HALONG SHIPYARD QUALITY STANDARD BOOK 1

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VIET NAM SHIPBUILDING INDUSTRY COrPORATIONHA LONG SHIPBUILDING COMPANY

HA LONG SHIPBUILDING COMPANY

QUALITY STANDARD

BOOK 1

H¹ LONG 2006

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This HLSQS describes the quality standards and the inspection practice which are

applied during repair and building ship process in HA LONG SHIPBUILDING Co.

This document is intended to provide standard instructions to Ship Owners, Class

Surveyors, QC, inspectors, and the production workers, aiming that proper quality level

is maintained during repair and building ship process and eliminating any possible,

disputes among them.

The contents of this documents are applied for all kinds of cargo ships, barges,

drilling rigs & special purpose etc. unless additional requirement are specified in the

contract specifications.

HALONG SHIPBUILDING Co.

preface

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* * contents * *

* * contents * *

Part i: quality standard …………………………… 1

1. hull construction

2. hull out fittings

3. machinery & out fittings

4. piping system

5. painting part

6. electric part

part II: inspection practice …………………………… 155

1. hull inspection

2. out fittings inspection

3. machinery inspection

4. piping inspection

5. electric inspection

6. painting inspection

7. list of inspection/test

part III N.D.E technique...................................................... 210

part IV appendix – I .............................................................. 225

part V appendix - II ............................................................ 256

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part I

quality standard

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Halong shipbuilding co.


Section 1 Hull construction

1.1 material ........................................................................................... 5

1.2 gas cutting ..................................................................................... 7

1.3 fabrication..................................................................................... 9

1.4 deformation................................................................................... 12

1.5 accuracy of hull form ........................................................... 15

1.6 welding ............................................................................................. 17

1.7 alignment & finishing............................................................... 20

1.8 welding technique ..................................................................... 30

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section IHull

construction* shipbuilding &

repair

1.1 Material

1.1.1 Surface flaw

1) Pit

Item Remarks

1. Grade A: Repair is unnecessary

2. Grade B:

1) Outer surface of shell plates. To be repaired by

grinding if necessary.

When painting with epoxy can not be done, grinding is

to be carried out.

2) Others: Repair unnecessary.

3. Grade C: To be repaired by grinding

4. Grade D: Repair method is to be determined after

discussion with owner and class.

* Recommended repair method: Grinding followed

by welding.

Area ratio (%) = 100xplateaofareaTotal

pitofArea

2) Flaking:

Item Remarks

1. Grade A: Repair is unnecessary

2. Grade B: Repair if necessary.

3. Grade C: Repair is necessary

* Repair method (d=depth of defects )

1) d 0.07t (max 3mm)- Grinding

2) 0.07t < d 0.2t: Welding and grinding ( The welded

area should be less than 2% of the total area of a plate ).

- 6 -

3) Other defects

Item Remarks

1. Grade A: Repair is unnecessary.

2. Grade B: Repair is necessary.

* Repair method (d=depth of defects )

1) d 0.07t (max 3mm): Grinding.

2) 0.07t < d0.2t: Welding and grinding. ( The welded

area should be less than 2% of the total area of a plate ).

1.1.2) Lamination

Item Remarks

Local

lamination

In case where the range lamination is

limited, it can be chipped out and built up

by welding as shown in ( a ).

In case where the range of lamination is

limited, also but is near the plate surface,

it is preferable to make the built up

welding as shown in ( b ).

Severe

lamination

requiring a local

renew of a plate

It is recommended to renew the plate

locally, in case where the range of

lamination is fairly extensive.

The standard minimum breadth of a plate

to be renewed is as below.

1) Shell and strength deck under large

constraint : 1600mm

2) Not under large constraint: 800mm

3) Other structural members: 300mm.


Section 1Hull


repair

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Section 1Hull

construction* shipbuilding

1.2 Gas cutting.

1.2.1 Notches. Unit: mm

Item Standardrange

Tolerancelimits

1) Upper edges of sheer strake.

2) Strength deck within 0.6L and free

edges of opening of shell plate.

3) Main longitudinal strength members.

Indentation 5.0

Longitudinal and transverse strength

members.

Indentation 0.1

Free edges

Others Indentation 3

Shell plate and upper deck

within 0.6L

Indentation 2Butt welds


Weld grooves

Fillet welds Indentation 3

Section 1. Hull construction * ship repair

1.2.1 Notches for repair ship Unit: mm

Item Standardrang

Tolerancelimits

1) Upper edges of sheer strake

2) Strength deck within 0.6L and

free edges of opening of shell plate.

3) Main longitudinal strength member.

Indentation 0.1

Longitudinal transverse strength Indentation 5.1

Free edges


Shell plate and upper deck

within 0.6LIndentation 2

Butt welds

Others. Indentation 3Weld grooves

Fillet welds Indentation 3

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Section 1Hull


1.2.2 Dimensions

Item Standardrange

Tolerancelimits

Length of taper

( L)

L 3d

0.5d 1.0d

Depth of

grooves 1.5 2.0

General members compared with correct

ones. 3.5 5.0

Depth of floors and girders in double

bottom 2.5 4.0

Sizes of

members

Breadth of face bars 2.0 3.0~4.0

Section 1 Hull construction * ship repair

1.2.2 Dimension for repair ship.

Item Standardrange

Tolerancelimits

Length of taper

(L)

L 3d

0.5d 0.1d

Depth of grooves 2.0 3.0

- 9 -


Section 1Hull


repair

1.3 Fabrication.

1.3.1 Flange longitudinals Unit: mm

Item Standardrange

Tolerancelimits

Breadth of webs

and flanges 3.0 5.0

Angle between

flange and websCompared with template per 100mm

in breadth of flanges

2.5 4.5

Curvature or

straightness in the

plane of flanges

Per 10m in length

10 25

Curvature of

straightness in the

plane of webs.

Per 10m in length

10 25

1.3.2 Flange brackets.

Item Standardrange

Tolerancelimits

Breadth of

webs and

flanges

3.0 5.0

Angle between

flanges and

webs Compared with template per

100mm in breadth of flanges.

3.0 5.0

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Section 1Hull


1.3.3 Built-up plate. Unit: mm

Item Standardrange

Tolerancelimits

Frames and

longitudinals

Deviation of face plates

1.5

per 100mm

3.0 per

100mm

Distortion of face

plates 1003

ba

1005

ba

Section 1 Hull construction * ship repair

1.3.3 Built – up plates for repair ship Unit: mm

Item Standardrange

Tolerancelimits

Fames and

longitudinals

Deviation of face plates

3.0 per

100mm

5.0 per

100mm

Distortion of face

plates 1005.3

ba

1006

ba

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Section 1Hull


repair

1.3.4 Line heating method

Item Standardrange

Tolerancelimits

Water cooing just after heating Under 6500C

Air cooling after heating Under 9000C* 50 HT

* TMCP Type

50HT

(Ceq>0.38%)

Air cooling and subsequent water

cooling after heating

Under 9000C

(Starting

temperature of

water cooling

to be under

5000C)

* TMCY Type

50HT

(Ceq 0.38%)

* AH~DH

Water cooling just after heating or

air coolingUnder 1000C

* TMCP Type

50HT

(Ceq 0.38%)

* EH

Water cooling just after heating or

air cooling.Under 900oC

1.3.5. Line heat/ cool’ cycles.

Item Remark

TMCP Type 50HT

(AH - DH)Within 3 cycles as far as practicable

TMCP Type 50HT

(EH)Within 2 cycles as far as practicable

Others Not defined

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Section 1Hull


1.4 Deformation

1.4.1.Unfairness Unit: mm

Item Standardrange

Tolerancelimits Remarks

Parallel part ( side ) 4 6

Parallel part ( bottom ) 4 6Shell plates

Fore and aft part 5 7

Double bottom

tank top plates4 6

Bulkheads

Longitudinal bulkheads,

Transverse bulkheads, Swash

bulkheads.

