Dasarapalli Harshavardhan Reddy · pg. - 4 - Master Thesis developed at “Dunarea de Jos” University of Galati, Romania Abstract Due to the high labour costs and the stiff competition

Interaction of design-production stages in

hull and piping shipbuilding works.

Dasarapalli Harshavardhan Reddy

Master Thesis

Presented in partial fulfilment

Of the requirements for the double degree:

“Advanced Master in Naval Architecture” conferred by University of Liege

"Master of Sciences in Applied Mechanics, specialization in Hydrodynamics, Energetics and Propulsion” conferred by Ecole Centrale de Nantes

Developed at "Dunarea de Jos" University of Galati in the framework of the

“EMSHIP”

Erasmus Mundus Master Course in “Integrated Advanced Ship Design”

Ref. 159652-1-2009-1-BE-ERA MUNDUS-EMMC

Supervisor: Prof.Ionas Ovidiu, "Dunarea de Jos" University of Galati.

Reviewer: Prof. Tadeusz Graczyk, West Pomeranian University, Szczecin.

Galati, February 2015

DASARAPALLI HARSHA VARDHAN REDDY

pg. - 2 - Master Thesis developed at “Dunarea de Jos” University of Galati, Romania

This page is intentionally left blank.

INTERACTION OF DESIGN-PRODUCTION STAGES IN HULL AND PIPING SHIPBUILDING

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“EMSHIP” Erasmus Mundus Master, period of study September 2013 – February 2015

pg. - 3 -

DECLARATION OF AUTHORSHIP

I declare that this thesis and the work presented in it are my own and has been generated by

me as the result of my own original research.

Where I have consulted the published work of others, this is always clearly attributed.

Where I have quoted from the work of others, the source is always given. With the exception

of such quotations, this thesis is entirely my own work.

I have acknowledged all main sources of help.

Where the thesis is based on work done by myself jointly with others, I have made clear

exactly what was done by others and what I have contributed myself.

This thesis contains no material that has been submitted previously, in whole or in part, for

the award of any other academic degree or diploma.

I cede copyright of the thesis in favour of the “Dunarea de Jos University of Galati”,

Romania.

Date: - 24/01/15. Signature.



Abstract

Due to the high labour costs and the stiff competition from the east, the shipyards and the

design offices are looking for a viable solution to keep the costs competitive and also at the

same time not compromising the quality of the build. A good suitable option is to build a

bridge between design offices and shipyards to understand each other better.

Allocation of more time on the detailed information and production information stages in

the design offices help the shipyard designers and workforce to simplify the production of

the ship as the information is easier to understand, thus reducing the time required at the

shipyard for the ship building. In turn reduction of the man hours required at shipbuilding

and also employing low skilled labour in turn saving a lot of money and improve the activity

on the whole. The saving of the raw material by optimisation the cutting plates using Auto

nesting is also investigated.

The summary of the thesis is to identify the cost estimates by using man hours at the various

stages of the detailed and production design stages and also optimising the material costs.

Thus providing a feast able solution for the design offices to do adapt this integration of

detailed design stage and the production information stages to the shipyards.

In the thesis due to the complexity of the ship, the analysis carried out is for a single

compartment of a ship and limited to the hull and piping works.

The thesis is carried out at a design office called S.D.G (Ship Design Group) located at

Galati, Romania and also at Damen Shipyard, Galati, Romania.


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pg. - 5 -

ACKNOWLEDGMENT

The author would like to acknowledge the following honourable dignitaries and professors

for their benevolent help towards the success of the thesis

1. Professor Philippe Rigo (ULG, Belgium.)

2. Professor Leonard Domnisoru (UGAL, Romania.)

3. Professor Jean David Caprace (UFRJ, Brazil.)

4. Mr.Ionas Ovidiu (Technical director at S.D.G, Romania.)

5. Mr.Stefan Giuglea (Deputy Managing Director at S.D.G, Romania.)

6. Mr.Giani Toma (Project manager at S.D.G Romania.)

7. Mr.Gabriel Chiriac (Project Manager at S.D.G Romania.)

8. Miss.Raluca Enache (Engineer at S.D.G Romania.)

9. Mr.Florin Spataru (Managing Director at Damen Shipyards, Galati.)

I would also like to acknowledge my family, friends and my close friend Laura for their

immense support during my entire tenure of studies.

This thesis was developed in the frame of the European Master Course in “Integrated

Advanced Ship Design” named “EMSHIP” for “European Education in Advanced Ship

Design”, Ref.: 159652-1-2009-1-BE-ERA MUNDUS-EMMC.



Table of Contents

INTRODUCTION ........................................................................................................ - 11 -

Description of the thesis ........................................................................................... - 14 -

SOFTWARE’S DESCRIPTION................................................................................. - 16 -

Introduction .............................................................................................................. - 16 -

Nupas Cadmatic........................................................................................................ - 17 -

Nestix ......................................................................................................................... - 24 -

Aveva hull detailed design ....................................................................................... - 27 -

DETAILED DESIGN AND PRODUCTION INFORMATION .............................. - 32 -

Piping module during this phase ............................................................................. - 33 -

Hull module of this phase......................................................................................... - 55 -

SHIP PRODUCTION AT THE SHIPYARD ............................................................ - 80 -

ECONOMIC ANALYSIS ............................................................................................ - 89 -

CONCLUSIONS .......................................................................................................... - 95 -

REFERENCES ............................................................................................................. - 96 -

APPENDIX ................................................................................................................... - 97 -


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List of Figures

Figure 1 Design spiral (Sourced- Practical Ship Design by D.G.M Watson) ............... - 12 -

Figure 2 various types of ships categorised (Sourced-Practical Ship Design by D.G.M

Watson) .......................................................................................................................... - 13 -

Figure 3 Stages of work at design office ........................................................................ - 14 -

Figure 4 The conventional type of general arrangement design in 2D (Sourced- Nupas

Cadmatic Handbook) ..................................................................................................... - 18 -

Figure 5 Nupas Cadmatic 3D General arrangement Design (Sourced-Nupas Cadmatic

Handbook) ...................................................................................................................... - 18 -

Figure 6 A typical example of a design bench in Nupas cadmatic ................................ - 20 -

Figure 7 Automatic panel and subpanel naming for easier access later ....................... - 20 -

Figure 8 Work bench breakdown tree view ................................................................... - 21 -

Figure 9 A typical 3d work bench sketch which is automatically generated (Sourced-

Nupas Cadmatic Handbook) .......................................................................................... - 21 -

Figure 10 A pyramid of Nupas Cadmatic software ....................................................... - 22 -

Figure 11 Process flow in Nupas Cadmatic package .................................................... - 22 -

Figure 12 2D view of the component designed .............................................................. - 23 -

Figure 13 3d view of the component .............................................................................. - 23 -

Figure 14 the plate selected from the component ready for cutting .............................. - 24 -

Figure 15 Flow diagram where Nestix is used .............................................................. - 25 -

Figure 16 various types of works undertaken by Nestix ................................................ - 26 -

Figure 17 Part of the plate nested using the Nestix software ........................................ - 26 -

Figure 18 the nested part created in Nestix exported to AutoCAD and send to the

shipyards ........................................................................................................................ - 27 -

Figure 19 an Example of an Aveva engine .................................................................... - 28 -

Figure 20 Flow diagram of the Aveva software............................................................. - 28 -

Figure 21 A high quality output can be obtained .......................................................... - 29 -

Figure 22 A section view of a plate with stiffeners in Aveva ......................................... - 29 -

Figure 23 A 3d view of the plate with stiffeners in aveva .............................................. - 30 -



Figure 24 Drawing created by Aveva for the component .............................................. - 30 -

Figure 25 Subchapters involved in the chapter ............................................................. - 32 -

Figure 26 Menu for Selection of drawings .................................................................... - 33 -

Figure 27 Managing of the drawings............................................................................. - 33 -

Figure 28 Creation of the drawing ................................................................................ - 34 -

Figure 29 Application of attributes to the drawing ....................................................... - 35 -

Figure 30 Creation of the title bar ................................................................................. - 35 -

Figure 31 Creation of views for the product .................................................................. - 36 -

Figure 32 Assign Views to Page .................................................................................... - 36 -

Figure 33 Annotation of the Views ................................................................................. - 37 -

Figure 34 Creation of the labels .................................................................................... - 38 -

Figure 35 Title box with attributes ................................................................................. - 38 -

Figure 36 Pictogram and listings obtained ................................................................... - 39 -

Figure 37 exporting the drawing ................................................................................... - 39 -

Figure 38 Identification of the menu .............................................................................. - 40 -

Figure 39 Piping Isometric Menu .................................................................................. - 40 -

Figure 40 Selection of system from Menu ...................................................................... - 41 -

Figure 41 Groups and piping isometrics ....................................................................... - 41 -

