of the
Subject as prescribed by the regulations of this Institute.

The Internship Training has been carried out at Tebma Shipyards Limited.

Training Coordinator,
Mr. Paul Lincoln

Place Malpe Udupi Karnataka

Date: 29-08-2016

Guddu Singh
 PREFACE
Practical knowledge means the visualization of the knowledge, which
we read in our books. For this, we perform experiments and get
observations. Practical knowledge is very important in every field. One
must be familiar with the problems related to that field so that he may
solve them and become a successful person.

After achieving the proper goal in life, an engineer has to enter in

professional life. According to this life, he has to serve an industry, may
be public or private sector or self-own. For the efficient work in the field,
he must be well aware of the practical knowledge as well as theoretical
knowledge.

To be a good engineer, one must be aware of the industrial environment

and must know about management, working in the industry, labour
problems and many, so he can tackle them successfully.

Guddu Singh
 ACKNOWLEDGEMENT

This training was a part of the curriculum of our 5th semester of B.SC
SHIP BUILDING AND REPAIR. Doing this Training over the past 01
month has been absolutely enriching experience not to mention the vast
amount of knowledge we gathered via experiencing some of the real
time difficulties in the field of SHIP BUILDING

I would like to express my sincere gratitude to my Training Coordinator

Mr. Paul Lincoln and HR Mr. Mithun K for their constant guidance and
overwhelming support throughout my project.
I also wish to express thanks to the staff of Tebma Shipyard and My
Faculty in HIND INSTITUTE OF NAUTICAL SCIENCE AND
ENGINEERING for their help during the Training.
Finally, I would like to add my heartfelt gratitude to my parents, family
and friends for their support and guidance.

Tebma Shipyard Malpe Udupi GUDDU SINGH

Date: 29/09/2016 (1435712007)

Guddu Singh
 QUALITY, HEALTH, SAFETY & ENVIRONMENT POLICY
OF SHIPYARD

Create value for shareholders and all other stakeholders by

making our shipyard an efficient, contemporary and integrated
yard for building/repairing ships and offshore structure.
Consistently meet and/or exceed customers need in India and
abroad whilst striving to place India on the map as major ship
building nation.
Prevent accident, ill health due to occupational hazards
and adverse impact on environment due to
construction/repairs related activities of Ship and Offshore
Vessel through continual improvement.
Ensure compliance of all applicable legal and other
requirements.

Ensure effective implementation of the system by achieving

well defined and set Quality, Occupational Health, Safety and
Environment objectives, which shall be reviewed from time to
time. Undertake all steps to communicate this policy to all
our employees & personal working under the control and to
make this policy available to the interested parties.

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 These can be achieved by teamwork, innovation, total
organizational involvement, continual improvement, process
orientation and integration thereof to create a holistic
management system for world class performance par
excellence.
The Policy will be reviewed as and when required to ensure
continuing suitability.

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 The essentials Of Safety
Oxygen content in confined spaces should be 16% to 20.8%.
In the ship, especially in the engine room and tanks, the oxygen
content should be 19.5% to 23.5%.
23.5% is not considered as safe
.
If work is being in progress ( it may be any hot work, painting, shot
blasting, testing etc.), then lock out that particular area and tag out
a sign over there that work is in progress please be clear off the
place.
This process is called LOTO.
Hydrogen Sulphide (H2S) which is a dangerous gas gets
accumulated where ever oil is used.
Its content above 5 ppm can even cause death.
H2S gas has got an identification property, if this gas is in
between 1 to 3 ppm it produces a rotten egg smell.
Carbon Monoxide (CO) is produced mainly when cutting, welding
operations are being done and in particular when the tanks are
closed for more days.
In case of accumulation of these gases in any enclosed
compartment, they are removed through forced ventilation.
At the deck we provide a decik around the vent pipe to protect the
spread of fuel oil, in case any overflowing through vent pipe.

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 Safety While working in confined spaces:-

Sufficient ventilation must be there.

Visual inspection and gas checks must be taken to allow
for a permit.
No electrical instrument or insulation or paint job should
be there near the hot work affected area.
Smoking is prohibited.
In confined spaces such as tanks the amount of lead content can be seen
which on smelling can even kill a person. So before entering in any
confined space :-
A person must have the permit of going in that region.
With the help of gas testing meter check the amount of oxygen
level.
One attendant should be there for immediate help and rescue Confined
spaces like ballast tanks should provide with explosion proof
lightening and adequate ventilation.
Before welding or cutting any material it is to be ensured that it is
certified.
While doing hot work it is to be ensured that :-
It is under permitted area.
There is no flammable material nearby.
There is an attendant.

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 Always disconnect the gas connections / hoses before leaving.
Have a gas meter for checking the gas leakage.
Have adequate forced ventilation.
Before commissioning of any work risk assessment has to be done.

Permit to Work In Confined Spaces

A Permit Includes:-
Identification of the person.
Date and purpose of the entry in confined space.
Risk Percentage etc.
Permit To Enter
Toxic Gas Clearance Certificate
Permit To Hot Work
Environment Clear From Flammable Materials

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 Guddu Singh
 Scaffolding

There will be a permit provided / issued by the inspector which

will describe all the details fit working in that environment.
From the safety point of view there will be a tag provided in the
scaffolding area.
Color Coding:-
Green Tag represents that the area is safe for passage.
Red Tag represents that it is the restricted area.
When working at a height above 3.0 meters one must tie a belt
around his waist and tie it to a rigid structure so that if a person
slips that belt provides support to him and saves his life.
We also use safety nets from preventing a person falling down.
There Are 4 Point Of Contact While Climbing On Ladder.
We Careful While Work On Scaffolding.
Dont Enter Between The Scaffolding While Work Is Going
On It.
A Permit Is Must Before Climb On Scaffolding
Always Wear All The PPE While Work On Height.
Never stand on unfinished scaffolding.
Slings must be tied.

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 Hydraulic platforms are also used (as having a major safety
factor) to take someone to a particular height. Even in that case
also, safety harness is necessary to wear.

Scaffolding in Tebma shipyards ltd.

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 Rigging Work

Hoisting and lowering equipment should have a periodic

checkup.
Rigging shackles, slings, chains, belts etc. after every one
year.
&
Crane, Hoist winch etc. after every 6 months.

Never stand below the cargo being lifted or lowered.

Never come in between the crane which is being rotated at
3600.

All the rules and regulations for a particular operation come under the
INDIAN FACTORY ACT & RULE (1948).

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 . Shot Blasting and Painting

One must wear a blasting hood with airline respirator so as

to avoid inhale of abrasive impinges.
An apron must be wear which will cover the body fully.
Air purifier respirators may be used.

For painting also a similar apparatus is being used, when

painting a confined space.

Periodic medical checkup must be done of the personnel.

Dont Enter In The Blasting Shop Without Prior Permission
No Hot Work Is Done During Painting
Smoking Is Not Allowed In The Area Of Painting
There Is Permit To Paint In Confined Spaces Is Must.

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 Shot Blasting and Painting

Shot Blasting and Painting Shop In Tebma Shipyards ltd.

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 Electrical Safety

Ensure that the installation should not be switched on without

your knowledge.
Check that the insulation is not live.
Ensure the insulation is earthed.
Remove or isolate potential conductors.

Cranes
The working area nearby the crane should always be
barricaded.
There should be one attendant also.
There should be audible signals.
There should be audible speakers with mike.
Insufficient planning and communication failure can lead to
the loss of life of a person.
One must ensure that before commissioning of any work he
must be aware of all safety measures

When working outboard PFDs (Personal Floating Devices) must

be wear.

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 Safety during Hot Work
The following safety precautions must be taken before doing hot work
in a compartment or tank having water or any liquid:-

Pump out the liquid and sweep out and dry it out fully.
No welding hoses should get interrupt with accommodation
ladder.
There should be no electrical connection within 50 feet of
working area.
Always use explosion proof lights when working in dark.

Shipyard Different Departments Visit

Pipe Bending and forming shop.

Shot Blasting Shop.
Painting Shop.
Prefabrication workshop.
Winch Room.
Spare shop.
Slipway.

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 Firefighting introduction

Introduction to Different Type of Extinguishing Medias

Dry Chemical Powder Type

Used for petrol, Gas and Electrical fires.
Fire extinguisher NO. TSL/m/339.
Inside pressure 30 kg/cm2
Standard IS 2171.

CO2 Extinguisher
Capacity 4.5 kg.
Fire extinguisher NO. TSL/BT/01.
Standard IS 2878.