6 8

Parallel part within 0.6L 4 6

Fore and aft part 6 9Strength deck

Covered part 7 9

Bare part 6 8Second deck

Covered part 7 9

Bare part 4 6Forecastle deck,

Poop deck. Covered part 7 9

Bare part 4 6Super structure

deck Covered part 7 9

Lift-able 10 12Car deck

Fixed 6 8

Intermediate deck 8 10

Outside walls 4 6

Inside walls 4 6Deck house wall

Covered part 7 9

Interior membersWebs of girders, transverses 5 7

Floors and girders

in double bottom6 8

Standard and/or

tolerance limits

are to be applied

per each frame,

longitudinal and

stiffener space

respectiveily.

Where above is

not applicable , it

is to be applied

per 1.8m in

length.

(Where above

space is over

1.8m paragraph

1.4.2 is to be

applied)

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Section 1Hull

construction* ship repair

1.4.1 Unfairness for repair ship

Item Standardrange


Parallel part side 4 6

Parallel part bottom 4 6

Shell plate


Double bottom

tank top plates6 6

Bulkheads Longitudinal bulkheads

transverse bulkheads, Swash

bulkheads.

6 8

Paralleled part with in 0.6L 4 6


Strength deck

Covered part 7 9

Bare part 6 8Second deck

Covered part 7 9

Bare part 4 6Forecastle deck,

poop deck Covered part 7 9

Bare part 4 6Super structure

deck Covered part 7 9

Car deck 10 12

Intermediate 8 10

Outside walls 4 6

Inside walls 4 6

Deck house wall

Covered part 7 9

Interior member Webs of girders, trans.5 7

Floors and girders

in double bottom6 8

Standard and/or

tolerance limits

are to be applied

per each frame,

longitudinal and

stiffener space

respectiveily.

Where above is

not applicable , it

is to be applied

per 1.8m in

length.

(Where above

space is over

1.8m paragraph

1.4.2 is to be

applied))

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section IHull


& repair

1.4.2 Deformation per basic length Unit: mm

Item Standardrange


Parallel part 2L/1.000 3L/1.000Shell plates

Fore and aft part 3L/1.000 4L/1.000

Decks, Double

bottom tank tops3L/1.000 4L/1.000

Bulkheads 4L/1.000 5L/1.000

Cabin walls 2L/1.000 3L/1.000

Curtain plates 2L/1.000 3L/1.000

Deformation per basic

length means the

deformation measured

between one transverse

space.

For cabin walls and

curtain plates, the basic

length is about 5m.

1.4.3 Distortion Unit: mm

Distortion of

girder and

transverses at the

part of upper edge

and flange.

Per span 5 8

L 1000 5 8

1000<L<35001000

23

L

1000

26

L

Distortion of

longitudinals,

transverses,

frames, beams

and stiffener at

the part of flange .

L 3500 10 13

Distortion of H

type pillars

between decks5 8

Distortion of

tripping brackets

and small

stiffeners.

Distortion at the

part of free

edges

1/2t t~

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Section 1Hull


& repair

1.5 Accuracy of hull form

1.5.1 Principal dimension

Item Standard range Tolerance limits

L.B.P. 50/100m Not defined

Breadth ( Moulded ) 15 Not defined

Depth ( Moulded ) 10 Not defined

1.5.2 Deformation of hull form Unit: mm

Item Standardrange Tolerance limits

Flatness of keel Deformation for the whole length 25 Not defined

30 Not defined

Cocking-up

20 Not defined

Rise of floor

Rise of floor amid ships

15 Not defined

1.5.3 Others

Unit: mm

Item Standardrange Tolerance limits

Draft marks 1.0 2.0

Free board marks 0.5 1.0

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Section 1Hull


& repair

1.5.4 Special sub-assembly

ItemStandard

range

Tolerance

limitsRemarks

Distance between aft

edge of boss and aft peak

bulkhead ( b).

5 10

Twist of sub-assembly

(c)5 10

Deviation of rudder from

shaft center line ( d )4 8

(C)Twist of plane including

Blo

ck s

ub-a

ssem

bly

ster

n fr

ame

Others Refer to the section of curved plate block

Twist of rudder plate 6 10 Correct or re-assemble partially

Rud

der

OtherRefer to the section of the curved plate block sub-

assembly

Flatness of top plate of

main5 10

Breadth and length of top

plate of main engine bed 4 6

Mai

n en

gine

bed

Others Refer to the section of the flat plate block sub-assembly

- 17 -


Section 1Hull


repair

1.6 Welding

1.6.1 Shape of bead

ItemTolerance

limitsRemarks

Butt

Over-lap

Fillet

090

1. 090 : Repair

is unnecessary

2. In case 090 ,

grinding or welding

in necessary to

make 090

Skin

plates

and face

plates

within

0.6L

d 0.5

(over

90mm

continuous)

Butt

Others d 0.8

Undercut

Fillet d 0.8

To be repaired by

using fine electrode

( Avoid short beads

for higher tensile

steel )

Leg length

and Throat

thickness L 0.9L0

t 0.9t0

L0: Design leg

length

t0: Design throat

thickness

- 18 -


Section 1Hull


& Repair

1.6.2 Distortion of welding joints Unit: mm

ItemTolerance

limitsRemarks

Skin plates within

0.6L

6

Fore and aft shell

plating and

transverse strength

member

7

Angular

distortion of

weld joints

Span of frames or

beams Others 8

In case where it is

over tolerance

limits, it is to be

repaired by line

heating or re-

welded after

cutting and

refitting

1.6.3 Short beads Unit: mm

Item Tolerance limits Remarks

Higher tensile steel ( 50kg/mm2 class ) 50

TMCP type 50HT (Ceq 0.36%) 10

Mild steel( including take and repair welding ) Not defined

1.6.4 Arc strike Unit: mm


Higher tensile steel ( 50kg/mm2

class ) and grade “ E “ of mild

steel.

Not allowed In case where arc strike made

erroneously, one of the following

repair methods is applied.

1) Weld over 50mm bead on the arc

strike.

2) Remove the hardened zone by

grinding.

1.6.5 Alternation case

ItemAcceptable

limitsRemarks

Short bead & Arc strike of Higher

tensile steel.

10 In case of during repair, building up

on surface after discussion with class

& owner.

1) To be preheating at fault areas.

- 19 -


Section 1Hull


& repair

1.6.6 Weld profile

1) Concave bead Unit:

Tolerance limits Remarks

Unacceptable L=min 0

2) Convex bead

Max 1.6

L 8

Max 3.0

8 L 25

Max 4.5

25 L

3) Division of position

Manual weldingMachine

welding

PlatVertical &

horizontalOverhead

H 3.0mm H 4.0mm H 4.5mm

H 4mm

4) Bead repair

It the bead height is over the standard range which shows bad appearance, the bead will be

repaired by grinding.

- 20 -


Section 1Hull


& repair

1.7 Alignment and finishing

1.7.1 Minimum distance of weld to adjacent weld Unit: mm

ItemTolerance

limitsRemarks

a 30

Butt

weld

to butt

weld

a 0

a 10

a 0Butt

weld

to

filler

weld

a 5

Smaller distance can be

acceptable in special

cases.