Figure 42 Creation of piping isometric menu ................................................................ - 42 -

Figure 43 viewing the pipe created ................................................................................ - 42 -

Figure 44 Creation of iso view for the pipe created ...................................................... - 43 -

Figure 45 Pictogram of the pipe isometrics ................................................................... - 43 -

Figure 46 View of the pipe isometrics on the sheet ....................................................... - 44 -

Figure 47 Drawings for the vessels compartment (Top View) ...................................... - 45 -

Figure 48 piping layout from the side view ................................................................... - 45 -

Figure 49 Foundation of the marine machinery ............................................................ - 46 -

Figure 50 Side view from the aft of the ship .................................................................. - 46 -

Figure 51 Part numbering to the final design ................................................................ - 46 -

Figure 52 Final details of the particular component ..................................................... - 47 -

Figure 53 Pipe isometric view of the compartment ....................................................... - 47 -

Figure 54 Schematic of the pipes with the system.......................................................... - 48 -

Figure 55 Spool drawing ............................................................................................... - 48 -

Figure 56 Continuous spool drawing ............................................................................ - 49 -

Figure 57 Bill of materials ............................................................................................. - 49 -


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Figure 58 Description of the compartment .................................................................... - 50 -

Figure 59 Iso Sketch Checklist ....................................................................................... - 50 -

Figure 60 Piping Layout during design ......................................................................... - 51 -

Figure 61 3D model Engine room Layout ..................................................................... - 52 -

Figure 62 Service spacing allowances ........................................................................... - 52 -

Figure 63 3d model showing the service space valve spacing ....................................... - 53 -

Figure 64 Pipe modification before the optimisation .................................................... - 53 -

Figure 65 Pipe modification after the optimisation. ...................................................... - 54 -

Figure 66 Selection of the project to be used. ................................................................ - 55 -

Figure 67 Position of the particular part in the work space.......................................... - 56 -

Figure 68 Aft view of the section in 2d model ................................................................ - 58 -

Figure 69 3d model of the section of the hull ................................................................. - 58 -

Figure 70 Logistics popup box ....................................................................................... - 60 -

Figure 71 Part List ......................................................................................................... - 61 -

Figure 72 Selection Criteria for the toolbar to open ..................................................... - 61 -

Figure 73 Selection of the parts in a particular panel of a block. ................................. - 62 -

Figure 74 Cam Toolbar ................................................................................................. - 63 -

Figure 75 Selection Criterion for a block using CAM toolbar ...................................... - 63 -

Figure 76 Part coding toolbar ....................................................................................... - 64 -

Figure 77 A chart of the coded components .................................................................. - 64 -

Figure 78 Selection of the report to be made ................................................................. - 65 -

Figure 79 Verification of the Cam Data ........................................................................ - 65 -

Figure 80 A typical drawing of the structure in assembly drawings ............................. - 67 -

Figure 81 List of Materials. ........................................................................................... - 68 -

Figure 82 Profiles being allocated on the plate ............................................................. - 69 -

Figure 83 Numbering of the profiles and components................................................... - 69 -

Figure 84 A typical 2D drawings of the panel ............................................................... - 70 -

Figure 85 Panel sketches sequencing ............................................................................ - 70 -

Figure 86 Additional Sketches with building sequence ................................................. - 71 -

Figure 87 Auto nesting software user interface ............................................................. - 72 -

Figure 88 Information regarding the parts in the operation ......................................... - 73 -

Figure 89 Selection of the DXF files for the profiles and panels ................................... - 74 -

Figure 90 Files to be placed .......................................................................................... - 74 -



Figure 91 Plate Dimensions set forth in terms of Length, Breadth and Height ............ - 75 -

Figure 92 Nesting Scenario with constrains set forth .................................................... - 75 -

Figure 93 Parts being arranged for nesting .................................................................. - 76 -

Figure 94 Report generated from Auto nesting ............................................................. - 76 -

Figure 95 Weight Specifications of the plate ................................................................. - 77 -

Figure 96 nesting document ........................................................................................... - 77 -

Figure 97 Coded information......................................................................................... - 79 -

Figure 98 measurement of the part using DCP100 tool ................................................ - 80 -

Figure 99 Simulation of the DCP 100 ............................................................................ - 81 -

Figure 100 Flow Chart of the process (Sourced- Damen Shipyards, Galati) ............... - 83 -

Figure 101 LOT (Sourced - Damen Shipyards, Galati .................................................. - 84 -

Figure 102 Job preparation layout (Sourced - Damen Yards, Galati) .......................... - 85 -

Figure 103 Building strategy with information on placement of blocks (Sourced from

Damen Shipyards, Galati) .............................................................................................. - 86 -

Figure 104 Welding procedure specifications (Sourced from Damen yard, Galati). .... - 87 -

Figure 105 Remarks section of the job description department. (Sourced - Damen

Shipyards, Galati) .......................................................................................................... - 88 -

Figure 106 Automated Nesting ...................................................................................... - 92 -

Figure 107 Automated Manual nesting.......................................................................... - 92 -


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INTRODUCTION

Economy plays a vital role in the trade for the buying and the selling of the ships. The

concept of the owner is to buy the ship which provides the best possible returns for the

investment produced and also the concurrent costs like running costs, maintenance and etc.

Therefore the final design made should be taken into account the present economic

situations also with the future predictions and the service life of the ship.

Prediction of the parameters is carried out by inputting a large number of assumed and

detailed values into the system and finding a feast able solutions to come up with.

Preparation of the design

The design of the ship involves in 3 stages primarily the conceptual design, the preliminary

design of the predictive design and the contract design.

These stages are developed using the design spiral which indicates the given objectives of

the design, the designer works towards the best solution adjusting and balancing the

interrelated parameters as he proceeds.

The conceptual design is based on the objectives created initially by the designer and at this

stage emphasis is more on the requirements of the owner and how effective is it to build it

by the designer. The concept of economic criteria is also regarded in this zone as the

profitability is the key issue rather than building the best of the best designs. However this

may be an exception in cases like the yachts and pleasure crafts where the owner emphasis

more on the design and comfort than the mere profits.

The design in this stage is not complete by the post production and the contract design are

estimated in this part which includes the structure, outfit, systems proposed by the owner

with a set of constrains.

The widely used concept is the design spiral which is as follows.



Figure 1 Design spiral (Sourced- Practical Ship Design by D.G.M Watson)

In the initial stages the ship as it is a complex system cannot be predicted 100% thereby the

following things are defined initially.

1. Dimensions

2. Displacement and general arrangement

3. Stability and structure analysis

4. Propulsive characteristics and hull forms.

As we progress further we get into the contract stage where the following types are covered

including

1. Brief description and essential qualities and characteristics of the ship

2. Principal dimensions

3. Deadweight and weight capacities.

4. Speed requirements and quality certificates

5. Accommodation details.

6. Trail conditions, machinery and fittings


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pg. - 13 -

The various types of ships include the

1. Passenger ships

2. Cargo ships

3. Warships

4. Ocean crafts

5. Fishing vessels

6. Offshore oil platforms

7. High speed crafts

Figure 2 various types of ships categorised (Sourced-Practical Ship Design by D.G.M

Watson)



Description of the thesis

The thesis consist of 7 chapters where the first chapter involves in the description of the

thesis and the importance of detailed design and production information stages are

discussed. The second chapter involves the list of the soft wares used in the design of the

package by the design office. The third chapter comprises of the detailed design and

production information stage’s package information which consist of the list of documents

to be submitted, the application of the software in order to produce these documents. In

specifically deals with the hull and the piping part of the design. The fourth chapter involves

in the ship production where the description of the various activities of the shipyard and the

strategy in production of the ship with regards to the information obtained from the design

offices. The fifth chapter involves in the economic analysis where the package of the

detailed and production information stages are analysed and the number of man hours spent

on the each stage is calculated. Basing on the economical pay scales of the country the cost

per man hour is identified and then calculated to obtain the values in Euros to check the

savings. There is also the conclusions to justify the work reports and references in the 6th

and 7th chapters of the thesis respectively.

Figure 3 Stages of work at design office

Requirements

Conceptual designBasic design

Detailed designProduction Information

Shipyard

Ship


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This design diagram shows how the flow of the work in the design office and shipyard takes

shape to design the final ship.

The first 5 stages from Requirements to the production information is done in the design

office and the designed product is send to the ship yard for the final production of the ship

as per the designs provided by the office.

The scope of the thesis includes the study of the documents needed for the production

information and detailed information stages to be required by the shipyards and calculation

of the amount of man hours required for the final design and estimation of the costs during

this stage.

However the thesis is limited to hull and piping works in shipbuilding and design as the

complexity of the ship is large and calculation of the work for the entire ship is very time

consuming and given the limited time in the work, we are restricted to hull and piping only.