Foam Type Fire Extinguishers

Capacity
Fire Extinguisher No.
Standard

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 Fire fighting training

Procedure
It was done with the combination of processes used in PASS.
P = Plan, which extinguisher is to be used.
A = Aim, at the base of the fire.
S = Squeeze the valve.
S = Sweep the nozzle sideways.

When we operate those extinguishers they produce:-

DCP: - White powder with high pressure.
CO2 Type: - White gas and was cool in nature.

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 After having a practicing hand on fire safety I saw some videos about
safeties for grinder.

Then I learnt about safety helmet and its parts,

Outer Shell.
Interior suspension.
Ventilation Space.
Helmet Belt.

Materials used are Plastic, Aluminum, High impact Plastic, Fiber

Glass etc.

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 Day 02
Health Safety training
Purpose of training- To Understand the First aid given at the
time of sudden accidents in shipyard.

FIRST AID TRAINNING & CPR

Aim of Training
TO PRESERVE LIFE
TO PROMOTE RECOVERY
TO PREVENT FURTHER DAMAGE
QUICK TRANSPORT OF CASUALTY TO A MEDICAL
FACILITY

Defination
First Aid is the immediate help or treatment given to a victim of
an accident, sudden illness or other injury before medical help is
obtained using materials.

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 CPR

WHEN TO PERFORM CPR

No breathing
No pulse
Unconscious

HEART ATTACK/CARDIAC ARREST

Heart Attack Reduced level of oxygen to the heart muscle.

Cardiac Arrest Heart stops beating.
Signs and Symptoms Pale, chest pain, pain moving to left arm,
upset stomach, shortness of breath, tired, denial.
Risk Factors Age, cholesterol, weight, heredity, diet, smoking,
fitness, high blood pressure, stress.

The first important steps in giving CPR are.

The three Cs!!

CHECK
CALL
CARE

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CHECK

Is the scene safe?

Check to make sure that the scene is safe!!! Fire, wires, gas,
glass, spills, traffic, falling objects etc.
Make sure you are also taking care of yourself!
Assess what might have happened
Check for ABC
Is there anyone around who can also help? Ask others
around the scene for as much help as they can offer!

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 Call

Calling for help is often the most important action you can take to help
an ill or injured person.
Call 100 or the local emergency number 108 (If there are other
people at the scene, ask someone else to call for you to help!)
If youre by yourself, call 100/108 and/or get AED before you start
CPR
Give the 100/108 operator the correct information about your
location, victim, what happened and any other information you
can. Be the last to hang up!

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Care

Once you have followed the first two Cs, you may need to give care
until EMS personnel arrive. Follow these guidelines:
Do no further harm.
Monitor the persons breathing and consciousness.
Help the person rest in the most comfortable position.
Keep the person from getting chilled or overheated.
Reassure the person.

Give any specific care

needed.

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 Frist aid for electric SHOCK

Shock is a condition of collapse which should be treated on top priority

second only to attending to obstructed breathing, stoppage of heart or
severe bleeding. It may lead to death if not treated in time.
a. Reassure the casualty (when conscious).
b. Put him comfortably on his back. Except in case of the injury of
the head, the chest, or of the abdomen, lower the head slightly
and turn into a side. In case of vomiting give fowlers position.
c. Loosen tight clothing, but do not remove clothing.
d. Wrap the light bed sheet or thin rug.
e. Never use hot water bottle or do not rub any part of the body
with anything.
f. Incase of injury to chest and abdomen do not give anything by
mouth as he may require operation or blood transfusion later on.
g. Observe all the above quickly in a minute if delayed death may
occur.
h. Shift to hospital as early as possible.

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 Day 03
Planning Department
Purpose of the training- The aim of the planning Department is to
provide a system to plan, monitor and evaluate the Ship building
activities to build and Deliver ships on time Meeting customers
requirements as per contract

Scope: All contracts For New Vessel construction & repair works.
Instructor: Mr. Gautham C and Mr. Shrinivas Rao

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 Project Planning
On finalization Of The Shipbuilding/Ship repairing Contract
Project Planning Department Informs The Planning
Department Regarding approved Project Plans And Cardinal
Dates :
Date of Contract
Fabrication
Keel laying
Float out
Sea Trails
Delivery

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Project plan Development for Material
Planning department prepare the above plan for block Fabrication
& Block erection Dates with the Full Details for all the Major
Activities pertaining to each department indicating start & Finish
Date and Duration of the work along with the activities Linked,
as per Sequence so as to achieve the envisaged delivery Date.
As and when the details are released from the Design Department
the Project plane gets revised, accordingly.
The periodicity of revision of project Plane is kept flexible
depending upon Complexity of the project and guideline from the
top management.
In Tebma All Work Is Done On A Software Name As Microsoft
Project Plan MPP.
Other Software Use for Project Planning is Primovera6.

In Tebma We Use WBS (work Breakdown Structure) To Create

Sub project ID & Activity ID in Microsoft Project Plan MPP and
the Exported It into IFS (international Finance System).

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 Activities are listed below:-
Milestone
Signing of contract
100% hull erection up to main deck
Superstructure erection without block 611
100% superstructure
Launching
Sea trails commencing
Ship delivery

Note- the Progress is updated once in three months to verify

whatever the Work is progress as per the Schedule.

Detailed activity/item wise list are prepared for each

department for all projects.
This is to analyze the completion of each activity, balance
work to complete, percentage completion and to prepare
fortnight schedule for production department.
Weekly progress summary for each department is also
prepared from the database on weekly basis.

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 Data Base Preparation
Detailed activity/item wise lists are prepared for each
department for all projects as given at next page. This is to
analyze the completion of each activity, balance work to
complete, percentage completion and to prepare fortnight
schedule for production Department.
The weekly progress summery of each department is also
prepare from the database.
Achieved steel tonnage report is also prepared from the
database on weekly Basis.
Weightage of 100% is distributed to the activities according to
the quantum and intensity of the work to each project.
The general distribution of weightage is shown on next pages
of each department.
The weightage distribution will vary from project to project
depending on the complexity of the project.
Planning department decides the weightage distribution while
creating data base for the project.

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 Weightage Distribution in Tebma
Design- Drawing Being Outsourced In Tebma Shipyards
Ltd. And in house made are monitored group wise with respect
to operation departments.

Activity Drawing Released

weightage 100%

Purchase- Material Procurement Activities are monitored at

various levels and weightage as noted below.

Activity BOM&PRQ Purchase Order Material Receipt

Weightage 25% 25% 50%

Hull- Fabrication And Erection Of Blocks Are monitored

in block wise with respect to weight of block and weightage
as noted below:
1) Block Fabrication
Activity Steel Cutting Fabrication Dry Survey
Weightage 5% 50% 5%
2) Block Erection
Activity Erection& Fairing Welding Dry
Alignment Survey
Weightage 5% 15% 15% 5%

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 (SOF) Structural Outfit Structural Work of outfit
items and fitment of deck items are Detailed with quantity
giving weightage as noted below:
Activity Fabrication Erection Dry Survey
Weightage 45% 45% 10%

Piping- Piping work is Monitored For Fabrication,

Erection, Pressure test And Is Detailed With Quantity Giving
Weightage As Noted below:
Activity Fabrication Erection Dry Pressure
Survey Test/Flushing
Weightage 45% 25% 15% 15%

Machinery- Machinery Work is monitored in Quantity

wise with Weightage as noted below:
Activity Shipping Bolted down
Weightage 30% 70%

Electrical-Electrical work is monitored in the quantity Wise

with Weightage As noted below.
Activity Hot Work Equipment Cable Cable
installation laying Termination.
Weightage 30% 15% 25% 30%

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 Accommodation- Accommodation work is monitored in the
quantity Wise with Weightage As noted below.
Activity Hot Flooring Furniture HVAC Insulation Paneling
Work Fitment
Weightage 15% 10% 15% 20% 15% 25%

Painting- Painting work is monitored in Area Wise with

Weightage As noted below.

Area Block Tanks External Superstructure Hull

Hull Ext. & Int. Marking
Weightage 25% 25% 15% 25% 10%

Tank Test- Tank Test list is prepared to ensure and monitor

the Completion of tank testing with weightage as noted blow:

Activity Penetration Air Test Dry Survey

Weightage 40% 20% 40%

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 Reporting In Tebma
Production Progress- Production Progress is Prepared in
every week to get the work progress in activity wise for the
project. Required data for this will be forwarded by the
Department to the respective department to the planning
department who will feed the data to the data base.

Constraints Analysis- It is observed that many a times,

delay could be due to any constraints which are beyond the
control of the production dept. concern. Hence identification
the constraints for non-achievement becomes essentials to
resolve constraints and also measuring performance of the
production dept. against what can be achieved
The performance of the particular dept. is monitored Vis a Vis
planned for after knocking off constraints beyond its control.
Constraints are identified, recorded and analyzed for corrective
action during review.