- 21 -


Section 1Hull


& repair

1.7.2 Minimum distance between holes and between hole and end of member.

Distance ( s)Description

“A” Space “B” SpaceRemarks

1) Between holes

2

21 dd d1+d2

2) Between hole and plate, and face

)75..(

22

1

nmi

dS

dS

S1=d

S2=2d

(min. 75)

3) Between hole and scallop

)50.(min2

21 dd d+R

(min. 50)

4) Between hole and slot

2

Bd d+B

s 200 (ABS)

s 180 (LR)

s D (NK)

5) Between slots

s1 2B

s2 2d and

s2 2B

- 22 -


Section 1Hull


& repair

1.7.3 Treatment of holes made erroneously.

ItemTolerance

limitsRemarks

A* Open the hole to over 100Skin plate

Or B* Open the hole to over 300

B* Open the hole to over 300

D<300

(D: diameter of holes )

Other

or C* Open the hole to over 100

Skin plate B*d 300

Others B* or C*

Scallop, slot B* or C*

* Method of treatment

A: spigot patch

0

5040

B: Closing by butt welding with back gouging

0

5040

C: Closing by lapping piece

L 50 or L 2t1+25

Whichever is greater

- 23 -


Section 1Hull


& repair

1.7.4 Gap of joints Unit: mm

ItemTolerance

limitsRemarks

1. Manual welding

a 5

1. 5<a 16

1) Welding with backing strip or flat type

ceramic back material.

2) Welding at reverse side after chipping.

2. 16<a 25

1) Build-up edges with backing strip of

flat type ceramic backing material to keep

the gap less than 5mm ( make stringer

beads )

2) Welding.

3) Welding at reverse side after shipping

3. a>25

Repair method is to be determined after

discussion with owner & class. Normally

partial renew by min. size 300mm is

applied.

Butt

joints

2. Flexible asbestos

Backing ( F.A.B )

a 5

a>5

1) First or second pass by FCAW or

GMAW as shown in 1.7.4 item 4.

2) The rest by automatic (SAW)

- 24 -


Section 1Hull


& repair


ItemTolerance

limitsRemarks

3. Submerged Arc welding

(S.A.W)

a 8

1. 0.8<a a 5: Make sealing bead.

2. a>5: Refitting

Butt

joints

4. F.C.A.W and G.M.A.W

a 12

1. 12< a 25

1) Build-up on edges with backing

strip of flat type ceramic backing

material to keep the gap within

12mm ( to make stringer beads.)

Build-up on the edges should not

exceed 1/2t1 . nor 12.5mm whichever

is smaller.

2) Welding.

2. a>25

Repair method is to be determined

after discussion with owner & class.

Normally partial renew by min. size

of 300mm is applied.

- 25 -


Section 1Hull


& repair


ItemTolerance

limitsRemarks

Fillet

Joints

1. Filler joints without

groove

t1 t2a 3

1. 3< a 5

Leg length to be increased: L=L0+(a-3)

(L: increased leg length)

(L0: Leg length indicated on drawing )

2. 5< a 16

Welding with bevel preparation

(1) To make bevel edge of web to 300~450

(2) To attach backing strip or ceramic

backing material.

(3) Welding.

(4) To weld at reverse side after chipping.

3. 16< a 25

1) Bevel preparation (300~450)

2) Build-up of each plate edge should not

exceed 1/2t1 nor 12.5mm whichever is

smaller.

Gap after build-up should not exceed

5mm.

4. a>25

Partial renew with a size of min. 300mm

- 26 -


Section 1Hull


& repair


ItemTolerance

limitsRemarks

Fillet

joints

2. Fillet joints with

groove

a 5

1. 5< a 16

1) To attach backing strip or ceramic

backing material.

2) Welding

3) To weld at reverse side after chipping.

2. 16< a 25

Build-up of base plate

Gap after build-up should not exceed

5mm.

3. Partial renew with a size of min.

300mm.

Lap

joints

a 3 1. 3< a 5

Leg length shall be increased by the

amount of gap ( indicated leg length gap )

2. a>5

Refitting.

- 27 -


Section 1Hull


& repair

1.7.5 Alignment

Item Tolerance limits

Strength

members

a 0.15t1,

(max.3)

a>0.15t1, or a>3

Refitting

Butt joints

a: Difference

t1 t2

Othersa 0.2t1

(max.3)

a>0.2t1, or a>3

Refitting

Strength

members

a 1/3t 1. 1/3t1<a 1/2t1

Leg length to be increased.

For “A” & “B”, increase leg length by

10%t1.

2. a>1/2t1: Refitting

* For members having small breadth ( i.e.

face plate of built-up member ), doublers

or carling can be attached after discussion

with owner & class.

Fillet joints

a: Difference

t1 t2

Others a 1/2t1 a>1/2t1

Refitting

- 28 -


Section 1Hull


& repair

1.7.5 Alignment

Item Tolerance Remarks

Alignment of butt

joints in stiffeners

Flange width

s 0.04b

max. 8mm

If s 0.08b

Grind corners to

smooth. Taper over

distance min.

L=30s

If s>0.08b release and

adjust over distance

min.

L=50s

Overlap brackets, gap

before manual

welding

For weld

throat

thickness

a 4mm

Gap s 2mm

for a>4mm

s 3mm

If s 5mm

Parts may be pulled

together and welded

If s>5mm

Release and adjust

- 29 -


Section 1Hull


& repair

1.7.5 Alignment

Item Tolerance Remarks

1. Position of nearest scallop

d 75mm

If d>75mm

The nib between scallop

and opening to be cut,

and lug to be welded to

plating, see figure

Openings for

stiffeners passing

through girder webs

2. Gap

s 3mm

s 3mm

s 5mm. Weld throat

thickness to be increased

by one weld bead or

2mm.

If 5<s 10mm.

Chamfer and build up by

welding.

If s>10mm. Cut off nib

and fit lug of same height

as nib.

Sufficient for weld

access.

- 30 -


Section 1Hull


& repair

1.8 Welding technique

1.8.1 Welding sequence

1. Welding sequence is to be carefully planned for each structural member. So that the parts can be

jointed freely without any deformation or residual stress after welding.

2. Welding sequence for each part actually have some varieties depending upon the surrounding

circumstances, but in principle, the following sequences are to be kept at every welding stages.

1) Welding is proceeded symmetrically from center of joint both sides. E. G. incase of erection joint.

Welding should be done from a mid-ship to stem or stern and from center line of the ship to the

direction of side shell.

2) The part where the deformation or residual stress is anticipated to be welded first, and then others to

be done secondly.

3. Welding sequence is generally adopted from be assembly stage.

1) Welding of panel.

2) Butt joints are welded prior to welding of seam line.

- 31 -


Section 1Hull


& repair

2) Welding of profiles on panel

Note that a release length of 100mm is provided in the horizontal seams at each corner of the insert

plate.

1. Weld framing to within 100mm of un-welded butts and seams.

2. Weld vertical butt complete

3. Weld vertical butt complete

4. Weld un-welded framing in way of vertical butts

5. Weld horizontal seam including release lengths

6. Weld horizontal seam including release lengths

7. Weld un-welded framing in way of horizontal seams

- 32 -


Section 1Hull


& repair

3) Welding of insert

- 33 -


Section 1Hull


& repair

4) Penetration parts

- 34 -


Section 1Hull


& repair

1.8.2 Slot welding

Symbol Application for thickness Kind of plate

t 50.5 All

t<16.0

w=t

t+8 2.25w

L<10.0w

p>2L

Det

ails

of

wel

d jo

ints

t 16.0

w t/2 vµ w 16

t+8 2.25w

L<10.0w

p>2L

Beveled angle Position welding Application of member

00 All All

- 35 -


Section 1Hull


& repair

1.8.3 Bilge keel joint weld

Welding detail ( For all type )

- 36 -


Section 1Hull


& repair

1.8.4 Stern frame structure

1) Thicker material ( build-up )

Joint Details of Cast Steel Stern Frame

2) Butt joints

Details of butt joints of steel castings/ Forgings and steel plates

3)Lap joints

Details of Lap joints of steel Casting/ Forging and Steel plates

- 37 -


Section 1Hull


& repair

1.8.5 Butt welding on permanent backing

- In case where it is method are to be applied, after discussion & approved with class and owner.