Recommendations to the shipyard and offices

Economical attributes

Production information stage

Detailed design stage

Hull and piping works



SOFTWARE’S DESCRIPTION

Introduction

The use of software’s in today’s ship design industry is a boon to all the naval architects

around the world. The present software’s used in the ship design industry provides realistic

and most precise detailing compared to the manual designing of the drawing, making the

engineers to produce near perfected products.

The various softwares used in present industries include a long list of modelling softwares

however the present thesis focuses more on using the industry best software’s like Nupas-

Cadamatic, Nestix and Aveva.

Nupas- Cadmatic is a dual module ship designing software where the Nupas module is used

for ship Hull design and Cadmatic is used for the outfitting module of the ship. They deliver

the packages like Detailed design information and production information packages basing

on the 3D model of the ship.

Nestix is a nesting tool used for the cutting components like plates, structure member parts

and etc. on the sheet of metal. This helps in reduction of wastage of material and proper

usage of the material.

Aveva is an advanced software based on the 3D model designed earlier but helps to provide

higher detailing levels. This software has a lot of modules embedded into its parent software

but for the marine applications the module called Aveva marine is used. There are sub

modules in the Aveva marine module like that of Aveva Hull which is used for the hull

detailing.

The description of the softwares used in the thesis development are given below starting

from Nupas Cadmatic, Auto nesting and Aveva Hull Module respectively.


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pg. - 17 -

The cost of the software has an influence in the strategy of the company.

A software will be viable to the company in terms of the following

1. The productivity of the software must be higher.

2. The man hours spent and the output obtained should be better than the other

software’s used.

3. The initial costs of the software along with the maintenance attribute.

4. Compatibility of the software with other software’s.

In terms of selection of the software the following data are to be kept in mind

1. Initial cost of the software

2. Maintenance cost of the software per year

3. Man hours spend for the particular section of the ship.

4. List of drawings that can be obtained from the software.

Nupas Cadmatic

Nupas- cadmatic is a high level, advanced software’s of ship design used for detailing of

the component introduced in the late 1980’s foreseeing the ever increasing demand of the

simple and effective design software. It offers a high level topological model with rule based

designing, parametric modelling, pipe routing technology, part nesting with auto

completion system making it one of the most effective software’s in the market. Numeriek

Centrum Groningen (NCG) develops and markets NUPAS-CADMATIC 3D ship design

software.

The software called Nupas is used for the design of the hull and the Cadmatic which is also

another software is used for the piping design. The integration of the both software’s into

one package is called the Nupas-cadmatic.

The concept behind this software is to integrate the works into one common platform to

make the work more productive, improvise the efficiency of the design and faster processing

times of the data and also to optimise the work flow in the various design activities in

particular the detail designing stage.



Using this software helps to ensure a higher level of productivity in comprising to the other

types of soft wares available in the market. This offers both client and the user, a better

solution to come with a solution which is cheaper and robust to use. The modules used in

the software are specially tailored to fit the needs in the domain of hull designing and piping

layouts.

Figure 4 The conventional type of general arrangement design in 2D (Sourced- Nupas

Cadmatic Handbook)

Figure 5 Nupas Cadmatic 3D General arrangement Design (Sourced-Nupas Cadmatic

Handbook)


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Main features of this software include

1. Modelling with the use of structured topology

By using this software we can create the planes topologically, thus offering higher flexibility

in modifying the components created earlier. There is a possibility to create multiple grids

in the design along the axis.

2. Calculation of the weights, volumes and other parameters inside the ship

The calculation of the weights of the structures, volumes of the tanks and the cargo holds

and other parameters can be done very fast once the compartment is defined

3. Application of the rules, attributes and properties of the developed components.

The rule based design used in the software allows us to define the components by the rules

where if there is a constraint of using a watertight bulkhead the option is selected and

automatically the software prompts for the use of gallops and the thickness of the tanks.

There is a possibility to optimise the compartment as per the needs automatically. Thereby

making the software semi-automatic.

4. Easier switching interface between 3D and 2D and drawing.

The possibility to switch between interfaces and also generation of the various views

automatically provides the user to have a better understanding of the ship design.

5. Seamless connection to detail design phase

The software uses attribute based designing where the component is defined for the

attributes and makes the work easier to apply for the rule based designing.

6. Ability to export to multiple software’s for easier compatibility

The compatibility of the software to use 3rd party vendors for the design helps the user to

have less difficulty in defining the mesh and creation of the variables in the new software.

As it is a surface based designing software, most of the software’s available today for the

simulation of the design, evacuation trail in case of the emergency and etc. are able to use



the software’s data files for the application.

Figure 6 A typical example of a design bench in Nupas cadmatic

Figure 7 Automatic panel and subpanel naming for easier access later


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Figure 8 Work bench breakdown tree view

Figure 9 A typical 3d work bench sketch which is automatically generated (Sourced-

Nupas Cadmatic Handbook)



Figure 10 A pyramid of Nupas Cadmatic software

Figure 11 Process flow in Nupas Cadmatic package

Nupas Cadmatic

Nupas

(Hull design)

Integration of the

softwares

Cadmatic

(Piping designing)


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pg. - 23 -

The working environment of this software is very stable and has a high GUI interface, the

below design shows a basic idea of the structure of the component designed with detailing

with Nupas cadmatic along with the highlighted part of the component to be nested for

production in the shipyard.

Figure 12 2D view of the component designed

Figure 13 3d view of the component

The highlighted part in white is also nested using Nupas cadmatic.



Figure 14 the plate selected from the component ready for cutting

Nestix

The Nestix software uses the concept of nesting of the sheet of metal. Nesting refers to the

process of laying out cutting patterns to minimise the raw material waste.

The main features of nesting process in metal cutting industry is

1. Minimize the amount of scrap raw material produced during cutting.

2. Producing the better quality of the processed metal sheets

3. Faster process times in cutting with lower work labour involvement

4. Integration of the nesting process in the computer integration manufacturing reduces

the errors made in the programming during the code development and also the

simulation of the process before actual nesting takes place.

The features of the Nestix software includes

1. The ability of the software to import and export data from various platforms like Tribon,

Nupas Cadmatic and etc.

2. Block timing and material information can be imported from external software sources

like that of MARS, Safran)

3. It has the ability to convert design assemble into production assembly tree with work

phases and production information.


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pg. - 25 -

4. Modelling and the work preparation of the detailing of the component is faster and better

compared to the conventional software’s.

5. Efficient material and machine capacity utilization is planned in integrated NESTIX Ship

plate and profile nesting.

6. Part production scheduling is possible using Nestix.

7. Material management

8. Integration into production

9. Ability to run on a standard platform like those of Microsoft windows operating system

and SQL server database.

Use of the software in the industry

1. Shorten throughput time and improves the block count

2. Save the amount of material as scrap.

3. Utilize machines efficiently.

4. Improve the quality of the production process.

5. Secure platform with higher reliability.

Figure 15 Flow diagram where Nestix is used

Detailed design

Production engineering

Nestix



Figure 16 various types of works undertaken by Nestix

Figure 17 Part of the plate nested using the Nestix software

Nestix

Scheduling of the process

Work preperation

Part nesting

Part Fabrication

Block assembly and component

design

Work Assignment

for subcontract


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pg. - 27 -

Figure 18 the nested part created in Nestix exported to AutoCAD and send to the

shipyards

Aveva hull detailed design

The full control of the manufacturing process and also the proper understanding of the hull

design which is essential for the shipyards for a successful production of the component.

The use of aveva hull detailed design is a right application using object centric approach

rather than the foundation styled approach for providing the production information and

detailed design. Having significant project savings for the design offices and also the

shipyards.

Most of the shipyards around the world use Aveva for their detailing and now became an

industrial standard for production drawings.

This aveva hull design covers the entire process from the hull designing to block assembly

for any type of ship selected, along with the documents required in the design and building

process.



Figure 19 an Example of an Aveva engine

Figure 20 Flow diagram of the Aveva software

Key features of the aveva hull detailed design

1. Interactive and one of the most advanced 3d model rendering software

2. Ability to handle large files of models

3. Higher compatibility to use with the other software’s

4. Good Graphic user interface with lighting and shadowing modelling

5. Advanced Simulation software

6. Object manipulation and clashing thanks to the creation of the objects in this generic

type

7. .net interface support capabilities


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pg. - 29 -

Figure 21 A high quality output can be obtained

The below shows a part of the plate with the stiffeners designed to Aveva with sectional

view, a 3d view of the component and also the 2d drawing of the plate to be used for

production drawings.

Figure 22 A section view of a plate with stiffeners in Aveva



Figure 23 A 3d view of the plate with stiffeners in aveva

Figure 24 Drawing created by Aveva for the component


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pg. - 31 -

Optional modules used for the aveva design

1. Aveva Hull Panel Line control

This module helps in the nesting of the assembly parts and also produce the Numeric code

for blasting, marking, burning and text labelling along with the automatic mounting of the

profiles.