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 Weekly Progress Report The weekly progress report
is prepared from the summary obtained in the data base file.
This is the presented in the weekly Production Review
Meeting (In Tebma at Every Thursday of the month). PRM
is attended by all the HOD to review the progress and take
corrective action. Also the work progress of each project is
calculated to see the percentage of the completion of the
project.

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 Day 04
Ship movement
Ship Launching in Tebma at malpe yard
Purpose
To Transfer ships from build bay/repair bay to the sloping
cradle and to launch the same trough an efficient and safe
process.
The ship during construction stage is erected on ground block
supports. For movement of the ship, these ground supports are
removed and trolleys are instructed as per trolley insertion plan,

Document Required
Block Support Plan.
Ships Docking Plan.
Ship Load Distribution Chart
Trolley insertion plan.

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 Ship Launching Procedure Flow Chart
Plan schedule for
movement and launching

Remove ground supports

and insert trolleys

Rig up for pulling

Move ship from build bay

to transfer cradle

Rig up for side movement

of transfer cradle

move transfer cradle in

line with sloping cradle

Rig up for pulling on

sloping cradle

Move ship from transfer

cradle to sloping cradle

Pre-Launch prepration

Launch

Berthing of ship

Retrieval of sloping cradle

and trolleys

Preservation of trolleys
and associated equipments

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 Ship Docking Procedure Flow Chart

Plan Schedule for docking

Positioning trolleys on
sloping cradle

Set dock block support

Lower the cradle to

required Depth

Rig up for side movement

of transfer cradle

Move transfer cradle in

line with repair bay

Rig up for pulling on

repair bay

Move ship from transfer

cradle to rapair bay

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Tool Required
Sledge Hammer
Buffing M/C
Cleaning gears& Grease/oil.
Shifting trolley Toe Jacks.
5T/10T hydraulic jacks.
Roller Pipes.
Wooden Blocks and wedges of assorted sizes (lower the
trolleys and to erect the block supports)
Butter Paper

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Procedure
Remove the ground support as per trolley insertion plan
and clean the area.
Buff, clean and Grease the rails.
Shift and insert the trolley to the required position with the
help of shifting trolley/ toe jacks and roller pipes. Lower
the trolley on the rails with the help of hydraulic jacks and
wooden blocks.
Arrange block support on the trolley as per block
arrangement plan.
Hammer tight, Block supports and take load (Block
supports to be covered with butter paper on top to avoid
damage to hull paint)
Repeat the above procedure for all trolleys and transfer
ships load.
Some ground supports are not disturbed to share ships
load till movement.
Precautions Or General notes:
Thoroughly clean and wash the area before trolley
insertion
Give Prior information to the project manager regarding
support removal and trolley insertion.
Wear proper PPE For Safety

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 Use proper and calibrated shifting and lifting equipments
to avoid injury to personnel and damage to the trolley and
rollers.
Use experienced Riggers for the work.
Work should be carried out under staff supervision only.
Avoid sudden Jerk while removing ground supports
Take precaution to avoid the damage of hull paint.
Do not use crow bars on roller surface.

Use of Transfer Cradle

The ship is pulled with the help of eye pads welded either on
trolley or under the ships hull which is depends upon the size
of the ship and load on the trolleys.
Document Required
Trolley loading plan.
Wire rope routing and layout plan
Pulling eye pad location
Procedure
Align the transfer cradle with building bay and connect
rails.
Connect the forward eye pad through bow shackles Wire
slings and pulleys.

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 Rig rope through pulleys and forward anchor point to
auxiliary winch.
Clean the trolley Movement area.
Clean and grease the rails.
Evacuate all personnel and remove gangway cable and
hose connections from the ship.
Inform the safety department to cordon off movement area
to ensure the sefty during movement.
Start auxiliary winch to the required speed to pull the ship.
Observe the rope movement to avoid any obstacles
Record the winch parameter start stop and duration of
movement
Side Movement of the transfer cradle
Procedure
Disconnect ropes and pulleys connecting ship to the aux.
winch
Remove rail interconnection between new building shed
and transfer cradle.
Rig the side movement of transfer cradle.
Clean transfer cradle rails and clean obstacle in cradle
movement area.
Move the transfer cradle with aux. winch and align with
the sloping cradle
Ships pulling on sloping cradle
Procedure

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 Connect the aft eye pads through the bow shackles.
Rig rope through pulleys eye pads on sloping cradle
Forward anchor points to the auxiliary winch
Start auxiliary winch for required speed and pull the ship.
Observe the rope movement to avoid any obstacles
Depending on the ship movement winch speed is
increased or decreased as required and necessary
instruction are given to the winch operator.
When ship in water then disconnect the bow shackles,
wire slings, pulleys and rope connecting ship to the
auxiliary winch
Remove the eye pads and painted eye pad area.

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 Day 05

Ship Design
Purpose of training- the purpose of this training is to
understand the Basic Design (Approved Drawings By
Classification Socity) and Detailed Drawings used in shipyard at
various stage of shipbuiding.
Tebma Shipyard doesnt have A Design Office So It Outsource
The Design From Various Ship Design Companies .The Design
Depart of Tebma only check the drawings.
Instructor: Mr. Shrinath /Mr. Mouraly C /Mr. Lingeshwaran

Tebma Design Department with Projects.

DESIGN

CHENNAI MALPE KOCHI

PROJECT PROJECT PROJECT

TUG MPSV PSV

DREDGER TUG AHTS

SURVEY
LAUNCH

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 DESIGN ROLE IN PROJECT

PROJECTS

SMALL SHIP OFFSHORE

DREDGER
L <40 m VESSEL

CO-ORDINATION
PREPARING DWG PREPARING DWG
TO PRODUCTION

SENT TO
SENT TO CLEARING
APPROVAL
APPROVAL COMMENTS

CO-ORDINATION
CO-ORDINATION
TO
TO AS FITTED
PRODUCTION
PRODUCTION

CLEARING
CLEARING
COMMENTS
COMMENTS

AS FITTED
AS FITTED

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 Design Department Tebma

DESIGN

HULL MACHINERY ELECTRICAL

Mr. Lingeshwaran Mr. Shrinath Mr. Mourly C

Machinery Design

MACHINERY

EQUIPMENT MATERIAL
DRAWING
SELECTION SELECTION

REUIREMENTS Depend on STD CLASS PRODUCTION

SUITABILITY fluid (BIS,DIN) DRAWINGS DRAWINGS

SPOOL
CO-ORDINATION
GENERATION

ARRANGEMENT PENERATION
DWG LIST

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 Hull Design
HULL

OUTFIT &
HULL FORM STRUCTURES
STATUTORY

GENERAL DECK MACHINERY

LINES PLAN
ARRANGEMENT FOUNDATION

PRELIMINARY LONGITUDINAL BULWARK/GUARD

T&S BOOKLET PROFILE PLAN RAIL

SOUNDING TABLE W.T.BHDS FCP

INCLINING FRAMING
LSA
EXPERIMENT SECTION

FINAL T& S SUPER INSULATION &

BOOKLET STRUCTURES PANELLING

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 Machinery Equipment by Mr. Shrinath sir
Introduction to various machinery used in a ship
1) Main Engine And propulsion
1.1. Main Engine.
1.2. Gearbox
1.3. Thrust Block
1.4. Bearings
1.5. Propeller

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3. Engine Room Auxiliaries
3.1. Auxiliary Generator.
3.2. Air Compressor
3.3. Fuel oil Separator.
3.4. Lube Oil Pump
3.5. Air Conditioning Plant Compressor
3.6. Starting Air Compressor.
3.7. Hydrophore Pump.
3.8. Main Sea Water Pump.
3.9. Other Pumps and Equipments.
4. Deck machinery and cargo handling
Crane
Mooring Winch
Capstan
Windlass
Anchor Handling equipments
Rope Reel Drum
Life Raft
Life Boat

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 Electrical Power generation & Distribution
To meet all the power requirement of the equipments discussed
above, Main Generators are available which have mostly diesel
engines as prime movers. Also Emergency Generators are
available, to power essential loads of the ship.
Generator
Box battery
Main distribution Board
DPS (Dynamic Positioning System)
Satellite systems
Other Navigation units and etc

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 Piping design By Mr. Mouraly c
Piping system
Piping includes pipe, supports, flanges, fittings, bolting, gaskets,
valves and the pressure containing portion of the equipment and
supports. Therefore the pipe when joined with fittings, valve and
equipments, supports are called PIPING.
System is the process how we are handling the fluids
Piping System in a Ship
Bilge System.
Ballast System.
Fire Fighting System.
Air Vent System.
Tank Sounding System.
Cargo Piping System
Hydraulic piping System.
Pipe Fittings
Welded.
Threaded.
Flanged.
Also Classified As,
Bends.
Branches.
Reducers.
Flanges.