Unit: mm


t 8 3 – 5

8<t 20 5 – 8

t<20 8 – 10

* Size of backing plates

- Normal: 6 - 10

- 38 -


Section 1Hull


& repair

1.8.6 Pre-heating of before welding

1) Environment

Proper precaution are to be taken to insure that all welding is done under condition where the welding

site is protected against the deleterious effects of moisture, wind and severe cold.

2) Method

The use of preheat control are to be considered when higher strength steels, thicker cross section and

subject to high restraint.

- Range of heating areas: Min.75mm from weld points.

- Heating direction: all direction

Item Which is heat temp’Control of heat

temp’Remarks

Mild steel -50C Min 160C

Min 160CH.T steel 00C

Min 500C - Thicker plate

- Restaint structure

TMCP type

(Ceq 0.36)

-50C Min 200C

- 39 -


Section 1Hull

construction* modification

1.8.7 Bulb plate modification method

Existing L2 Type

* C=15 mm

L3 type

* C=15 mm

Joint detail ( L3 type )

Looking down

- 40 -

xcx


Section 1Hull

construction* modification

* Size comparative sheet

Bulb plate L3 Type L2 TypeID.N

HT B T Area HT B T1 T2 A HT B T1 T2 A

(mm) (mm) (mm) (Cm2) (mm) (mm) (mm) (mm) (Cm2) (mm) (mm) (mm) (mm

)

(Cm2)

1 140 19.0 7 12.6 155 20 7 10 12.85 140 50.0 7 10 14.12 140 19.0 8 13.8 155 20 8 10 15.6 140 50.0 8 10 15.43 140 19.0 9 15.2 155 20 9 10 17.3 140 50.0 9 10 16.74 160 22.0 7 14.6 175 25 7 10 15.8 160 50.0 7 10 15.55 160 22.0 8 16.2 175 25 8 10 17.7 160 50.0 8 10 17.06 160 22.0 9 17.8 175 25 9 10 19.6 160 50.0 9 10 18.57 180 25.0 8 18.9 195 25 8 10 19.3 180 50.0 8 10 18.68 180 25.0 9 20.7 195 25 9 10 21.4 180 50.0 9 10 20.39 180 25.0 10 22.5 195 25 10 10 23.5 180 50.0 10 10 22.010 180 25.0 11 24.3 195 25 11 10 25.6 180 50.0 11 10 23.711 200 28.0 9 23.8 215 30 9 15 25.2 200 50.0 9 12 22.912 200 28.0 10 25.6 215 30 10 15 27.5 200 50.0 10 12 24.813 200 23.0 11 27.6 215 30 11 15 29.8 200 50.0 11 12 26.714 200 23.0 12 29.6 215 30 12 15 32.1 200 50.0 12 12 28.315 220 31.0 10 29.0 235 30 10 15 29.5 220 60.0 10 12 28.016 220 31.0 11 31.2 235 30 11 20 33.5 220 60.0 11 12 30.117 220 31.0 12 33.4 235 30 12 20 36 220 60.0 12 12 32.218 240 34.0 10 32.4 255 35 10 20 34 240 60.0 10 15 32.519 240 34.0 11 34.9 255 35 11 20 36.7 240 60.0 11 15 33.820 240 34.0 12 37.3 255 35 12 20 39.4 240 60.0 12 15 36.021 260 37.0 11 36.7 275 30 11 20 39.9 260 60.0 11 20 38.422 260 37.0 11 36.7 275 40 11 20 39.9 260 60.0 11 20 38.423 260 37.0 13 43.9 275 40 13 20 45.7 260 60.0 13 20 43.224 280 40.0 11 42.6 295 40 11 25 44.1 280 62.0 11 20 41.925 280 40.0 12 45.5 295 40 12 25 47.2 280 62.0 12 20 48.626 280 40.0 13 48.2 295 40 13 25 50.3 280 70.0 13 20 47.827 300 43.0 11 46.7 315 40 11 30 48.3 300 75.0 11 20 45.828 300 43.0 12 49.7 315 40 12 30 51.6 300 75.0 12 20 48.629 300 43.0 13 52.8 315 40 13 30 54.9 300 75.0 13 20 51.430 300 46.0 14 55.8 315 40 14 30 58.2 300 80.0 14 20 55.231 320 46.0 12 54.2 335 45 12 30 55.5 320 80.0 12 20 52.032 220 46.0 13 57.4 335 45 13 30 59 320 85.0 13 20 56.033 320 46.0 14 60.7 335 45 14 30 62.5 320 85.0 14 20 59.034 320 49.0 15 63.9 335 45 15 30 66 320 85.0 15 20 62.035 340 49.0 12 59.8 355 50 12 32 60.4 340 90.0 12 20 56.436 340 49.0 13 62.2 355 50 13 32 64.1 340 90.0 13 20 59.637 340 49.0 14 65.5 355 50 14 32 67.8 340 90.0 14 20 62.838 340 49.0 15 68.9 355 50 15 32 71.5 340 90.0 15 20 66.039 370 53.5 13 69.6 385 60 13 32 71.2 370 90.0 13 25 67.440 370 53.5 14 73.3 385 60 14 32 75.2 370 90.0 14 25 70.841 370 53.5 15 77.0 385 60 15 32 79.2 370 90.0 15 25 74.342 370 53.5 16 80.7 385 60 16 32 83.2 270 90.0 16 25 77.743 400 58.0 14 81.4 415 65 14 35 82.95 400 90.0 14 30 78.844 400 58.0 15 85.4 415 65 15 35 87.25 400 90.0 15 30 82.545 400 58.0 16 89.4 415 65 16 35 91.55 400 90.0 16 30 86.246 400 58.0 17 93.4 415 65 17 35 95.85 400 90.0 17 30 89.947 430 62.5 15 94.1 445 75 15 35 95.25 430 95.0 15 35 92.548 430 62.5 17 103.0 445 75 17 35 104.5 430 95.0 17 35 100.449 430 62.5 19 111.0 445 75 19 35 113.7 430 95.0 19 35 108.350 430 62.5 21 126.0 445 75 21 35 122.9 430 95.0 21 35 116.2

- 41 -


Section 2 Hull outfitting

2.1 hatch cover ................................................................................. 42

2.2 hatch coaming ........................................................................... 50

2.3 small hatch .................................................................................. 52

2.4 air vent system .......................................................................... 53

2.5 steel inclined ladder……………………………………… 54

2.6 Steel vertical ladder............................................................ 54

2.7 Hand rail........................................................................................ 55

2.8 Storm rail ..................................................................................... 55

2.9 Guard rail ..................................................................................... 55

2.10 anchor chain ............................................................................... 56

2.11 Derrick boom ............................................................................... 58

2.12 derrick boom repair................................................................ 59

2.13 Deck covering ............................................................................. 60

2.14 insulation ..................................................................................... 63

- 42 -


Section 2 Hull outfitting * h/c fabrication

2.1 Hatch cover Unit: mm

ItemStandard

range

Tolerance

limits

1) Hatch cover ( single pull type )