2. Aveva Hull profile Cutting interface

This module transfers the profiles which are nested to the profile cutters which are generally

done by the robots for profile manufacturing

3. Aveva Hull Genauigkeit

This module helps in the automatic marking equipment for the shipyards without using extra

design hours and increasing the accuracy by making automatic alignment of parts and part

generation.

This plays an important part of the workshop drawings.

4. Aveva Hull Dotori-Variable Bevelling

This module helps us to setup and control the bevel standards both for bevel types with

fixed angles and where the bevel angles vary.

The various bevel situations which are processed by this module include

1. at the plate edges

2. in the lugs of cut-outs

3. along profile traces (shell and planar)

4. in profile ends.

5. at bracket edges

6. in the holes

7. in flange ends

8. in the clips

5. Aveva Robot interface

This module enables users to transform the hull model in a volume format for welding robot

facilities by offline programming system.



DETAILED DESIGN AND PRODUCTION INFORMATION

This part of the chapter involves the detailed design stage and the production information

stages of the ship design. These stages come after the 2d design is made in the basic design

stage and the 3D model is created basing on the 2d model to obtain the detailed design

information and also production information.

For the sake of convenience the author has decided to split the work into 2 subchapters of

the present chapter which would be Hull and piping stages.

These stages are then sub-divided into many small sections for an in-depth understanding

of the stages.

The various stages involved in the hull stage would be Assembly drawings, Production

information and optimisation of the information.

The various stages involved in the piping stage would be Combination drawings, Production

information and optimisation of the information.

Figure 25 Subchapters involved in the chapter

Hull

Assembly Drawings

Production Information

Optimistion of the

information

Piping

Combination drawing

Production information

Optmisation of the

information


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pg. - 33 -

Piping module during this phase

Cadmatic software application

Procedure of using the “Cadmatic” module in the combination drawing part of the piping

module of the detailed information stage.

Step 1:- Initialisation of the software

The software is initialled started using the module present on the work desk’s software and

the work starts with the identification of the drawing box.

This drawing box is used to start the drawings required to create for the desired project

Figure 26 Menu for Selection of drawings

Step 2:- Managing of drawings

After the required drawing setup is made, the drawings are to be managed with the users.

So the second step involves the managing of the drawings

Figure 27 Managing of the drawings



The drawings menu provides drawings to users. The All drawings menu is used for the

creation of the drawings to be used as public where the drawings can be added, created and

altered by other users who are active in the module. The drawings menu is sole proprietary

of the user who created it and the alteration of the drawings are not possible.

This is used when there are multiple operators working on a compartment of the project.

So the new drawing is made from the pop up block opened by the user.

Step 3:-Creating the drawing

The third step involves in the creation of the new drawing where the drawing is created and

is visible to cluster of operators.

Here the attributes for the drawings are made which includes the name of the drawing, how

the bill of the material is processed, the scale of the drawing compared to the actual ship to

be designed and also the revision number. The revision number is the number of

modifications made upon the drawing as per the requirements proposed to the designer.

Figure 28 Creation of the drawing


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Step 4:-Drawing sheet with the attributes visible to the user

Figure 29 Application of attributes to the drawing

After drawing creation is complete, a blank sheet with the information of the title block is

made automatically by the computer with all the information inputted by the designer.

Step 5:-Creation of the sheet without information

At this stage the presentation is given more importance and the details about the vessel, the

revision number, scale and other attributes created are checked for errors.

Figure 30 Creation of the title bar



Step 6:-Creation of the views for the sheet

The views are created for the sheet which is designed which would be the next step of the

design.

Figure 31 Creation of views for the product

The view types which are to be used for the drawing sheet to be submitted by the designer

along with the axis of the view in 3 directions (x, y and z directions) are fixed by the user.

Step 7:- Assign views to the page

The views are then assigned as per the rules of the company and the shipyards for the

respective compartment.

Figure 32 Assign Views to Page


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Step 8:-Creation of the annotation of the views

After the views are placed on the drawing sheet, the annotation of the views are created.

Figure 33 Annotation of the Views

This includes the creation of text, lines, arcs, hatching, dimensioning of the created part,

symbol to be used, operations to be carried out, editing of the values, deleting the part of

the compartment, importing and exporting of the data as there is a lot of flexibility to use

many software’s to import and export data, tools and also the revisioning of the part which

is highlighted where the verifier of the project can check where all the revisions are made.

Step 9:-Creation of the labels

After the drawings are made with the above attributes, the labelling’s of the parts for the

particular component is made. This helps for faster understanding of the parts when the

drawings are made in hard copies.



Figure 34 Creation of the labels

Step 10:- Title bar of the sheet for the drawing.

The main sheet’s title bar is check again for any possible errors.

Figure 35 Title box with attributes

Step 11-Pictogram of the drawing with the listings

After the drawings are checked a pictogram of the drawing along with the listings of the

drawings on the sheet is checked.


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Figure 36 Pictogram and listings obtained

Step 12:-Export the designed product

Then the drawings are exported to the respective format proposed by the company.

Normally the most commonly used format is dwg (AutoCAD).

Figure 37 exporting the drawing



Procedure of using the “Cadmatic” module in the Pipe isometrics part of the piping module

of the production information stage.

This stage involves in the creation of the pipe isometrics views to be given to the shipyards

as a part of detailed design and production information stages.

The Isometric views are the three axis view (along X, Y and Z axis) in a 2 dimensional

frame (on a drawing sheet.)

Step 1:- Initiation of the piping isometrics.

In the similar manner of the combination drawing we initiate the drawings by using the pipe

isometric block in the drawings menu

Figure 38 Identification of the menu

Step 2:-Selection of the piping isometrics attributes.

After the piping isometric box is selected the menu for the piping isometrics is selected and

includes the basic information about the drawing

Figure 39 Piping Isometric Menu


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Step 3: Selection of system to be used.

The selection of the system to be used is selected from the menu. The systems are already

created by the user and could be found in the selection menu

Figure 40 Selection of system from Menu

Step 4:-Grouping of the isometrics.

The groups of the isometrics to be created is selected from the piping isometric menu.

Figure 41 Groups and piping isometrics



Step 5:-Creation of piping isometrics

The created group isometric of the pipe is then made to be visible and the list of the

objects are verified for its respective section.

Figure 42 Creation of piping isometric menu

Step 6:- Viewing the pipe created.

The view from the system which is group is made on the sheet of the paper.

Figure 43 viewing the pipe created

Step 7:- Identification of number of items constituting the pipe.

The attributes of the drawings are made which includes the options of what all part to be

needed for the sheet drawings which includes annote, preview, plot and export along with

the attachments block where the isometrics and the spools which are to be attached to the

current drawing object is also added.


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Figure 44 Creation of iso view for the pipe created

Step 8:-Creation of the pipe isometrics with pictogram

The created isometrics of the pipe with pictogram are viewed in the pictogram menu and

the data required to be placed are also made.

Figure 45 Pictogram of the pipe isometrics



Step 9:- Placing the Pipe drawings onto the sheet created.

Finally the created pipe isometrics are placed on the sheet.

Figure 46 View of the pipe isometrics on the sheet

Description

The piping module consists of 3 stages which includes the combination drawings part of the

detailed design stage where the large amount of detailing is provided for that particular

compartment, the spool drawings, pipe isometrics along with the material documentation

like bill of materials, spool list and etc. are together combined in the production information

part and the last stage is the optimisation of the information.

Combination Drawings

In the package of combination drawings provided to the shipyards for the construction

includes a view of the structure from the top and the decks above and beneath the deck,

foundation drawings particularly the combination drawings for the engine and other marine

equipment’s which needs foundation or supports. The package also consists of the view of

the compartment from the side view which in the case of our selected compartment would

be seen from the aft.


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Figure 47 Drawings for the vessels compartment (Top View)

Figure 48 piping layout from the side view



Figure 49 Foundation of the marine machinery

Figure 50 Side view from the aft of the ship

After the 2D drawings are made basing on the 3D model, the numbering of the specific parts

are done manually with unique numbering which helps to identify each part and thus making

the design more productive. The below picture shows the final output with the text

describing the part details and numbering.

Figure 51 Part numbering to the final design


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Figure 52 Final details of the particular component

Production Information

The production information involves the isometrics of the piping system which is more like

a schematic of the flow of the pipes with the pipe attributes and the length of the pipes

flowing across the entire vessel.

These schematics helps to identify the entire pipe flow distribution and used for the better

understanding of the system during the construction phase.

Figure 53 Pipe isometric view of the compartment

The below picture describes an insight view of the pipe along with the system used for building the

pipes. These help in cross checking the final product more easily and also for creation of a strategy

for the shipyard to complete the work.