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 Piping drawings
Layout Arrangement Drawings.
Process flow Diagrams.
Equipment Drawing.
Isometric Drawings.
Coordination Drawings.
Process Instruments drawings.
Symbols Used In Piping Drawings

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 Day 07/08

Hkt

Pre Fabrication yard at hkt

Propose of training- to explain the procedure of pre fabrication
of sub assembly nesting welding and plate bending.
Drawing required
Nesting plan
Block fabrication drawing with part list
Procedure
1. Marking/cutting
The various parts and elements are required for the sub-
assemblies of the block are marked/cut on plates and sections as
per nesting plan either manually or CNC cutting according to
part list of sub-assemblies required for block.
A control register is to be maintained showing the heat no.
and grade of the plate.
2. Edge Preparation
Edge preparation of required beveling of plate required for
various skin plates and panels viz. Bottom/side shell tank top
and bulkhead panels are prepared by either automatically by
CNC machine or manually by semi-automatic bug cutter (gas
cutter).

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 3. Forming
Cold forming is done for sections and bilge strakes as per
templates prepared from lofting table.
Hot forming is done for higher thickness plates like stem bar and
nose plate I fore peak, Bulbous bow shell plates and also plates
to be formed in multiple shape by rolling and bending.
After forming Yard no. block no. and part no. is to marked for
identification
4. Palletisation
Various part and elements cut as per nesting plan are segregated
identification no. marked and kept in pallets block wise and yard
wise.
Each part/elements is marked the yard no. block no. part no.
Each palate is marked the pallet no, yard no. block no. of
elements contained in it. This is done to prevent from misplaced
or loss, Register is to be maintained for the details of such
pallets.

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Pre Fabrication of sub assembly
Fit up of intercostal floors brackets to girder stiffener to
continuous floors etc.
The root gap for plates fit ups and vertically of profiles to
be ensured.
Welding of these assemblies in down hand position.
Distortion if any is removed by the line heating
Join the tank top panel plates together bottom side upward
Weld seam by SAW or CO2 preferably with the ceramic
backing as per approved WPS.
Mark punch all the frame .girder line including check line
of entire girder fit up check line. Check line is the line
marked either port or starboard of the center line of the
girder to ensure whether the half thickness of the center
girder is falling exactly on either side or two lines parallel
to center line showing the thickness of girder.
Weld temporary guide cum stopper for automatic
alignment while placing sub assembly.
All Sub Assembly fillet or butt joint should start from the
Centre to outward of the panel or sub assembly
Welding schedule to be followed to avoid excess or under
fill weld and to ensure correct reinforcement
Block Fabrication flow at hungercatta yard

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Block Fabrication Process Flow Chart

Relese of Drawing

Identify the material required

for panels, plates profile etc.

Nesting, Marking, Cutting

Identify welding process

Fit Up Of plates

Fit Up Inspection by IQC

Welding of Panels

Inspection by IQc

Shift to block Assembly

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 Welding By Mr. Paul Lincoln Sir

Definition- Welding is a process of joining material, usually

metals, often by melting the work piece and adding a filler
material to form a molten material, which when cools will
become a strong joint

Classification of welding

Fusion welding
Union of parts is accomplished by melting the two parts to be
joined, in some cases adding filler metal to the joint
Examples: arc welding, resistance spot welding, oxyfuel gas
welding
Solid state welding
Heat and/or pressure are used to achieve coalescence (union), but
no melting of base metals occurs and no filler metal is added

Examples: forge welding, diffusion welding, friction welding

Arc welding
An electric arc struck between the electrode and the base metal
to melt the metals.

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The power supply can be DC or AC
In welding, the positively charged anode will have a greater
heat concentration and, as a result, changing the polarity of
the electrode has an impact on weld properties.
If the electrode is positively charged, it will melt more
quickly, increasing weld penetration and welding speed.
A negatively charged electrode results in more shallow welds.
AC supply results in medium penetration welds.
AC machines less expensive to purchase and operate, but
generally restricted to ferrous metals.
DC equipment can be used on all metals and is generally
noted for better arc control.

The electrode can be consumable or non-consumable

Common consumable electrode welding are: SMAW -
shielded metal arc welding, also called as MMAW (Manual
metal arc welding) - the most common type of welding.
An electric current is used to strike an arc between the base
material and a consumable electrode rod or stick
(producing around 5500 C). The electrode rod is made of a
material that is compatible with the base material being
welded and is covered with a flux that gives off vapors that
serve as a shielding gas and provide a layer of slag, both of
which protect the weld area from atmospheric
contamination. The electrode core itself acts as filler
material, making a separate filler unnecessary

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 An electric arc is a discharge of electric current across a
gap in a circuit
To initiate the arc in AW, electrode is brought into contact
with work and then quickly separated from it by a short
distance
It is sustained by an ionized column of gas (plasma)
through which the current flows

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 A pool of molten metal is formed near electrode tip, and as
electrode is moved along joint, molten weld pool solidifies in
its wake

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Shielded Metal Arc
Process:
Intense heat at the arc melts the tip of the electrode.
Tiny drops of metal enter the arc stream and are deposited on the
parent metal.
As molten metal is deposited, a slag forms over the bead which
serves as an insulation against air contaminants during cooling.
After a weld pass is allowed the cool, the oxide layer is
removed by a chipping hammer and then cleaned with a wire
brush before the next pass.

At high temperatures in AW, metals are chemically

reactive to oxygen, nitrogen, and hydrogen in air
Mechanical properties of joint can be degraded by these
reactions
To protect operation, arc must be shielded from surrounding air
in AW processes
Arc shielding is accomplished by:
Shielding gases, e.g., argon, helium, CO2
Flux

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 GMAW Gas Metal Arc Welding

Constant voltage, direct current power source is most

commonly used with GMAW, but alternating current are
also used.
MIG (Metal Inert Gas) - a continuously fed consumable wire
acting as both electrode and filler metal, along with an inert or
semi-inert shielding gas flowed around the wire to protect the
weld site from contamination. Argon and Helium are mostly
used as shield gas, sometimes as a mixture too.

MAG (Metal Active Gas) In a GMAW if CO2 is used as the

shield, it is called Metal Active Gas welding

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Applications of MIG and MAG:
Mostly used for aluminum welding
Also used for non-ferrous and ferrous material
Widely used in automobile industry
Good quality and speed achieved -
No slag formation
Because of the need to maintain a stable shroud of shielding gas
around the weld site, it can be problematic to use the GMAW
process in areas of high air movement such as outdoors

Better arc time because of continuous wire electrode

Sticks must be periodically changed in SMAW
Better use of electrode filler metal than SMAW
End of stick cannot be used in SMAW
Higher deposition rates
Eliminates problem of slag removal
Can be readily automated

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 Submerged Arc Welding
Consists of an electrode fed from a spool. The molten weld and
the arc zone are protected from atmospheric contamination by
being "submerged" under a blanket of granular fusible flux
consisting of line, silica, manganese oxide, calcium fluoride, and
other compounds. When molten, the flux becomes conductive,
and provides a current path between the electrode and the work.
This thick layer of flux completely covers the molten metal thus
preventing spatter and sparks as well as suppressing the intense
ultraviolet radiation and fumes.
SAW is normally operated in the automatic or mechanized
mode, however, semi-automatic (hand-held) SAW guns with
pressurized or gravity flux feed delivery are available. The
process is normally limited to the flat or horizontal-fillet
welding positions

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 TYPE OF WELDING JOINTS
Butt Joint
A joint between two members aligned approximately in the
same plane

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 Lap Joint
A joint between two overlapping members

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 T Joint
A joint between two members located approximately at right
angles to each other.

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 Corner Joint
A joint between two members located at right angles to each.

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 Edge Joint
A joint between the edges of two or more parallel or nearly
parallel members

Intermittent welding

Weld geometry and

dimensions.

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Welding positions.
Fillet welds
1F down hand
2F Horizontal
3F Vertical
4F Overhead

Groove welds
1G down hand
2G Horizontal
3G Vertical
4G Overhead
5G - for fixed horizontal pipes
6G - for inclined fixed pipes

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 Welding Defects
Crack
Incomplete fusion
Porosity
Incomplete join penetration
Undercut
under fill
Overlap
Spatter
Slag inclusion
Excess penetration
Convexity
Concavity
Lack of fusion
Face Reinforcement
Throat crack

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 Nesting by Sunil Sir

Definition-The process of planning to optimally accommodate

Maximum components to be cut from a plate with minimum
material wastage and effort is called nesting

Nesting can be done manually by trial and error method

Needs skill and expertise for good result
Time consuming
Software are available to do nesting like Sigma nest
Expensive, but saves lot of time
Scrap factor: wastage of plates in the form of scrap.
Limiting it to 10 to 12 % is considered good.