Length ( 1 hatch ) L 5 )000,10

43(

L

Length ( 1 panel ) W 3 5

Breadth B 3 )000,10

43(

L

Height of hatch cover h 3 4

Diagonal difference ( hatch ) (L1-L2) 5 8

Diagonal difference (1 panel) (L3-L4) 4 6

Vertical deflection d1 3 4

Transverse deflection d2 3 4

Deformation of top plate d3 4 6

Height of packing gutter d4 1 2


Breadth of packing gutter d6 1 2

- 43 -


Section 2 Hull outfitting * H/c fabrication

ItemStandard

range

Tolerance

limits

Top plate clearance d7 3 5

Top plate difference (d8) 2 4

Side & end plate difference (d9) 2 4

Width of packing groove d10 1 2

Deviation of compression bar centering d11 32

t

Compression of packing d12 3 5

Span ( between centering ) d13 2 3

Installing height d14 2 3

Installing pitch d15 2 4


Balancing wheel height d17 2 3

Balancing wheel distance d18 2 4

Balancing wheel pitch d19 2 4

- 44 -



ItemStandard

range

Tolerance

limits

2) Hatch cover ( side rolling type )


43(

L


Breadth B 5 )000,10

43(

L


Diagonal difference ( 1 hatch ) (L1-L2) 5 10

Diagonal difference ( 1 panel ) (L3-L4) 4 5



Deformation of top plate (d3) 3 4

Height of packing gutter D4 1 2

Height of packing gutter D5 1 2

Breadth of packing gutter D6 1 2

- 45 -



ItemStandard

range

Tolerance

limits



Sid & end plate difference (d9) 2 4



t



Installing height d14 2 3



- 46 -



ItemStandard

range

Tolerance

limits

3) Hatch cover ( folding type )


43(

L


Breadth B 3 )000,10

43(

L



Diagonal difference ( 1 panel ) (L3-L4) 4 5







- 47 -



ItemStandard

range

Tolerance

limits



Sid & end plate difference (d9) 2 4



t



Height of wheel d14 2 3

Distance of wheel & main hinge d15 2 3

Distance of main hinge & inter hinge d16 2 3

Distance of wheel & inter hinge d17 2 3

Gap of main hinge & cylinder pin d18 3 –

Height of main hinge & cylinder pin d19 3 –

Height of main hinge d20 2 3

Height of inter hinge d21 2 3

- 48 -



ItemStandard

rangeTolerance limits

4) Hatch cover ( pontoon type )

Length ( 1 panel ) L 5 )000,10

43(

L

Breadth B 5 )000,10

43(

L




Diagonal difference d2 3 5





- 49 -



ItemStandard

rangeTolerance limits

4)

Container cone level (20ft) 3 4

Container cone level (40ft)d7

3 4

Length ( container cone 20ft ) 3 5

Length ( container cone 40ft )L3

3 5

Breadth (container cone 20ft ) 2 3

Breadth (container cone 40ft )B1

2 3

Diagonal difference( 20ft ) 6 8

Diagonal difference ( 40ft )(L4-L5)

8 10

- 50 -


Section 2 Hull outfitting *h/coamingfabrication

2.2 Hatch coming

2.2.1 Typical dimension

ItemStandard

range

Tolerance

limits

Length L 5 10

Breadth B 5 10

Diagonal (L1-L2) 10 15

Straightness of top plate ( side coaming ) d1 3 5

Straightness of top plate ( end coaming ) d2 4 5

Straightness of top plate ( partially/m ) d3 2 3

Straightness of hatch coaming ( partially/m)d4 3 Not

defined

Straightness of hatch coaming ( all length )d5

)000,10

43(

L ″

Alignment of wheel & guide rail d6 – Min.0

- 51 -


Section 2 Hull outfitting *h/coaminginstallation

2.2.2 Dimension of repair ship

Item Tolerance limits

Length d1

Breadth d2

Diagonal (L1-L2)

A. H.coaming wall d1 d2 L1-L2

1) Single pull type 10 10 15

2) Side rolling type 12 12 15

3) Pontoon type 12 12 15

4) Folding type 12 12 15

B. Compression bar fitting

Item Distance Straight Level

1) Single pull type 6 7 5

2) Side rolling type 5 5 5

3) Pontoon type 5 5 5

4) Folding type 5 5 5

- 52 -


Section 2 Hull outfitting * small hatch

2.3 Small hatchs

2.3.1 Height ( refer to ILLC code )

1) Position 1: H=600 mm

2) Position 2: H=450 mm

2.3.2 Dimension & Material.

1)New shipbuilding: As followed design factor.

2) General repair : As followed ship’s drawings.

3) Material: Mild steel ( Normal practice )

4) Thickness : 10mm or more ( class require )

Item Standard Tolerance

* Small steel hatch cover type ( square type )

a. Width or length d1,2

b. Difference between diagonal d3

c. Straightness/m d4

d. Bending/m d5

2

2

1

2

5

- 5

+2

3

- 53 -


Section 2 Hull outfitting * Vent/ ductsystem

2.4 Air vent system

1) Height of air pipe

- Position 1: Min 900m

- Position 2: Min 760m

2) Height of others.

- Refer to design standard or existing ones.

3) Installation/type or size ( shipbuilding )

- Refer to design dwg’ with class and owner requirement representative

4) General repair, when during dry docking for I.L.L

Item Wire net (SUS 304) Remarks

Float type

Air pipe head

2 mesh x # 19 S.W.G

10 Mesh x # 31 S.W.GInsect proof screen

2 Mesh x # 19 S.W.G Rat proof screenLouver and Mushroom vent

2 Mesh x # 19 S.W.G B/fly closing device

- 54 -


Section 2 Hull outfitting * ladder & rail

2.5 Steel inclined ladder

2.5.1 Installation Unit: mm

Degree ( ) Breadth Pitch

Normal 50 – 550 Min. 600 200 – 280

Tolerance ±50- -

2.5.2 Other rule & regulation

Authority ( ) Breadth Pitch

SBG 450 - 550 MIN. 600 180 – 230

NMD 450 MIN. 800 250 – 350

USCG MAX.450 MIN. 710 -

NSASN 550 – 650 400 – 700 250 – 350

DOT 600 300 – 600 -

2.5.3 Clear height

2.6 Steel vertical ladder

Breadth Pitch ( step ) Depth ( support )

Normal 300 300 150

Tolerance 400 350 180

- 55 -


Section 2 Hull outfitting * ladder & rail

2.7 Hand rail Unit: mm

Item Standard Remarks

Total height Min. 1000

Clear lower height Max 230

Clear middle height Max 380

Clear upper height Max 380

Space of stanchion 1200 – 1500

Space of stavs 3600 – 4500

2.8 Storm rail

2.9 Guard rail

Gate type guard rail chain rail type guard rail

DECK DECK

- 56 -


Section 2 Hull outfitting * anchor chain

2.10 Anchor chain cable

2.10.1 Cable measuring

- Measure at 3 links of each shots

- Loss limit: B.V = 13.5%

Others =12.0%

2.10.2 Stud repair of common link

1) Loose stud: welding ( one side only )

2) Missing stud: fabrication & welding

- Grade U1: SF45 or similar

- Grade U2: SF 45 or similar

- Grade U3: SF 65 – 70 or similar

(T.S: 690 N/mm2)

2.10.3 Shot marking

1) Paint: Kenter shackle : red color

: Common links : white color

2) The cotton canvas shall be secured by wire ( sus or copper )

- Detail of cotton canvas

* D: Cable normal diameter

- 57 -


Section 2 Hull outfitting * anchor chainsmarking

- 58 -


Section 2 Hull outfitting * derrick boom

2.11 Derrick boom construction


limits

a. Length d1

b. Bending d2

c. Diameter d3

d. Roundness for piece fitting ( At boom seat ) DL- DS

*Boom & piece fitting d

7

5

0 - 0.01d

10

10

10

10

0 + 0.01d

20

20

l

- 59 -


Section 2 Hull outfitting * derrick boom

2.12 Derrick boom repair

2.12.1 Boom insert repair

- Material: Same as original DWG

- Bevel: 45 – 500

- Root gap: 4 – 5mm

- Backing: Steel or pipe

(Min’ : 5.0t)

2.12.2Boom reinforcement by double plate

- Material : Same as Dwg’

- Thickness: 10t

2.12.3 Test, after repair ( welding )

1) Butt joint: visual & N.D.T ( P. T or U. T )

2) Fillet joint: Visual inspection.