Figure 54 Schematic of the pipes with the system

Figure 55 Spool drawing

The above picture involves the spool drawing for the particular part location. It includes the pipe

information and the type of bushes to be used for the welding and the angle of placement of the

components.


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Figure 56 Continuous spool drawing

A Rough overview of another spool with the neighbouring spools is shown to analyse how the flow

of the construction is to be done.

Figure 57 Bill of materials

The bill of material is an important information provided to the yard for the details about the details

of equipment like the position of the each pipe in the system, quantity required for the particular

type of pipe along with the location of the pipe on the ship, the unique article code set by the 3rd

party distributers, the unique code set by the shipyard for that particular item, the description of the

item, material to be used, weight of the item and certification.

Depending on the shipyard additional information like Delivery of the item, revision status and the

remarks for the revisions made for the item can also be specified.



Figure 58 Description of the compartment

Apart from the piping attributes, the effect of the pipe in respect to the total length of the pipe to be

used, total weight of the pipe, its centre of gravity values along the x, y and z directions are also

given to provide a better output of the weight estimates and can be used for a more precise weight

calculations, stability calculations, and also for the understanding of the shipyards.

Figure 59 Iso Sketch Checklist

The Iso numbering of the sketch list which includes the iso sketch number which is manually entered

by the designer during the production information stage along with the spool number, the length of

the pipe, drawing of the particular part, the section numbering and its weight along with the

revisioning if carried are also part of production information to be delivered to the ship yard.


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Optimisation of the information

After the 3d model drawings are generated the manual optimisation of the work is carried

out.

The optimisation of the model’s piping would be an essential task to reduce the extra effort

needed during the construction, made in the design stage.

Some of the optimisation works carried out during the design stage of the compartment are

as follows:

1. Reduction of number of welds required.

2. Placement of casings at heat emitting components

3. The consideration of service space for the components

4. Service Space Valves

5. Reduction of the pipes at the junctions

1. Reduction of number of welds required.

In the shipyards, the cost of the manufacturing is carried out in terms of the length and type

of welding equipment used for the parts. Reduction in the weld length and number of welds

required offers cost savings towards the manufacturing.

In the figure shown below instead of using a straight piece of pipe after the elbow before a

flange, the elbow could be connected directly to the flange to reduce the weld required.

Figure 60 Piping Layout during design



2. Placement of the casings at heat emitting components

Placing the heat casings at the exhaust pipes which are visible to the engineers and are prone

to get in contact could be avoided by placing a railing around the zone and preventing in

contact directly.

Figure 61 3D model Engine room Layout

3. Consideration of service spaces

Service space is an allowable space to a component which can be in reach to the service

engineer in case of malfunction of the components.

The space placed should be easy enough for a person to get inside, repair and exit without

much difficulty.

Placing the black hatchings as shown in the figure helps to avoid building any other extra

material at the service space and manage a free and flexible workplace.

Figure 62 Service spacing allowances


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4. Service space valves.

The placement of the valves at the right place is also essential basing on the usage. Some

of the valves maybe used less frequently however the accessibility to these less frequently

used valves could be considered in placing them near service spaces.

Figure 63 3d model showing the service space valve spacing

5. Reduction of the pipes at the junctions

The number of welds needed for the pipes means higher cost at the shipyard, these can be

avoided by placing the pipes in a right fashion with smart thinking than mere placement of

the pipes without much thinking.

The below picture shows a best case scenario of the improvement of the pipe’s cost as

instead of using 2 pipes for the same function, it can be avoided by placing a single pipe.

Figure 64 Pipe modification before the optimisation



Normal design of the pipe designed by the operator.

Figure 65 Pipe modification after the optimisation.

Optimised design of the pipe by the verifier.

The optimised products help in reduction of the costs and also provides higher productivity

and also the service rate factors for the material usage.


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Hull module of this phase

The hull part contains the information about the hull design during the production

information and detailed design stage.

For the sake of convince the author has decided to spilt the part into three parts where the

following are discussed.

1. Assembly drawings under detailed design stage.

2. Production information stage.

3. Optimising the compartment using Auto nesting software.

Procedure in the application of Nupas module in the design for creation of assembly

drawings.

The procedure of the Nupas module in creation of assembly drawings include:

1. Initialising the project.

2. Creation of the Views

3. Working Space Setup.

4. Creation of the 3d Model.

5. Additional Commands for modelling.

Initialising the project

1. The project is initiated from the setup by the designer and the attributes like Block

number, the active user at that moment in the software and description of the block

are selected.

Figure 66 Selection of the project to be used.



2. Creation of the views

After creation of the project initial details the views requested by the firm are to be designed.

The Views can be selected from view menu and the various possible views defined in the

software include Frame View, Side View, Top View and Perpendicular View.

The additional attributes like weld symbols, scaling, the frame dimension’s for the view and

the drawing numbers are setup.

Figure 67 Position of the particular part in the work space

Working space setup

The selection of the work space is essential for the software as certain functions are limited

in the working environment selected by the user.

The Working space can be selected from the application toolbar menu.

The various working spaces available in the software include:

1.2D contek

2.3D contek

3.3D show

4. Plantek

5. Shell


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However for most of the cases of design the 3D contek is preferred as it’s the most suitable

for building the 3D modelling and obtaining information faster.

Creation of the 3D model

The 3D model is created using the insert toolbar which creates the information for the model

used for the generation of the views.

The various options possible in the toolbar include

1. The Plates for the structure.

2. Profile Members.

3. Pillars for the supporting member.

4. Face Plates.

5. Flange Creation.

6. Brackets.

7. Holes.

8. Cut outs.

9. Draining Holes.

10. Splitters/Slots.

11. Welds/Bevelling.

12. Weld Symbols.

13. Foundations.

The most widely used tools include Plates, Profiles, Pillars, Flanges, Holes, cut-outs and

Splitters.

These help in the creation of the 2d drawing along with the 3d model created in the Hull

viewer module which is a part of the Nupas module.



Figure 68 Aft view of the section in 2d model

This figure shows the 2d drawing seen from the aft to the compartment which describes the

information about the design.

Basing on the 2d model the 3d model can be obtained using the Hull viewer module. As

shown in the picture below.

Figure 69 3d model of the section of the hull

Additional commands for the detailing

The various other types of commands include the tool menu which includes the view

creation, iso view creation, modification of the block number along with the changes in the

block location, hull attributes and etc.


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Additional Information tool bar which includes the Trimming of the lines, extension of the

polylines, fillet of the lines, creation of the lines and circles.

Apart from these commands one important command which is widely used is the Draw

toolbar. It is used for writing additional information for the detailed design stage on the 2d

drawings which is prescribed after a discussion with the shipyards.

The various types of Drawing commands include the creation of lines, circles, arcs, ellipses,

rectangle, parallel lines, symbols, text, hatches, surface colouring and pillar centreline.

Procedure for the production information stage of the hull design for the compartment

The production information stage in the design using Nupas module involves two main

items in the software.

1. Logistics part

2. CAM part

The logistics part involves in the creation of the process codes, the auto numbering, action

reporting, part labelling, rearranging the part numbers, updating the logistical data and

logistical parts.

The cam part involves the creation of the production information, coding one part,

modification of the coded parts, creation of the report file, workbench break down using 2D

modelling and 3d modelling, AutoCAD supported format design into sketching, checking

the CAM data and Plotting of the parts.



Logistic menu in the Nupas module.

The main stages in the logistic menu in the module includes

1. Logistic information toolbar.

2. Creation of the process codes.

3. Action Report page.

4. Rearranging part numbering

1. Logistic information toolbar.

The logistic toolbar includes the creation of the process codes how they are created, the

numbering of the parts, report generation tool, a possibility to change the numbering once

the numbers for the parts are entered using the rearranging tool and updating the logistical

data after the series of modifications are carried out.

Figure 70 Logistics popup box

2. Creation of the process codes.

The process codes are essential for identification of that particular part using a unique

number which helps to reduce the confusion during the assembling in the ship yards.

No two parts will have the same unique codes and will be placed in order.


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Figure 71 Part List

It includes the block details, unit details, and panel, subpanel and part details in an orderly

manner. The creation of the codes can be done either by the creation of the part in an orderly

manner or by using relation with the other parts in the particular unit.

3. Action Report Page

The Action Report page includes the list of the type of report required by the manufacturer

set by the designer.

These include part list, Cog selection list and panel sketches.

Figure 72 Selection Criteria for the toolbar to open



4. Rearranging the part numbers.

After the part numbers are set by the designer and carried out, there may be possibility to

use different part numbers for shipyard standards.

Therefore these numbers of the parts can be modified after they are created by using the

rearranging of the part numbers told.