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 Day 09
Rigging and lifting equipments
Purpose of the training- to understand the all rigging and lifting
equipments used in shipyard.
Training instructor- Mr. Anandan V
List of rigging and lifting equipments used in shipyard
1. The D lugged joining shackle is used extensively for
joining the cable to the anchor in more modern vessels. In
the past this type of shackle was used, as the Kenter lugless
joining shackle is used today, in the joining of the shackle
lengths of cable together. If it is to be used for this purpose,
the rounded crown part of the shackle should always face
forward, so that it does not foul the anchor when letting go.

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 Lifting belt- 6T capacity, (polyester material)
Lashing belt
Bow shackle
Vertical lifting clamp
Wire slings
After that he took me for a round to show the lifting
equipment present in the shipyard.
Hydraulic crane-15T capacity
Lifting Beam- it is used to lift the blocks and place it by
turning it at any direction.
Transporter- for taking the blocks and placing inside the
shot blasting chamber.
Crawler crane- for lifting heavy blocks of ships and
placing it where the overhead gantry crane cannot reach.
Its SWL is 30T.
Gantry Girder crane- 4 nos. each of 30T
Sir said that for lifting any block eye pad must be welded
on the block rigidly through which hooks of the chain block
from the overhead gantry crane or the crawler crane passes.
After finishing all these sir explained about the terms
related to rigging and seamanship.
Whipping- the binding round the bare end of the rope
for preventing the strands from unlaying.
Mousing- a length of line or small wire rope between the
point and shank of a hook to prevent unhooking. This
can also be done for a D-shackle.
Lashing- two crossed spars can be secured together
either with a square lashing or a diagonal lashing.

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 Seizing- it may be defined as being a method of
fastening together two parts of rope sufficiently strongly
to stand a required strain.
Then sir showed me an:-
Eyebolt- which is used for securing an eye to a wooden
structure.
Block- is a portable pulley made of wood or steel.
Turn Buckle- these are also called rigging screw .
various kind of rigging screws are used to set up i.e. to
adjust for length or tension, any rigging equipment.

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 Day 10/11

Hull Fabrication
Purpose of training- the purpose of this training is to
understand the work flow and operation procedures of
production process of hull fabrication.
Hull fabrication is done in the new building shed of the Tebma
shipyard malpe.

List of Document and Drawing require in hull fabrication

1. Set of production drawing issued by drawing department
of TSL.
2. Project Schedules.
3. Technical Specification.
4. TSL Quality standards for hull.
5. Welding Schedule Given By Welding Department.
6. Approved welding procedure specification WPS copy
from QA/QC.
7. Approved Quality Assurance Plane (QAP) copy from
QA/QC.
8. Welder Qualification copy from QC/QA.
9. Material test Certificate.
Tools Used in Shifting of Hull Blocks.

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 1. EOT in New Building Shed.
2. Hydraulic Jacks.
3. Hydraulic jacks for push and pull.
4. Bottle screw and turn buckle.
5. Chain locks

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 Hull Block Fabrication flow chart
Recipt Of Drwing

Qualification of welder

Verify material grade as per drawing

Nesting Marking and cutting

Pre fabrication of sub assembly

Pre Fabrication Survey

Fabrication Of Hull Block

Block Dry Survey

Grand Assembly

Block Eraction Fit-up

Dry survey of block erection

Non destructive test

Air pressure test/vacuum test

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Pre-fabrication of sub assembly:-
The parts of sub-assemblies as per sub assembly part list
drawing are marked on plate/sections. The marking and
cutting of plates are done as per nesting plan by using CNC
Plasma Cutting Machine in Hungerkatta Yard.
Prefabrication of sub-assemblies are done ensuring
dimension control as per drawing and work instruction
(MPE/HUL/WI/007) and distortion control during various
stages of welding is done as per work instruction
(MPE/HUL/WI/05).

Pre fabrication Survey

Pre Fabrication survey of sub assembly is done to
check the dimension of sub assembly and welding defects
if any
This survey is done as per rule if the classification
society.
It is done By Internal Quality Control Manager.

Fabrication of Hull Block

A. Fabrication of double bottom blocks.
Tebma Follows the Process Of Block Fabrication And
erection
Block Fabrication is done As per block drawing in two
operation as per work instruction MPE/HUL/WI/007

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First align and fit up all sub-assemblies on top of tank top
panel upside down condition on the skid.
Fit up Inspection by QC department as per check list fit up
MPE/QC/F/CLF and dimension report (MPE/QC/F/DR).
After clearance from QC department, Complete the
welding I down hand position as per Welding procedure
Specification WPS., Welding Sequence, Follow the Correct
Welding sequence.
Next turn this tank top assembly and place it on bottom
shell panel, align, fit up and weld.
Rectify weld distortion, angular deformity if any by line
heating and fairing.

B. Fabrication of other blocks including super structure.

All bulkheads are fabricated and welded as sub-assemblies

as per drawing and lifting capacity of the crane.
Align the deck panel on the skid upside down. Fit up all
stiffening members.
Align and fit up all the pre-fabricated bulkheads and
assemblies on top of the deck panel as per drawing.
Fit up Inspection by QC department as per check list fit up
MPE/QC/F/CLF and dimension report (MPE/QC/F/DR).
After clearance from QC department, Complete the
welding I down hand position as per Welding procedure

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 Specification WPS., Welding Sequence, Follow the Correct
Welding sequence.
Rectify weld distortion, angular deformity if any by line
heating and fairing.
Block Dry Survey:-
Dry Survey is first carried by Internal Quality Control
Department
The final survey is carried by Owner and Classification
Society.
Results are recorded as the inspection report.
Grand assembly of blocks:
Small Blocks are joined together aligned, fit up done as a
grand assembly of blocks as per work instruction
This is limited to the capacity of EOT crane in the new
building shed.
Fit up Inspection by QC department as per check list fit up
MPE/QC/F/CLF and dimension report (MPE/QC/F/DR).
After clearance from class, welding carried out as per
approved WPS, welding schedule and follow weld
sequence.
Rectify weld distortion, angular deformity if any by line
heating and fairing.
Erection of hull blocks and grand assembled blocks.

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After dry survey of blocks and grand assembled blocks
erection of hull blocks and grand assembled blocks are
carried out as per drawing.
Block erection sequence is as per block erection schedule
issued by planning dept.
Double bottom unit block is erected first as a keel laying
block.
Then bilge/side shell blocks are positioned, aligned. Fit up
done.
Finally deck units are erected, aligned and strapped to
complete the ring construction.
Erection joints fit up inspection of blocks and grand
assembled blocks are offered to QC/Class/Owner after
verification by production as per check list fit up and
dimension report.
Results are recorded in the inspection report.
After clearance from class, welding carried out as per
approved WPS, welding schedule and follow weld
sequence.
While erection fit up is cleared and welding is progressing,
adjacent blocks are erected and attached to this ring on
forward and aft direction, For stability and maintaining
accuracy in half breadth, height and center line Further
erection should be also Completed ring wise,
Welding is done by using Ceramic backing strip, If
ceramic backing strip is not used then after root run

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 welding of erection joint back gouging and DP test is
carried out,
Subsequently block erection joints fit up and dry survey
inspection is carried out.
Dry Survey of block erection:-
On completion of block erection joints Stiffening members
welding and removal of temporary supports and grinding
dry survey is carried out. Dry survey by visual inspection is
carried out by production department
Results are recorded in the inspection report.

Non Destructive Testing NDT:-

After clearance of dry survey by class NDT of weld Seams
and butts as per class approved NDT plan is carried out.
Weld defects if any found during NDT are rectified and the
weld joint is re checked.
NDT report is submitted to class for review and held with
QC.

Air Pressure testing/Vacuum testing:-

Air pressure testing of all the tanks carried out as per QC
work instruction

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All weld seams and butts of underwater hull tank top
external hull up to
Main deck side shell of sponsoon and all bulkheads
forming watertight boundaries up to main deck are
requirement to be checked.
Vacuum testing is carried for weld seams butts which is a
part of watertight integrity and not covered under APT as
per QC work instruction.
Inspection results are recorded in inspection report.