2.12.4 Test confirmation of load applied.

- Load test: Proof load test with steel weight.

* Following I.L.O guidance

- 60 -


Section 2 Hull outfitting * inaccommodation

2.13 Deck covering

2.13.1 A- 60 deck covering ( Floating floor type )

7 Finishing materialVinyl sheet or

carpet

6 Top coat Latex + powder1mm or

0.5mm

5 Middle coat Latex + powder 14mm

4 Base coat Latex + powder 3mm

3 Expanded metal SS41 (galv’d) 2.3t

2 Mineral wool 40t d=200kg/m3

1 Silica bond silica 2mm

No Description Material Size Q’ty Remarks

STEEL DECK

- 61 -



2.13.2 A-60 deck covering ( Silicate board type )

7 Finishing materialVinyl sheet or

carper

6 Top coat Latex + powder

5 Middle coat Latex + powder 10mm

4 Metal lath SS41 (galv’d) #22

3 Base coat Latex + powder

2 Silicate board 25mm

1 Silica bond silica 2mm

No Description Material Size Q’ty Remarks

STEEL DECK

- 62 -



2.13.3 Gutter way ( for galley )

(1) SUS type (SUS-304) (2) Tile type.

2.13.4 Finishing material.

(1) Vinyl tile

(2) Vinyl sheet

(3) Carpet

(4) Rubber mat

1) Perforated ( ring ) type: Outside floor

2) Groove type : inside floor

(5) Tile

1) Non slip quarry tile

2) Mosaic tile

3) Ceramic tile

4) Corner tile

2.13.5 Wooden deck

(1) Oregon pine

(2) Apiton

3) Red pine

(4) Cedar

(5) Teak

- 63 -



2.14 Insulation ( Typical only )

2.14.1 Deck insulation ( A-60)

2.14.2 Bulkhead insulation ( A-60 )

Vertical section Horizontal section

- 64 -



2.14.3 Det. Of insulation bottom

Not sweat

gutter way

area

Note: finishing material is glass cloth where not covered with lining

material

Sweat gutter

way area

Note: 1. The A-60 class insulation should be wrapped 380mm to

adjacent deck head and steel bulkhead.

2. Finish material is glass sloth where not covered with lining

material.

- 65 -



2.14.4 Pipe insulation method

(Typical of prov’ refr’ system )

Sketch

Mark Name Material Remark

Pipe Copper

Insulation mould Poly ethylene with al-foiled fiber glass cloth

Cable tie Nylon P=300(ABT)Material

TypeAl-foiled fiber glass cloth

tape.

0.32mmx8

100

Application of insulation

Type of insulationThickness of piping

insulationPiping

systemLocation

Pipe Flange Nom. Dia.Thickness

of insul.

Remark

Refrigerant

(R-22)

pipe

(return gas

pipe oily)

Provision ref.

system All size 25mm

- 66 -


Section 3 Machinery & outfittings

3.1 Main engine & shaft line ................................................................ 67

3.2 Rudder arrangement ....................................................................... 69

3.3 steering gear ........................................................................................ 70

3.4 Pintle / bush ............................................................................................ 71

3.5 Rudder repair( structure ) ............................................................ 73

3.6 Rudder repair( jumping ) .................................................................. 73

3.7 Rudder repair ( pintle locking ).................................................. 73

3.8 Rudder repair ( Gudgeon )............................................................... 74

3.9 Rudder repair ( alignment ).......................................................... 75

3.10 Propeller ( iso r4841).......................................................................... 76

3.11 Blade damage repair........................................................................ 79

3.12 Tip preparation for welding........................................................ 80

3.13 Propeller welding............................................................................. 81

3.14 Stern tube............................................................................................... 82

3.15 Tail shaft sleeve limit .................................................................... 82

3.16 Shaft cone ( taper ) part................................................................. 82

3.17 Coupling alignment.......................................................................... 83

3.18 Line shaft alignment ....................................................................... 83

3.19 Aux’ machinery.................................................................................... 84

3.20 D/G engine ................................................................................................ 86

3.21 traveling deck crane ..................................................................... 87

3.22 boiler tube deformation............................................................... 88

3.23 Boiler tube repair.............................................................................. 89

3.24 boiler tube repair.............................................................................. 89

3.25 boiler drum fab’ & welding ......................................................... 90

3.26 Boiler tube joint welding ............................................................. 94

- 67 -


Section 3Machinery

& outfittings* Main

machinery

3.1 Main engine & Shaft line Unit: mm


1) Seating

Flatness of top of main engine bed

(before milling)

8 12

2) Crank shaft deflectionx

000,10

1 stroke

*Note: this range may

be changeable as per

maker’s standard

xS000,10

1

* Note: this

range is repair

ship practice

3) Installation

(1) Contact, ratio

- Main engine chock liner

- Bearing chock liner

(2) Clearance between liner and base

70%

60%

0.04

60%

50%

Not defined

25-35 Min 12

160C

(3) Chock fast orange

1. Thickness t

2. Metal temperature

3. Curing time 130C external heat

210C 12 hour

160C 24 hour

130C 48 hour

- 68 -


Section 3Machinery

& outfittings* Main

machinery

Unit: mm


4) Centering ( New shipbuilding )

(1) Diameter of piano wire: d

(2) Tension of piano wire : t

(3) Deviation between rudder center line and

shaft center line.

- Dead weight over 100.000 ton: t1

- Dead weight below 100.000 ton : t2

5) Centering ( Repair ship )

(1) Diameter of piano wire : d

(2) Tension of piano wire : t

(3) Deviation between rudder center line and

shaft center line.

d=0.7

t=50kg

t1 5

t2 4

d=0.5-0.7

t=50kg

d=0.7 0.1

t=50 5kg

t1 8

t2 6

0.1

10kg

t1 10

t2 8

- 69 -


Section 3Machinery

& outfittings* rudder

3.2 Rudder arrangement Unit: mm


1) Installation

(1) Contact ratio

(2) Clearance between carrier and liner

60%

0.04

>50%

<0.05

2) Centering

Deviation between center line of rudder carrier and

pintle.

3) Centering of repair ship for checking only

d<0.3

d<1.0

d 0.5

d<1.5

- 70 -


Section 2Machinery

& outfittings* Steering gear

3.3 Steering gear arrangement Unit: mm


1) Installation

(1) Ram cylinder type

- Contact ratio

- Clearance between liner and base

(2) Rotary vane type

- Contact ratio

- Clearance between liner and base

<0.06

60%

Not defined

Not defined

2) Alignment

3) Alignment for general repair

(d1) 1

(H1-H2) 0.08

d1 1.5

H1-H2 0.2

(d1) 2

(H1-H2) 0.15

d1 2.0

H1-H2 0.5

- 71 -


Section 2Machinery

& outfittings* Rudder

pintle/ bush

3.4 Pintle/ Bush


1) Contact ratio of cone part

2) Pintle clearance

3) Material: sleeve

4) Thickness ( bush/ sleeve)

Unit: mm

Dia <100 100-

150

150-

200

200-

300

>300

Sleeve 7.5 9 10 12 15

Bush 10 12 15 20 25

* NK:

- Thickness of pintle sleeve

- Thickness of pintle bush

- dp<300

- dp>300

- Thickness of stock sleeve

- Thickness of neck bush

- dp<300

- dp.300

5) Non-Metallic bush material (HMD)

* Brand: HFG-LITE CR 510

* Max’ surface pressure: 56kg/cm2

* Class authority: KR, NK, BV, LR, DNV, GL,

ABS

60%

Builder’s practice

bc/sus, bc/resin

0.03dp+5

0.05dp+5

0.05dp+11

0.03dp+3

0.05dp+2

0.03dp+8

50%

Metal:

0.8~2.0mm

Non metal:

1.5~2.5mm

Metal:

- Sleeve: 6.0

- Bush: 8.0

Non metal

- Bush:10.0

- 72 -


Section 2Machinery

& outfittings* Rudder

pintle/ bush

3.4.2 Rudder bearing clearance recommended values

● A.B.S guidance

Approximately 1% of the pintle diameter to a maximum 6.3mm

Other: R/100x3.0 or 0.4 mm/inch

● N.K guidance

The limit of wear down of the pintle bush is 5 to 6mm the bearing clearance in diameter, and the neck

bearing is 3 to 4mm abnormal wear-down.