Figure 73 Selection of the parts in a particular panel of a block.

It includes the free spacing required, the unit for which the part is made for, panel and

subpanel.

CAM Toolbar in the Nupas module.

CAM Toolbar

The cam toolbar refers to the computer aided manufacturing toolbar where the user takes

the help from the computer to design the drawings of the parts.

The main functions of the tool include the creation of the production information, coding of

the part, creation of the reports, workbench sketching from either 2d drawing or 3d Sketch

and also verification of the data for integrity.


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Figure 74 Cam Toolbar

Figure 75 Selection Criterion for a block using CAM toolbar

The information about the attributes like the yard number, the group number and the

drawing numbers are inputted in this part, the use of the reference lines as to where the

referencing of the drawing is carried out is also inputted.

Coding of the parts

The parts after they are designed are coded for the part detailing.



Figure 76 Part coding toolbar

The coding script for the parts in the format set by the shipyards, the type of configuration

needed and other attributes are inputted in this stage.

After the coding details are set the computer then designs the part as per the attributes

entered.

Figure 77 A chart of the coded components

There is also a possibility to modify the parts for the coding again.


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Creation of the report

The report file is then created using the report generation tool in the CAM tool box to

generate the report.

The software then asks for which type of report is required by the user.

Figure 78 Selection of the report to be made

It can be a part list, cog selection list, panel sketch list and etc.

Checking the cam data

After the report is generated the cam data is checked if the work carried out is successful or

if there needs more tasks to be done on that particular block.

Figure 79 Verification of the Cam Data

It includes the number of available blocks by the user, the type of the bloc selected, the type

of check needed if it were to be for the profile sketches, list of the parts and etc.



Package of Hull Module

The package of the hull module for the shipyards include

1. Assembly drawings

2. List of materials.

3. Part sketches.

4. Profile and Panel Sketches.

5. Assembly Sketches.

The layout of these information is customisable and is additional information may be

created and some of these information may not even be created and is depending on the

factors like

1. Experience of the shipyards.

2. Level of information requested by the owner.

The flow pattern in the Hull part during the detailed design and Production information

stage.

Det

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1.Assembly drawings.

Pro

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form

atio

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Stag

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2.Part Details.

3.Profile Sketches

4.Panel Sketches

5.Assembly Sketches

Op

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the

wo

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pg. - 67 -

Detailed Design Stage.

During this stage the 2d drawings created earlier are taken which are used for class approval.

Therefore the structure details are confined after the class approval is obtained for the vessel

from the classification society.

This package include the assembly drawings.

Figure 80 A typical drawing of the structure in assembly drawings

This includes the top view from the deck and also the section above the base for the

particular compartment, the side view seen from the port side of the ship and also the

starboard side of the ship respectively. The various frame views are also presented in this

package.

The other essential attributes for the shipyards upon the request like the weight of the

compartment on the whole with the centre of gravities along the 3 axis is provided.

Please refer to the appendix for more drawings and in-depth representations of the selected

compartment.



Production information stage

The additional information as a part of the package of the production information typically

includes

1. List of materials.

2. Part sketches

3. Profile and Panel Sketches.

4. Assembly Sketches.

List of materials

The list of materials includes the list of the parts required for the manufacture of the

particular compartment which includes the information about the part information, part

number, type of the material to be used for the construction, the dimensions of the part

which includes the length, width and thickness along with the weight of the material and

also the grade of the material to be used for the manufacturing process.

Figure 81 List of Materials.

The above picture shows the list of the parts required for the compartment to be designed.


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Part sketches

The part sketches includes the various shapes of the parts required for the construction stage

of the ship.

The shipyard requirements are essential as some of the shipyards require the dimensions to

be specified and some of them just require the shape of the part and the location.

Figure 82 Profiles being allocated on the plate

Figure 83 Numbering of the profiles and components

It has a unique numbering to have a clear and progressive building approach.

Profile and Panel Sketches

The profile sketches are used for the description of the profiles required for the hull

construction.

A typical package of the profile sketch includes the information about the yard, information

about the part and the inclination seen from various sides. A typical chart of this package is

shown in the picture below.



Figure 84 A typical 2D drawings of the panel

The panel sketches on the other hand includes a systematic number of the additional parts

to be attached to the panel, the building sequencing of the sketches, the properties of the

part along with the length of the weld required for each part is specified in the panel

sketch package.

A typical panel sketch drawing is given below.

Figure 85 Panel sketches sequencing


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Assembly Sketches

The assembly sketches include the approach suggested by the designer to the shipyard in

terms of the sequence of operations to be carried out during assembling.

A typical drawing provided to the client is given below.

Figure 86 Additional Sketches with building sequence

The sequence of phase is also suggested along with the other part attributes and the

numbering of the drawing. The drawing also includes the maximum Dimensions for the

assembly which includes the length, breath and height of the assembly respectively.

Optimising the work

The optimising of the work includes the effective way to produce the above drawings of the

packages of production information and detailed design stages.

The use of Auto nesting is widely used in the industry as it provides an optimised value as

to how to arrange the parts to get the maximum productivity.

Auto nesting is an advanced system of sheet metal nesting. It provides dynamic packaging

capabilities, which allow you to package sheet metal reference parts (along with existing

NC sequences, if desired) and cells of parts from existing manufacturing models

automatically.



You can easily change the number of the nested instances, customize the offsets between

the models, and select nesting algorithms to create an ideal balance of performance and

packaging optimization. (Source:-http://www3.eng.cam.ac.uk)

Procedure using Auto nesting software

The procedure of Auto nesting involves 9 stages before the part is finally nested which

includes

1. Initialising the auto nesting software.

2. Verification of the part’s if they are confined within a specified area.

3. Input of the part’s made using Nupas module of the Nupas Cadmatic software.

4. List of the part’s to be imported.

5. The plate dimensions of the metal sheet taken are added.

6. Optimising of the area of the plate for fitting the parts.

7. Creation of the parts on the plates automatically by the software.

8. Making the report of the data obtained during the process.

9. Checking for weights of the parts and verify with the weight details set up the designer

initially.

1. Initialising of the auto nesting software

The software is initially started and a user interface is opened to start the nesting operation.

Figure 87 Auto nesting software user interface


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There are various set of operations that can be pre entered like the nesting document code

which describes the part numbering entered, and also includes options like how the

document should look like.

2. Verification of the part’s if they are confined within a specified area.

The software does not accept the components which process open dimensions (i.e. the lines

in the given part are not joined together.) So initially they are checked if there are any

openings in the part and are closed for the software to update into its environment.

Figure 88 Information regarding the parts in the operation

3. Input of the part’s made using Nupas module of the Nupas Cadmatic software.

The parts are then inputted into the auto nesting environment, the company where the work

is carried out uses AutoCAD files format and this format is supported by the auto nesting

software.



Figure 89 Selection of the DXF files for the profiles and panels

4. List of parts to be imported.

After the inputting of the DXF format is selected which represents the AutoCAD format,

the parts required to be nested are selected, which may include initially from a particular

compartment rather than doing it for the whole ship directly.

The part list is then checked in a new window opened after the input of the parts is selected.

Figure 90 Files to be placed


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5. The plate dimensions of the metal sheet taken are added.

The dimensions of the plate which includes the length of the plate, the breath of the plate

and also the thickness of the plate are to be specified to the system which helps the software

to understand the environment confined by it to work.

Figure 91 Plate Dimensions set forth in terms of Length, Breadth and Height

This includes the various set of plates to be used for the part manufacturing as the thickness

of the plate various depending on the thickness of the parts.

The various data includes the dimensions of the plate, the material grade to be used for the

manufacturing, quantity of plates required.

6. Optimising of the area of the plate for fitting the parts.

Figure 92 Nesting Scenario with constrains set forth



The software then gives a scenario of the parts which will be nested, it includes how the

nesting should take place, which sheet plates are to be used, the distance between two

successive parts, the scrap level needed, the margins in all the directions for the operation

to take place and additional options which includes holes, bridging and etc.

7. Creation of the parts on the plates automatically by the software.

The parts are created by using the auto nesting option after the above parameters are set.

Figure 93 Parts being arranged for nesting

8. Making the report of the data obtained during the process.

After the parts are nested a report is made to the verifier to analyse if the process is done

correctly. This includes the set of parts required for nesting.

Figure 94 Report generated from Auto nesting


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9. Checking for weights of the parts and verify with the weight details set up the designer

initially.

The weights are checked with the weights set up by the designer, if the weights obtained by

nesting’s are equal to the weight set by the designer.

The weights if not equal may be due to

1. Improper parts added to the nesting.

2. Improper calculations due the designer.

3. Parts are not nested to the right plate.

Figure 95 Weight Specifications of the plate

After the parts are nested they are then made into 2 types of files which include the files in

a format of AutoCAD supported type and also a file which contains the codes for the

manufacturing of the part provided to the shipyards.