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 Day 12/13

SOF (structural outfitting)

Definition- Outfitting is the process of installing parts and

various subassemblies (e.g., piping systems, ventilation
equipment, electrical components) on the block prior to joining
the blocks together at erections
Outfitting at each stage of construction is planned to make
the process flow smoothly throughout the shipyard:
Unit outfitting
On-block outfitting
On-board outfitting

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 Unit outfitting
Unit outfitting is the stage where fittings, parts, foundations,
machinery and other outfitting materials are assembled
independent of the hull block.
Unit outfitting allows workers to assemble shipboard
components and systems on the ground, where they have
easy access to the machinery and workshops.
Outfitting materials come in varying sizes, shapes and
complexities. In some cases, units are as simple as a fan
motor connected to a plenum and coil. Complex outfitting
are mainly composed of components in machinery spaces,
boilers, pump rooms and other complex areas of the ship.
Unit outfitting involves assembling piping spools and other
components together, then connecting the components into
units.
Outfitting units on the ground increases safety and
efficiency by reducing the work hours that would otherwise
be allocated to on block or on-board work in more confined
spaces where conditions are more difficult.

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 On-block outfitting
On-block outfitting is the stage of construction where
most of the outfitting material is installed onto the
blocks.
Outfitting materials installed on block consist of
ventilation systems, piping systems, doors, lights,
ladders, railings, electrical assemblies and so on.
Many units are also installed at the on block stage.
Throughout the on-block outfitting stage, the block
can be lifted, rotated and moved to efficiently facilitate
installing outfitting materials on the ceilings, walls and
floors.
All of the shops and services in the shipyard must be
in communication at the on-block stage to ensure that
materials are installed at the right time and place.

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 On-board outfitting
On-board outfitting is performed after the blocks are
lifted onto the ship under construction (i.e., after
erection). At this time, the ship is either at a building
position (building ways or building dock), or the ship
could be berthed at pier side.
The blocks are already outfitted to a large extent,
although much more work is still needed before the
ship is ready to operate. Onboard outfitting involves
the process of installing large units and blocks on
board the ship. Installation includes lifting the large
blocks and units on board the new ship and welding
or bolting them into place. On-board outfitting also
involves connecting the shipboard systems together
(i.e., piping system, ventilation system and electrical
system). All of the wiring systems are pulled
throughout the ship at the on-board stage.

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 List of Post outfitting Items
Mast and Sampson post erection
Cranes and derricks
Doors, hatches, ramp doors
Ventilation refrigeration, insulation
Firefighting equipment
Lifesaving equipment
Steps, ladders, lifts
Guard rails
Flooring
Interiors, furnishing Galley equipments
Bathrooms, toilets
Navigation, communication equipment
Engine control
Lighting

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 Day 13/14
Painting

Surface preparation of metals for painting

Factors affecting performance of paint
Surface contamination including salts, oils, grease, drilling
and cutting compounds
Rust and mill scale
Surface profile
Objective of surface preparation
The main objective of surface preparation is to ensure that all
such contamination is removed to reduce the possibility of
initiating corrosion so that a surface profile is created that allows
satisfactory adhesion of the coating to be applied.
Methods of surface preparation
Degreasing:
It is essential to remove all soluble salts, oil, grease, drilling
and cutting compounds and other surface contaminants prior
to further surface preparation or painting of the steel.
The most common method is by solvent washing, followed
by wiping dry with clean rags. The wiping clean is critical,
because if this is not carried out thoroughly the result of
solvent washing will simply spread the contamination over
a wider area.

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 Proprietary emulsions, degreasing compounds and steam
cleaning are also commonly used.

Hand tool cleaning:

Loosely adhering mill scale, rust and old paint coatings
may be removed from steel by hand wire brushing,
sanding, scraping and chipping.
However, these methods are incomplete, and always leave
a layer of tightly adhering rust on the steel surface.

Power tool cleaning:

Generally more effective and less laborious than hand tool
cleaning for the removal of loosely adhering mill scale,
paint and rust.
However, power tool cleaning will not remove tightly
adhering rust and mill scale.
Power wire brushes, impact tools such as needle guns,
grinders and sanders are all commonly used.

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 Care should be taken, particularly with power wire brushes,
not to polish the metal surface as this will reduce the key
for the subsequent paint coating.

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Blast cleaning:
By far the most effective method for removal of millscale,
rust and old coatings, using abrasives such as sand, grit or
shot under high pressure.
The grade of blasting suitable for a particular coating
specification depends on a number of factors, the most
important of which is the type of coating system selected.
Prior to blasting, steelwork should be degreased and all
weld spatter removed. If salt, grease or oil is present on the
surface it will appear to be removed by the blasting
process, but this is not the case. Although not visible, the
contamination will still be present as a thin layer and will
affect the adhesion of subsequent coatings
Weld seams, metal slivers and sharp edges revealed by the
blasting process should be ground down, as paint coatings
tend to run away from sharp edges, resulting in thin
coatings and reduced protection.
Weld spatter is almost impossible to coat evenly, in
addition to often being loosely adherent, and it is a
common cause of premature coating failure.
The surface profile obtained during blasting is important,
and will depend on the abrasive used, the air pressure and
the technique of blasting. Too low a profile may not
provide a sufficient key for coating, while too high a profile
may result in uneven coverage of high, sharp peaks
possibly leading to premature coating failure, particularly
for thin film coatings such as blast primers

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The following table gives a brief guide to typical roughness
profiles obtained using various types of abrasive:

HYDROBLASTING (hydro jetting)

Hydro blasting is a technique for cleaning surfaces, which
relies entirely on the energy of water striking a surface to
achieve its cleaning effect. Abrasives are NOT used in
hydro blasting systems.
Consequently the problems caused by dust pollution and by
the disposal of spent abrasives are eliminated.
Two different hydro blasting operating pressures are
commonly encountered:
High pressure hydro blasting, operating at pressures between 680
bar (10000 psi.) and 1,700 bar (25000 psi.).
Ultra high pressure hydro blasting, operating at pressures above
1700 bar (25000 psi.).

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 The steel surfaces produced by hydro blasting do NOT look
the same as those produced by dry abrasive blasting, or
slurry lasting.
This is because water on its own cannot cut, or deform steel
in the same way as abrasives. Hydro blasted surfaces
therefore tend to look dull, even before they flash rust.
Hand wire or bristle brushing to remove heavy flash rusting
may be acceptable for small areas, but will generally
produce an inadequate surface. Mechanical rotary wire
brushing can however produce acceptable surfaces for large
areas.
When large areas are hydro blasted, flash rusting which
obscures the original blast standard may occur, before an
inspection can be carried out.
Establishing the required standard by blasting a small test
area prior to the main blast may help, providing the rest of
the job is blasted to the same standard.
Methods for ensuring the rest of the job is blasted to the
same standard will vary from project to project.

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Nonferrous metal, Aluminum:
The surface should be clean, dry and greasefree (see under
SteelDegreasing). If any corrosion salts are present they
should be removed by lightly abrading.
Before painting, apply one thin coat of a proprietary acid
etch primer to provide a key for further coats. If this
reaction does not take place, adhesion will be found to be
poor. The surface should be scraped clean, and treated with
a proprietary aluminum pretreatment solution, and the acid
etch primer then reapplied

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International Standards of surface preparation
Followed by International ISO 85011 and Swedish SIS 05 5900

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 Painting

No paint can perform all the desired functions

Separate paint scheme required for underwater (u/w) hull,
boot top area, above water hull, deck, hold, tanks, bilges,
compartment, superstructure, Engine Room etc.

Paint areas of external hull

Underwater hull should resist corrosion and fouling
Boot top is susceptible to heavy corrosion, fouling and
aberration
Above water hull should resist corrosion, and aberration

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 Function of paint on ship structure
Each type of paint applied to specific areas on ships have
a different role to play.
Almost all paints on ship structure should provide
anticorrosive protection.
Underwater paints should provide anticorrosive as well as
anti-fouling protection.
Above water paints should provide anticorrosive as well
should be visually appealing.
Paints of Engine Rooms should provide resistance to
corrosion, heat and oil.
Deck paints should resist corrosion and well as be non-
skidding.
Flight deck paints should have high impact resistance and
have high friction.
All external paints should resist effect of suns rays.
External paints of warships should be radar absorbent type.

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 Conditions during paint application

The most important factors are to consider the

condition of the substrate, the surface temperature, and
the atmospheric conditions at the time of painting.
Painting should not be undertaken
When the air temperature falls below the lower drying or
curing limit of the coating
As a guideline surface temperature should be 3 deg. Above
due point and RH<85%
During fog or mist conditions or when rain or snow is
imminent
When the surface to be painted is wet with condensation
or when condensation can occur during the initial drying
period of the paint

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 Components of a paint scheme
Primer: This is the layer that adheres to the substrate. It
is most important that the primer is applied with great
care as it has a definite effect on the overall life of the
paint scheme.