● B.V guidance

* Pintle diameter 50 to 100 = 5mm

* Pintle diameter 100 over = d/100+4

● Yard guidance

* D/100+2= Upper pintle clearance

* D/100+3= Lower pintle clearance

● D.N.V guidance

I = Renewal necessary

II = Renewal recommended

III= New/ repaired

● L.R guidance- Recommend: 4.0+0.002 pintle diameter- Renewal: 5.0+0.02 pintle diameter● K.R guidance- 0.01 Dia’+4mm of pintle- 0.01 Dia’+2mm of neck

- 73 -


Section 3Machinery


repair

3.5 Structure welding

Dimensions ( m)Plate thickness

(mm) a b

Kind of fillet

weld

Up to 6 65 35

7~18 75 40

19 85 45

F1

Slot welding

Aft end construction of rudder

3.6 Jumping stopper Unit: mm

Item Standard range Tolerance

The clearance between jumping stopper and

rudder carrier

C 2.0 2.0

3.7 Pintle locking

Locking device for pintle nut Locking ring or bar

- 74 -


Section 3Machinery


repair

3.8 Center of gudgeon

Tolerance

1.50mm

- Carrier

- Upper

- Lower

3.8.1 Gudgeon repair ( case 1)

1) Build –up by welding

2) Re- boring

3) Re- alignment check

smaw

Machine practice

Piano wire

3.8.2 Gudgeon repair ( case 2)

1) Boring to oversize

2) Fabricated steel liner

3) Inserted the steel liner

Machine practice

Forged steel

interference

0.005~0.01

T: Min 6.0mm

W: 0.35xL

- 75 -


Section 3Machinery


repair

3.9 Rudder alignment


Deviation of height(H) 0.5 1.5

Deviation of center line 0.5 1.5

3.9.1 Adjustment

1) Machine-up the palmMin thickness

0.03 x stock dia

2) Contact ratio0.04mm

(70%)(50%)

3) Distance of bolt hole and flange edge DE: 0.75xF.T

- 76 -


Section 3Machinery

& outfittings* propeller

3.10 Ship Scrw propeller

* Refer to ISO 484/1 or 484/2 Ship building manufacture tolerance 1981(E)

3.10.1 Classification

Choice of the class should be made by the user: the indications in table 1 below afferent guidance

for this choice.

Class Accuracy of manufacturing Normal use

S High precisionScrew propeller of superior quality for

special purposes

I and II Medium precision For majority of merchant vessels

III Large tolerances For vessels without special characteristics

Note-class III: Applies in general only to cast iron screw propellers.

3.10.2 Tolerance of pitch

ClassDescription

S I II III

1.5% 2% 3%Local pitch with a minimum of

15mm 20mm 30mm

1% 1.5% 2% 5%Mean pitch per blade at any radius With

a minimum of 10mm 15mm 20mm 50mm

0.75% 1% 1.5% 4%Mean pitch per blade with a minimum of

7.5mm 10mm 15mm 40mm

0.625% 0.75% 1% 3%Total pitch with a minimum of

6mm 7.5mm 10mm 30mm

Note:

1. For screw propeller with constant as well as for screw propellers with variable pitch, the pitch of

screw propellers according to classes S. I and II should be measured at least on 5 radius ( e.g

0.3R; 0.5R; 0.8R; 0.95R and for class II on 3 radius ( e.g 0.5R; 0.7R; 0.9R ). As far as possible

the measurements should be taken on at least 3 point on each radius.

- 77 -


Section 3Machinery


3.10.3 Surface finish

The surface texture of the blades, expressed as an arithmetic mean deviation, R 2 , in

micrometers, in accordance with ISO/R 468, shall have a roughness not greater than:

- 3 from the hub for propellers of class S;

- 6 from the radius 0.3 R for propellers of class I;

- 12 from the radius 0.4R for propellers of class II;

- 25 from the radius 0.5R for the propellers of class III;

The smoothness of the surface of the propeller blades should be determined by the mean height.

Hm of the surface roughness of the blades at least for the radius of the screw propeller over

0.3R.

)...21(1

HnHHn

Hm

- 78 -


Section 3Machinery


3.10.4 Static balancing

Unit: mm


Deviation of blade ( maximum ) 150 Refer calculation

* Max’ permissible unbalancing mass.

( According to ISO R481/1 1981)

2Rn

mCp or Km, whichever is the smaller.

P =............................ Km= x m= kg

p = kg

Where :

m: propeller weight in (kg)

R: propeller radius in meter (m)

n: propeller r.p.m

C&K: factors of class given.

S I II III

C 15 25 40 75

K 0.0005 0.001 0.001 0.001

* Actual unbalancing mass at the blade deviation

m: 0.269 269.0.

.

SinR

HM

= kg

Where

M: test ( attached) weight in kg

H: length of deviation ( Hmax-H min)

R: propeller radius in meter

Sin : angle of propeller blade (sin 900 : 1.0, 720 : 0.95, 600 : 0.87)

- 79 -


Section 3Machinery


repair

3.11 Damage repair areas

3.11.1 Yard’s practice

R= propeller radius

C1= chord length at radius

Repair jones of bladeSection

Kind of repair A B C D

Propeller

boss

Damage & cavitation part

build up weldingx O O O -

Crack part welding x O O O O

Partly renew x O O O -

Straightening O O O O -

Cold straightening x O O O -

Grind out x x x O -

3.11.2 Classification practice

* Refer to class permissible rectification range

- 80 -


Section 3Machinery


repair

3.12 Blade tip repair preparation

- 81 -


Section 3Machinery


repair

3.13 Propeller welding

3.13.1 Welding process ( refer to W.P.S)

1) minor repair: in use GTAW

2) Major repair: in use GTAW + GMAW

3.13.2 Temperature control

1) Pre heating: propane torch

2) Stress relief: induction PAD/ COIL analysis

( Electric heating element )

3)Cooling: should be retarded by asbestos blankets.