A.The AutoCAD supported type of format is used to analyse how the parts look like during

the nesting.

Figure 96 nesting document



The percent of utility is an important data to be used by the shipyards to understand how

much of the plate is used for the nesting. Here the number 36% refers to the percent of plate

optimised by the software to arrange the parts according to the attributes.

The number is lower due to the usage of only a 55% of the total plate used for the nesting

process. The other part of the plate is used for making bigger components.

Normally the utility factor is about 80% and may increase depending on the various

attributes added during nesting.

The other attributes in the file includes the

1. Running length- The length which is being nested by the machine.

2. Marking length- The length which includes the markings present on the plate for the

cutting to take place.

3. Cutting length-The length of the plate to be cut in total from the parts.

4. Weight of cutting pieces- The total weight of the cutting pieces obtained after cutting.

5. Total time-The time which is required by the system to undergo cutting operation.

6. Oxygen/Fuel numbers-These numbers are the amount of fuel and oxygen expected by the

machine to cut the plate into parts. This number varies from the shipyard to shipyard

depending on the shipyard facilities.

B. The machine codes for the cutting operation

These includes the codes used for the cutting operation to be inputted into the cutting

machine.

These codes are in numeric digitized format used for machine.


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Figure 97 Coded information

After the codes are entered into the cutting machine the desired output is obtained and the

machine is shut down and the codes are changed to produce a new batch of parts again.



SHIP PRODUCTION AT THE SHIPYARD

In this chapter of the thesis the discussion is carried out on the processing of the information

from the design offices to the shipyards where the actual production of the ships is carried

out.

After all the drawings are transferred to the shipyards, a specific department called Project

engineering and drawing control department validates the design to check if they are as per

the standards set forth by the yards earlier. The remarks are carried out and suitable changes

are carried out respecting the classification rules. The information is then carried out to the

Production and QC departments for the production and quality testing of the final product.

The shipyards structuring and the strategy towards building changes from yard to yard. In

the thesis, during the description of the yard it is here forth considered the yard to be Damen

Shipyard, Galati.

Apart from the design collection by the shipyard, the organisation has its own 3D modelled

work station for the CAD/CAM interface measuring the documents dimensions, analyses

them and also simulates them.

Measurement using the 3D DCP100 Modeller

This DCP100 modeller is a tool which allows the user to import the 3D model build by the

design offices to create its own unique file (.PRD) to measure the critical points required

for the production which includes dimension points, stiff points, CL points and measuring

frame points.

Figure 98 measurement of the part using DCP100 tool

Analysis using the tool

After the measure has been successfully carried out the analysis and the report making of

the errors and the possible counter measures are carried out in this stage. This stage can be


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used only after the measure is carried out as the software creates a new file with ARD

extension to be used by this analysis tool of the software. It in turn generates in depth

graphical reports and the dimensional tolerances set by the industry standard.

Simulation of the tool

After the analysis is carried out the new extension file with the extension of production

actual data (.pad) which consist of the information to check the amount of the weld material

to be removed, the excess material to be cut after the weld and the weld gap between the

two adjacent structures.

Figure 99 Simulation of the DCP 100

Now that the engineering analysis is completed by the yard, the part catalogue is analysed

by the job production department which has three sub stages include inventory, purchase

and issues area.

The inventory part creates the inventory details of the parts to be required for the

manufacturing and also the location of them material placed in the yard. They allow to

account for the weight and volume requirements during this particular stage.

The purchase part involves in the purchasing of the additional material required for the

manufacturing of the component. It can either be a completely finished product or a semi-

finished product. It indicates the buyer ID and also the purchase group number to denote

the product attributes when bought by the yard.

The final stage of the sub stage is the issues area where the information of the type of weld,

the angle of weld and the possible problems encountered during the stage is provided to

give a quicker solutions.

This also provides information regarding the stocking and destocking of the parts and

components used up by the various departments.



The shipyard is a uniquely patterned layout to ensure a highest productivity values with an

ample of work space in order to facilitate bigger ships and also for the future advancements

in the yard.

The work flow of the yard is specified in the chart provided from Damen. (Sourced from

Damen Shipyard, Galati, Romania.)


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Figure 100 Flow Chart of the process (Sourced- Damen Shipyards, Galati)

Detailed Engineering stage is the information received from the design offices to the yard

in order to have all the designs requested by the yard. It involves a collective number of

companies each assigned with a specific area of the ship depending on the size of the ship.

The various companies include DSco, Mega and etc.

The package which includes the information like hull and piping credentials described in

the earlier chapters of the thesis along with the letter of transmittal, contracts and initial

discussions towards the approach to develop a strategy.

Letter of Transmittal which is LOT in short is the transmission of the documents from the

third party design company to the yard using the IFS Document management protocol where

the companies are invited to transfer the data to the reliable server of the yard.



Figure 101 LOT (Sourced - Damen Shipyards, Galati

A sample letter is shown below where the information of the drawings are specified with a

unique ID.

After the documents are received by the yard, they involve in the 2nd stage of the production

which is the standard engineering production information (SEPI) where the activities like

auto nesting of the plates and profiles, outfitting profiles and arrangements and N.D.T

evaluations for the specimens.

Then the analysis stage is seen where the launching calculations, 3d piping layouts if not

provided by the design offices and also dimensional controlling of the entire ship during

each block arrangement. These are specified earlier in the DCP100 documentation.

After this stage is complete the documents are then transferred from respective detailed

design department to the other departments using the intranet protocol using the FTP (File

Transfer Protocol).

The departments include the Job preparation department, Production department and

Quality control department.


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The production department ensures the production is taken place correctly at the right

specifications set forth and also ensuring the tolerances are met using the DCP tool.

The Quality control department ensures the quality for building the ship is met with highest

standards set forth by the SQS regulations.SQS regulations refers to the ship building

quality standard which a small booklet with an information about

The material information for the structured members in regard to the quality of the

material to be used, surface defects and imperfections.

The welding type to be used and also the weld gap acceptable by the standards.

Removal of the temporary fabrication material.

Tightness tests and waterproofing where the doors and hatches are tested for the

proper functioning and also the waterproofing of the bulkheads and water sensitive

areas are well in limits set forth.

The information about the hull deviations especially in the form of the ship at the

fore part is provided.

The painting of the blocks and also the entire ship both internally and externally

with an importance to areas where they are paint sensitive.

The most important department here after the detailed design department in the yard is the

job preparation department.

Figure 102 Job preparation layout (Sourced - Damen Yards, Galati)

The first is the Building strategy part where the department makes the initial building

strategy draft keeping in mind the building location where it was to be build and also the



launching platform to be used. This is closely coordinated with the planning department and

then the final building strategy is put in place.

This includes the placement of the block to be constructed and also priority to the blocks.

Figure 103 Building strategy with information on placement of blocks (Sourced from

Damen Shipyards, Galati)

Cutting of the plates and profiles are either provided by the design offices directly or are

made in the in house department of the yard.

Job preparation activities domain in the job preparation department includes

Devices and special tools area involves in the new tool devices and also supporting devices

for the hull erection.

The welding laboratory is also put up in place with the weld type to be used and also the

welding instructions. This varies from yard to yard and also the type of standards

implemented in the particular yard.


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Figure 104 Welding procedure specifications (Sourced from Damen yard, Galati).

There is also an important job role for this department where the remarks for the current

drawings and the verification of the documents are made to ensure a smooth transition from

design to production at the yard.

A typical example of the remarks are shown where there was an error in the actual value

and the value shown in the design.



Figure 105 Remarks section of the job description department. (Sourced - Damen

Shipyards, Galati)

The certification is not updated in the documents with respect to the changes made after the

documents are sent. Thereby a remark is made and sent back to make required corrections.


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ECONOMIC ANALYSIS

This chapter of Economic Analysis involves the cost estimates observed in respect to the

man hour’s consumption at the shipyard. All the information provided in this chapter are

conducted as per the Romanian salary pay scale at the particular shipyard and design offices

mentioned earlier. The information is converted into Euros to ensure that the uniformity in

the cost analysis can be observed.

In this chapter the first stage is the cost estimates information received from the design

offices during the detailed design and production information stages.

The time taken to produce the 3d model is around 59 man hours and 1 hour for the

generation and verification of the documents downscaled from the 3d model to the general

2d drawings.

Which refers to the total of 60 man hours each for the hull part and the piping part of the

stage. Considering the cost per man hour in the particular design office to be around 45

Euros per hour which includes the salary compensation of the worker, the software

procurement in terms of hourly basis (which is downscaled from the actual cost of the

software to the number of hours spent on the software per licence for one year) and the

company margin in terms of maintenance and profits. Similarly the cost of manufacturing

for the particular section in the production department is 20 Euros per man hour and the

cost of the section at the in house design office in the shipyard is around 30 Euros per man

hours taking into consideration the cost of the software and also the worker pay scale.