Anticorrosive paint: The primary aim is to prevent the

corrosion of the substrate. Anticorrosive properties are
obtained by barrier protection, which means that the water
vapour transmission of the system should be very low.
Polyurethene (PU) or Coal Tar Epoxy (CTE) were very
popular. Several countries have imposed ban on these now.
Vinyl or Chlorinated rubber paints are also used.

Tie coat: It is an intermediate paint layer to can ensure

adhesion of two otherwise incompatible paint types

Antifouling paints: Aim is to prevent marine organisms

to attach themselves to the hull. Copper and Tri-butyl Tin
paints were used. By regulation Tin and Copper Free
paints are to be used.
Antifouling paint, being the outermost layer of the u/w hull
paint scheme influences the skin friction of the hull.
SPC (Self polishing co-polymer) prevents marine growth as
well as ensure a smooth hull surface by wearing off with
the water flow, leaving a smooth surface at all times.

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 Methods of paint application
Brush
For small areas
For decorative parts
Slow
Roller application
Faster than brush application
Thickness control difficult
Air spray (conventional)
Paint atomized by low pressure air stream
Paint introduced to air stream under suction or gravity
Simple and inexpensive equipment
High build paints are to be thinned
High loss of paint
Air spray (pressure pot)
Paint introduced into air stream under pressure
Better performance than conventional air spray
Airless spray
Atomization of paint achieved by high hydraulic pressure
High build paint application possible
Low loss of paint
Costlier equipment

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 Components of a paint scheme

Nonskid paints used on decks have sand or similar particles

embedded in it to increase friction.
Typical u/w paint scheme

Surface preparation by blasting to recommended standard

Three coats of anti-corrosive

alternate colours.

Two coat of anti-fouling alternate

colours.

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 Machinery
Purpose of training- To Understand all Machinery Fitted in
the ship onboard and the procedure of the installation and
commissioning of main engine and other machineries
Instructor- Mr. Arvind/Mr. Sachin
Introduction to Machinery installed in Yard-158
Main Engine-An engine room will usually contain 02
engines, either diesel or heavy fuel. The engines are used to
provide mechanical power for the propulsion through
propeller. The engine use in YARD-158 are manufacture
by YANMAR having power 1180 KW. The driven Rpm Of
the engine is 900 RPM.

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 Propeller- A propeller is need to move ship and turn from
one place to other through thrust. A thrust is creating
according pitch position of the propeller.
A propeller that turns clockwise to produce forward thrust,
when viewed from aft, is called right-handed. One that turns
anticlockwise is said to be left-handed
YARD- 158 contains SRP (Steerable rudder propeller) and
YARD-159 equipped with Voith propulsion system.

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Engine Room Auxiliaries
An engine room is where the main engine, generators,
compressors, pumps, fuel/lubrication oil purifiers and other
major machinery are located. It is sometimes referred to as the
"machinery space" Auxiliary generator
Air Compressor
FO separator
Fi-Fi pump
Lube oil cooler
Hydrophore System
Sewage Treatment plant
Bilge purifier
Harbor Diesel Generator
Fresh Water generator
Main Generators
Emergency generator
Fuel Transfer pump
Sea water pump
Other pumps and equipments

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Deck Machinery & Cargo Handling
To raise/ lower ships boats (for life safety and harbour use),
winches are provided. To raise/lower ships anchor, capstans or
windlass are provided. For cargo handling, cranes are provided.
All these equipment are electric or electro hydraulic.
Crane
Mooring/Towing winch
Life raft
Life Boat
Rope Reel Winch
Windlass
Derrick
Main Fi Fi Pump on the top of wheel house
Capstan
Anchor
Anchor handling unit

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 STP (Sewage Treatment Plant)
A sewage treatment plant for use aboard ship comprises a vacuum
assisted fresh water flush system delivering sewage to a collection
tank for treatment. Disposal of sewage from ships alongside or in
coastal waters is a considerable current problem. Some harbours
have sewage collection facilities, however, these are not always
available. Thus sewage collection and treatment plant is required
where port facilities are unavailable.

Sewage treatment plant

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Installation of main engine
Engine is specified by the owner and some time by shipyard
and owner both.
Shipyard placed an order for the new engine to the engine
manufacturing company.
Engine manufacturer send a copy of the engine foundation
drawing to the shipyard
Shipyard makes a foundation of the engine before the engine
receipt.
The engine receipt in The shipyard with the copy of
registration
Shipyard Done a trail of engine in shop in presence of OEM
The machinery department take the engine to the engine room
of a new build ship by means of crane and other machinery.
Put the engine on the main engine foundation and start
alignment of the engine with respect to the propeller shaft
After the alignment the engine is bolted down to the
foundation.
When installation is complete the trail of the engine is done in
presence of internal quality control. If quality control found
any fault or excessive noise and vibration the It need to be
corrected.
Then a trial is done on front of class surveyor and owner
representive.
The Final Trail is done on the time of Final Sea trail.
Same Procedure is followed for all other machinery
installation

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 Accommodation
Purpose of the training-To understand the procedure of
construction of the accommodation space in a ship with full
human comfort
Training instructor- Mr. Nidhin Das
Definition- Accommodation space in a ship must have adequate
ventilation and supply of the air and it is free from the outside
condition
Insulation in Accommodation-
There are three type of insulation used in accommodation
1. Fire Insulation.
2. Noise Insulation.
3. Vibration Insulation.
Fire insulation:
There are four Class of Fire insulation used in ship
A60
A30
A15
A0
A60- It is mostly used in high fire risk areas. It can hold the
fire for 60 Minutes
For bulkhead there are Two Layers of A60 Of thickness
30mm+30mm are used

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A30- It is used in medium fire risk areas. It can hold the fire
for 30 minutes.
It is mostly in celling of the accommodation room. There is a
layer of class A30 insulation of thickness 45mm is used.
A15 and A0 Is used in low fire risk areas. These are used in a
ship at very low level.
Sound Insulation:
It is used in accommodation space to prevent the noise
disturbance from one compartment to other compartment
It is only used in the compartments where running machinery
having greater noise. So it creates a comfort for a person for
easy to sleep.
It have a sheet of 50mm is fitted with bulkhead shell.
Thermal insulation:
50mm thickness Sheet used with celling.
100mm Thickness Sheet Used with Bulkhead

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 Procedure to install the Insulation
On the time of fabrication the insulation holding pins are
welded with the bulkhead by using stud welding
Insulation holding pins have a distance of 300mm from
each other.
Check all the pipelines are passing for the area
Take clearance from all departments for remaining hot
work or work with bulkhead.
If Any work is pending then no insulation work can be
done
Check final paint of the insulation area bulkhead by pain
survey for DFT.
Put the insulation on the bulkhead on the insulation
holding pins.
Protect the Insulation by using Aluminum Foil.
Tight It with the mesh.
Post insulation survey is done by IQC.

Paneling
Panels are used in Accommodation space for giving the shape
to the room.
There are three type of panels used in ship
1. Wall Panels:
It is used with the bulkhead side
50mm thickness panel used with partition bulkhead.

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 25mm thickness panel used with bulkhead side.

Top Profile- It is used in top to lock the wall panel.

Bottom Profile- It is used in bottom to lock to lock
the wall panel.

2. Stainless Steel Panels:

It is only used in galley of the ship.
3. Celling panels:
It is used in the celling of the room.
Furniture used in accommodation space
Wardrobe
Double bed decker
Tea table
Table with wardrobe
Sofa
2 chair
Book self

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 Day12/22/23
Electrical
Purpose of training- To understand the all equipment and wiring
and panels fitted in a ship.
Training instructor- Mr. Vijay
He started me with the basics of electrical and electronics:-
The power generation and distribution onboard ship.
Various control systems
Various signaling system
He then explained me about installation of panels, cables,
MCBS, generation units and electrical accessories.
Then he send me to Mr. Guru Prasad SP who was in the wheel
house of the vessel.
He asked me some concepts about the electrical equipments
and systems and then explained them in detail:-
- Power Distribution system (PDS)
Five power generating units are on the vessel i.e. 2
auxiliary generators, 2 shaft generators and 1
emergency generator.
Power is distributed to various systems using
MSBS, LDBS, EDBS etc.

- Dynamic Positioning system (DP)

It is an integrated automation system in which all the
systems onboard ship are combined together which
will work simultaneously on the basis of feedback
from a reference unit.