Table 1

Hull Part of the section

Duration Taken at the Design office for a Section 60 Man Hours

Cost of 1 man hour at the Design office 45 Euros/hrs.

Shipyard details

Steel processing 109 Man Hours

Section Building 376 Man Hours

Hull Assembly 192 Man Hours

Welding 449 Man Hours

Total Time required at manufacturing 1126 Man Hours

Cost of 1 man hour at the shipyard for production 20 Euros/Hrs.



Additional time required

Time required when documents are missing from the design offices

Missing details

Part List 12 Man Hours

Profile Sketches 25 Man Hours

Panel Sketches 16 Man Hours

3D model 8 Man Hours

Assembly Sketches 112 Man Hours

Nesting Document 8 Man Hours

Building Sequence 50 Man Hours

Total time spent 231 Man Hours

Cost of 1 man hour at the shipyard 30 Euros/hrs.

No of man hours saved per section if the document list is complete 231 Man hours

Cost savings per section at the shipyard 6930 Euros

Table 2

Piping part of the section

Duration Taken at the Design office for a Section 60 Man Hours

Cost of 1 man hour at the Design office 45 Euros/hrs.

Shipyard details

Total Time required at manufacturing 875 Man Hours

Cost of 1 man hour at the shipyard for production 20 Euros/Hrs.

Additional time required

Time required when documents are missing from the design offices

Missing details

Pipe iso views 12 Man Hours

Schematics of entire piping system 25 Man Hours

Spool drawings 16 Man Hours

Continuous spool drawings 8 Man Hours

Bill of materials and description of components 112 Man Hours

ISO sketch list 8 Man Hours

Total time spent 181 Man Hours

Cost of 1 man hour at the shipyard 30 Euros/hrs.


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Total Man hours saving 181

Cost savings 5430 Euros

This information provided consist of also the values obtained from the shipyard on the time

consumption on an average for a section in general for a ship.

Apart from the hull and piping activities the nesting of the plates is also taken into

consideration for the economic analysis. In general the design office uses three types of

possible nesting operations which include the manual-automated nesting, quick automated

nesting and automated nesting.

In the manual-automated nesting the plates are initially auto nested using auto nesting

software and then manually edited by a skilled worker to ensure that the maximisation of

the productivity in the confined area is noticed.

The quick automated nesting is the nesting of the plates done using the quick option in the

auto nesting software where the nesting is carried out with a limited time thus reduction of

the plate usage in terms of making the panels and profiles.

The automated nesting is similar to the manual automated nesting but in this type of nesting

the use of skilled worker to manually alter the pieces to ensure the productivity is not taken

into account.

In regard to these types of nesting’s the calculations are carried out.

Table 3

Manual Nesting

Auto

nesting(Quick) Optimised Auto nesting

Man Hours Taken 4 0.08 0.11

Utility factor 80 65 78

Average material consumption for a unit is found to be approximately 40 tonnes

Per section Details

Total material to be consumed 48 54 48.8

Cost of a man hour is found to be around 45 euros per hour

Total cost in designing 180 Euros 3.6 Euros 4.95 Euros

Cost of the a ton steel is taken as 1000 euros per tonne

Total material cost 48000 Euros 54000 Euros 48800 Euros



Total Cost of design +material 48180 Euros 54003.6 Euros 48804.95 Euros

Cost saving in comparison with manual and auto nesting 5823.6 Euros

Cost saving in comparison with manual and auto nesting (optimised) 624.95 Euros

The difference between the manual-automated nesting and the automated nestings are

shown below:-

Figure 106 Automated Nesting

In this figure the parts present outside the figure are not nested because of the spacing

problems due to computer allocation. Thus there would be a reduction in the utility factor

of the panels.

Figure 107 Automated Manual nesting

With the automated manual nesting the pieces could be nested together in one single place.

In relation with the hull where there are bent plates considered the bending of the plates is

carried out at the design offices which is as follows in terms of cost estimates


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Table 4

Bending Activities for a section

Time consumption for a plate to be bent 1.5 Hours

Average bent plates needed for a section 7

Total time consumed 10.5 Man hours

Cost of a man hour in design office 45 Euros/Hrs.

Total cost occurred at the design office 472.5 Euros

Work at the shipyard

material wastage level allocated 10% of the total plate

Weight of a plate on an average 5 tonnes

Material wasted due to tolerance 0.5 tonnes per plate

Cost of a ton of steel is found to be 1000 euros per tonne

Cost incurred due to tolerance 500 Euros per plate

Total cost for 7 plates 3500 Euros per section

Man hours spent on activities 25 Man hours

Activities include polishing and cutting of additional material

Cost per man hour at the yard 12 Euro per man hour

Total cost of the production 300 Euros

Total cost observed at the yard 3800 Euros

Total saving observed 3327.5 Euros

The cost of the bending of the plates per man hour at the yard is for the low skilled workers

which account to 12 Euros per man hour and no of plates to be bend for a section varies

from section to section location thereby the global average is taken into account.

In relation with the total cost estimates the summary of the total costs including all the

attributes considered for the analysis is provided in the table below.



Table 5

For a section of the ship

For the shipyard

Total cost savings at the hull area 6930 Euros

Total cost savings at the piping area 5430 Euros

Total cost savings at the nesting part 624.95 Euros

Total cost savings at the plate bending 3327.5 Euros

Total cost savings of all the parameters 16312.45 Euros

For a ship with 20 units in our case

Total cost savings of all the parameters 16312.45 Euros

Number of units 20

Total savings on the ship for the yard 326249 Euros

This refers to a total savings of 326,249 Euros for the shipyard if the integration of the work

outsourced from the design offices to the shipyards is carried out. This number may vary

from a ship to a ship depending on the number of sections present and the time taken from

the section to be built.


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CONCLUSIONS

The work carried out at the economic analysis of the thesis, we could clearly see a noticeable

amount of saving at the shipyards and also involving more workforce and space at the

shipyards towards manufacturing rather than focusing more on in house design offices.

Thereby spending a considerable amount of time in the design stage would certainly benefit

the outcome of the ship during the production stage and also a better level of detailed

information which can provide any type of worker to understand the information and

process it in a much faster rate. The nesting operations if done semi-automated (i.e. It is

initially automated using the software and manually adjusted later.) provides better savings.

Having lower tolerance values by providing higher level of documents in the plate bending

ensures lower material wastage and man hours. The 3D model created in the design offices

helps to modify the work faster and update depending on the remarks provided by the

shipyards.

Further work on this particular domain could be carried out by even considering the

outfitting part of the design and production of the section and then reciprocating the same

into the economic analysis would ensure a more precise number in terms of savings of the

costs. Also considering the various markets around the world to check for the possibility, if

this integration could be implemented specially in the Europe.



REFERENCES

Literature

M.R. DUFFEY and J. R. VAN DORP Risk Analysis for Large Engineering Projects:

Modelling Cost Uncertainty for Ship Production Activities.

Volker Bertram, ENSIETA ,Jean-Jacques Maisonneuve, SIREHNA and Jean-

David Caprace, Philippe Rigo, ANAST, University of Liège Cost Assessment in

Ship Production.

Integrating cost estimating with ship design process by Laurent Deschamps and

Charles Greenwell SPAR Associates Inc.

Maritime engineering reference book by Antony F Molland.

Practical ship design by D.M.G Watson.

Ship construction by D.J.Eyres.

Practical Ship Design by D.G.M Watson.

Economic Analysis and information from Wikipedia.

Software Related

Geert Tepper,Theodoor de Jonge Nupas Cadmatic vision on cad/cam system

development in today’s ship building environment

Nupas Cadmatic Basic user v6.0 Version manual

Nested Material Manufacturing Technology Improvement from centre of Naval

Ship building information(www.cnst.us)

Aveva user manual handbook

Guide on learning Aveva Marine provided by Aveva Inc.

Auto nesting Procedures taken from http://www3.eng.cam.ac.uk

Auto nesting user manual handbook

Technical Information

Ship Design Group office in Galati, Romania.

Damen Shipyard in Galati, Romania.

Ship Building Quality standards (IT 2370) Damen Shipyards in Galati, Romania.

http://www.cnst.us/

http://www3.eng.cam.ac.uk/


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APPENDIX

The appendix consist of the drawings in a bigger scale to in order to have a better

understanding of the pictures downscaled for the thesis.

Figure 48 Enlarged View



Figure 49 Enlarged view



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---------------------------End of Thesis---------------------------

Documents

Dasarapalli Harshavardhan Reddy · pg. - 4 - Master Thesis developed at “Dunarea de Jos” University of Galati, Romania Abstract Due to the high labour costs and the stiff competition