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Used to place the ship in a particular pre-defined position with
the help of GPS, side thrusters, propellers, steering gear, anti-
heeling system etc. keeping in mind the reference line of the
voyage of the ship and alterations occurred due to winds and
wave action

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 Day 24/25
Piping
Purpose of the training- to understand the piping system
used in ship and all the valve and pumps used in ship
Training instructor- Mr. A.R Ravi/ Mr. Sarath P.V

Pipe: - A hollow cylinder of metal used for the convenience

of water, gas, steam, petroleum etc.
Purpose of pumping and piping arrangement:-
- Cargo loading and discharging.
- Tank washing
- Bilge drainage
- Blasting
- General services.

Piping consist of :-
- Piping
- Valves
- Pumps
- Flanges/Couplings
- Elbows
- Sleeves
- Expansion joints
- Reducer
- Gasket etc.

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 Piping
Copper-Nickel-Iron alloy piping is used for the piping of
the salt water main and its branches, sanitary system, hull
and fire, fire and bilge, overboard discharge from
water/fuel displacement system, salt water supply to and
overboard discharges from bathroom ejectors, bathroom
drains.
Galvanized mild steel piping is used for all suctions to
compartments, overboard discharge of salvage pump
system, suction pipes within fresh water storage tanks, oil-
fuel residue suctions.
Steel pipes below 3/2 inch bore are connected by screwed
sleeves and large pipes by flanges welded to the pipes.
No non-ferrous piping is introduced into any part of the
ship so low as to come in contact with the bilge water.
Pipes connected to the other bottom or to protective
bulkheads are worked with generous bends or alternatively
with weaken shearing joints, so that they cannot act as
struts in the event of deflection of the structure
Air and Sounding pipes
Air pipes are provided for all tanks to prevent the air being
trapped under pressure in the tank when it is filled, or a
vacuum being created when it is emptied. The air pipes may
be fitted at the opposite end if the tank to the filling pipe
and/or at the highest point of the tank.
From oil fuel and cargo oil tanks, cofferdams, and all tanks
that can be pumped up, the air pipes are led to an open deck,

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 in a position where no danger will result from leaking oil
or vapors.

Sounding pipes are provided to all tanks and compartments

not readily accessible and are located so that soundings are
taken in the vicinity of the suctions, i.e. at the lowest point
of the tank.
Each sounding pipe is made as straight as possible and is
lead above the bulkhead, deck except in some machinery
spaces where this might not be practicable.
Valves
- Seacock
- Screw down valve
- Screw down non return valve
- Screw down non return and flood valve
- Butterfly valve
- Screw down and non-return drain valve
- Reducing valve

Manifold
A manifold is a wide and/or bigger pipe or channel, into
which smaller pipes/channels lead.
Types of manifold:-
I. Exhaust manifold
It is used to collect the exhaust gases from multiple
cylinders into one pipe.
II. Hydraulic manifold
It is used to regulate the fluid flow in a hydraulic
system, thus controlling the transfer of power between
actuator and pumps.
III. Inlet manifold

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 It is used to supply the air or fuel/air mixtures to the
cylinders.
IV. Manifold scuba
In a scuba set it connects 2 or more diving cylinders.

Valve actuator
A valve actuator is a mechanism of opening and closing the
valve.
Manually-operated valve require someone in attendance to
adjust them using a direct or geared mechanism attached to
the valve stem.
Power operated actuators, using gas pressure, hydraulic
pressure, electricity allow a valve to be adjusted remotely
or allow rapid operation of large valves.
Power operated valve actuators may be the final elements
of an automatic control loop which automatically regulates
some flow, level or other process.

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 Day 26
Quality control
Purpose of the training- to understand the quality control
system used in shipyard.
Training instructor- Mr. Praveen K/Mr. Srinivasn K/Mr.
Ganesh Samaga

First of all he explained me the objective of quality control:

To meet the quality requirement of classification
societies.
To ensure safety and reliability of ships during
construction and during service.
To minimize defects and reworks during production
process.
To meet production within reasonable variation.
To ensure prompt and effective response of action and
receipt customer complaints
From the time of plates received at the yard till the delivery
of the ship QC plays an important role at each step. For
e.g.:-
Material inspection
Block fabrication
Block erection
Installation of machineries
Piping
Painting
Accommodation etc.

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 I was then told to go with Linesh sir who was the quality
control of machinery department.
He said that the commissioning and trials of the machinery
is checked by the QC but when trials will be commenced
QC of the shipyard, class surveyor and owners
representative will be present.
During survey if any deflection occurs it should be within
permissible limit may be upto 2-3mm. After then only QC,
owner and class surveyor signs on the satisfactory survey
sheet of that particular department.
There are two types of trials being commenced for a ship:
I. Dock trials
The trials which can be done while the ship is at the
dock for e.g. running the Main DG set, pumps,
compressors, emergency generators etc. are known as
dock trials.
II. Sea trials
The trials which need to be done at sea like
Speed trials
Endurance trials
Crash trials
Astern trials
Maneuvering trials
Anchorage trials
After that sir gave an example of ballast tank trials
According to the rule book the whole procedures will be
followed.

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 The ballast pump will be started and the valve present in
the manifold on the discharging line to the particular tank
will be opened while other will be closed.
All the ballast tank

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 Day-27

Materials
Purpose of the training- to understand the activities in
procurement and material inspection.
Training instructor- Mr. Maheshwer S/ Mr. Pawan S

He explained me the procedure followed by material

department from the time of receiving material from the supplier
to the delivery of the same to the production department:-
Project planning department will send purchase order to the
supplier according to the design and production requirements.
After the material is released from the supplier it arrives to
the material department.
Firstly, gate entry pass is made by the security at the gate
after verification of address on delivery challan.
Then, material comes to the material inward section.
Physical inspection of the logs will be done to check the:-
- Quantity
- Bill
- Delivery challan
- Tested certificates
All provided by the supplier.

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 During physical inspection we will compare the PRQ
(Purchase Requirement) with the quantity received.
If any difference is there, we will make a material discrepancy
note (MDN).
If no discrepancy, inform QC for quality inspection.
After inspection, QC gives a quality inspection report.
On the basis of it, we make Goods Receipt Note (GRN).
GRN bill is then handed over to the accounts department.

In case any discrepancy in GRN and bill provided by the

supplier we will make a debit note (DN).

Material is stored at designated location according to:-

- Nature i.e. heavy/medium/light
- Groups with necessary preservation
- Space availability and storage facility.

Storage and preservation

To maintain the quality of the material, stores does the
preservation activity.
For e.g.:-
i. Rust and corrosion prevention of machinery parts apply
light coat of grease or rust preventive oil.
ii. Rubber seal is given to prevent the moisture.
iii. Cushioning material is inserted to prevent them from
getting dents, indentations etc.
iv. Shelter is provided from the sunlight and rain.
v. In some areas, A.C. rooms are also introduced so as to
maintain minimum temperature which will procure electrical
and electronic equipments paints etc.

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 Material delivery from material department to production
department:-
Shop order will be given by the project planning
department to the material department and in consolation with
the production department.
Material issue slip will be made and passed to the material
department through production department.
Dispatch of material will be done from the material
outward section and an out-pass is made at the gate.
This out-pass can be in two-ways:-
i. Returnable basis
ii. Non-returnable basis

Cannibalization:- In few cases, production department

requests material from one project due to design
change/modification/defects noticed during working etc.
to meet the production schedule as alternative material
from OEM having a long lead time.

For the delivery of the final product, the approvals

and permissions are obtained by head stores from
statutory agencies.

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 CONCLUSION

As a student of HIND INSTITUTE OF NAUTICAL SCIENCE AND

ENGINEERING, I have to undergo the industrial training for one month from 29
August to 29 Sept. 2016. I had chosen to do my practical training in one of the
famous SHIPYARD TEBMA SHIPYARD LIMITED MALPE in India.

As A student of B.sc Shipbuilding and repair course, I have been briefed and
introduced to current and most used shipbuilding techniques in the industry.

Although I was not familiar with the practical knowledge, I dont know how the ship
exactly made.

I am glad that I had chosen TEBMA SHIPYARDS LIMITED as my industrial

shipyard in here, I had finally understood every process how a ship is build, I was
given the opportunity to do the simple task such as ship design welding cutting and
electrical line looping and many more. During the practical I had gain lot of
knowledge as well as working experience.

The opportunity offered from this field increasing. By undergoing practical in

shipbuilding I had been exposed to the shipbuilding working environment, which
may help me in my future career. During the period of practical, I learned to be
discipline and punctual.

I have to go to work on time and pass up the task given me on time as the date stated
by engineers

As a conclusion, I gained I lot of knowledge from this industrial training. Therefore

all the student from HIND INSTITUTE OF NAUTICAL SCIENCE AND
ENGINEERING should undergo industrial training. So the student can gain much
more experience in shipbuilding field

Guddu Singh