Material Preheat’ Temp 0C Stress relief Temp 0CStraightening

Temp. 0C

Mn-bronze 150-250 350-550 500-800

NiMn- bronze 150-250 350-550 500-800

NiAl-Bronze 50-150 Kh«ng 700-900

MnAl-bronze 100-250 450-600 700-850

3.13.3 Welding material

Material U.T.P Gricu Ampco

Mn-bronze A-34 ALBZ-9 Trode 10

Ni-Al-bronze A-3444 ALBZ-26 Trode 46

Mn-Ni-Al-bronze A-34N T-8 Trode 40

AWS SPEC’ = A 5.7

CLASS = ER CU x x x x

* Refer to propeller welding procedure

- 82 -


Section 3Machinery

& outfittings* stern tube/

shaft

3.14 Stern tube clearance


Stern tube lignum vitae clearance

a. Tail shaft dia < 230mm

b. 230mm Tail shaft dia < 305mm

c. Tail shaft dia 305

Stern tube simplex Type clearance

4.5mm

6.5mm

7.5mm

- Builder’s

practical

6.0mm

8.0mm

9.5mm

400~500 0.7~0.8500~600 0.8~1.0600~700 0.9~1.2700~800 1.0~1.3800~900 1.0~1.4

Tail shaft dia. ( mm)

900~1000 1.2~1.5

2x Original

clearance

(builders

practice)

3.15 shaft sleeve thickness loss limits

N.K.G.L L.R, DNV Remarks

t= 0.03DS+7.5

T1≠3/4TT=

32

230ds

T1=0.75T

ds: Shaft dia’

T: Brg’ surface

T1: non Brg’ surface

3.16 shaft cone part


1) Contact ratio of propeller / shaft 90% 70%

* Smooth ground

* Decide by class / owner for

renewal

2) Shaft crack detection

* ABS repair guidance

- Max’ depth

- Max’ length ( total circ’ ) 1/4’’(6.35mm)

1/4C(0.25C)

- 83 -


Section 3Machinery

& outfittings* shaft

alignment

3.17 Coupling alignment Unit:

mm

ItemStandard

range

Tolerance

limits

1) Simplex ( oil – bath ) type - gap

– Sag

Builder’s

practice 0.20

0.30

2) Lignum vitae ( water lub’ ) type

- Gap

- Sag

a. Gap = (g1-g2)

b. Sag = (s1-s2)

Builder’s

practice 0.30

0.70

3.18 Line shaft alignment

1) Reaction load on the bearing surface Builder’s

practice

- 84 -


Section 3Machinery

& outfittings* Aux’

machinery

3.19Aux’ machinery Unit: mm


1) Classification of auxiliary and deck machinery

(1) Grade “A”

Windlass

Diesel generator

(2) Grade “B”

Turbo generator

Mooring winch & turbine

Cargo winch

(3) Grade “C”

Other machineries which are not listed in Grade “A”

and “B”

2) Installation

(1) Clearance between liner and base

Grade “A”

Grade “B”

Grade “C”

(2) Liner contact ratio

Grade “A”

Grade “B”

Grade “C”

(3) Chock fast orange thickness

0.04

0.08

Not defined

60%

50%

Not defined

25-35t

* Other maker

0.05

0.1

Not defined

60%

50%

Not defined

Min’ 12t

guidance

- 85 -


Section 3Machinery

& outfittings* Aux’

machinery

ItemStandard

range

Tolerance

limits

3) Alignment ( solid type ) Grade “B” only

4) Alignment of deck machinery

- Solid type

- Shaft type

S 0.05

G 0.07

Gap/sag 0.15

Gap/sag 0.18

Not defined

Not defined

5) Alignment of pumps ( flexible coupling type )

- Shaft dia’ <50mm

- 50 Shaft dia’<100mm

- Shaft dia’>100mm

Gap/sag

0.15

0.20

0.25

cbGap

baSag

2

- 86 -


Section 3Machinery

& outfittings* D/G engine

3.20 Diesel generator Unit: mm


Cold

condition 000,10

1 x stroke

000,10

2 x stroke

1) Crank shaft deflection

- New installation

Hot

condition 000,10

2 x stroke

000,10

3 x stroke

- General repair ship

Cold

condition 000,10

2 x stroke

- 87 -


Section 3Machinery

& outfittings* deck crane

3.21 Traveling deck crane

Item Standard rangeTolerance

limits

(1)Installation of rail

- Distance between center of rails ( common type )

- Distance between center of rails ( Gantry type )

- Straightness of rail ( transverse, vertical direction )

- Difference of height between port and stb’d

d1 5

d2 10

d3 5

(per 10m)

d4 8

To be measured

at each 5m

Not defined

Not defined

Not defined

Not defined

- 88 -


Section 3Machinery

& outfittings*boiler tube

damage


* Boilers

3.22 Boiler tube deformation

1. Water tube

* d = tube dia.

2. Smoke tube

* d = tube dia

d 0.5d

d 0.3d

Not defined

Not defined

- 89 -


Section 3Machinery

& outfittings* boiler tube

repair


3.23. Edge preparation of the pipe or

tube and cutting of the window patch

method

3.24 Procedure for effecting a

permanent repair mono wall tubes.

( with wedge in place )

A=50 50C

B=1.5 1mm

A=1.5 1mm

B=50 50C

C=2 1

A=50 100

B= 212

A= 25.1

B=50 100

C=2 2

- 90 -


Section 3Machinery

& outfittings* boiler repair

3.25 Boiler repair procedure

1. Applicable to aux boiler drum repair ( partly )

2.Pressure range: 7.0~12.0kg/cm2

3. Material grade: for pressure vessel jis SB410 or similar

4. Working sequence

1) Material confirmation

- Same as original maker or similar

- Confirmation of the material mill sheet

* Class certificate

* Chemical composition

* Mechanical property

2) Fabrication of the drum shell

* To be rolled to circumference( mm in diameter )

3) Preparation

1) To be made edge shape the end of plate by grinder and machining.

2) Refer to attached joint details.

3) Permissible misalignment at the butt joint

- Longitudinal: 1/4t or max’ 3.0mm

- Circumferential: 1/4t or max’ 4.0 mm

- 91 -


Section 3Machinery


5. Welding

1) Welding is to be performed by approved welders.

2) Preheating : temp: 100-1500C

Method: Propane torch.

5-1) Electrodes

1) Manual: S7016-LF (produces by HWMCO )

LB-52 (produce by kobe steel )

2) TIG : TGS-50 (produce by kobe steel )

3) MIG: MGS-50 (produce by kobe steel)

5-2) Size of rods

1) Manual: (3.2-5.0 )

2) TIG & MIG: (1.2-1.6 )

5-3) Post weld heating ( if necessary )

1) Temperature: 6250C 250C (According to Class rules )

2) Holding time : One ( 1 ) Hour/25 t

* To be smooth ground to unbeaded weld metal and spatters.

6. Test and inspection

1) Fit –up and Edge – preparation ( Class, Q.C, owner )

2) Visual inspection after grinding ( Class, Q.C, owner)

3) N.D.T.

3-1) Radiograph test (100%): Drum shell butt & seam joints.

3-2) M.P.I or DYE – check (100%)

: Fillet and other joints.

4) Hydro static test: test pressure: D.Px1.5 time

5) Final dimension check if necessary.

- 92 -


Section 3Machinery


Typical joint detail

- 93 -


Section 3Machinery


6.Burner Plate

7. Flue Pipe

- 94 -


Section 3Machinery

& outfittings* boiler tube

joint

3.26 Typical joint of boiler tube within tube nests

1) Plan tube seal welding

2) Stay tube welding

3) Flange connection

- 95 -


section 4 piping system

4.1 general .................................................................................................... 96

4.2 Fabrication............................................................................................ 99

4.3 installation.......................................................................................... 104

4.4 ship side line repair........................................................................... 106

4.5 Scupper pipe ........................................................................................... 107

4.6 Hull piping in accommodation .................................................... 110

4.7 P.V.C piping in accommodation .................................................... 113

4.8 Pipe support in accommodation ................................................. 114

4.9 hyd-line grade.................................................................................... 115

4.10 piping joints............................................................................................ 116

- 96 -


section 4 piping system * piping grade

4.1 General

1. Grade of pipe

The grade specified by each classification society shall be divided as follows

(1) LR

Class 1 Class 2 Class 3Grade

Service Press. Temp. Press. Temp. Press. Temp.

Steam P>16.3 or T>300 7.116.3 or T>150 7.140.8 or T>300 16.3343 P 10.5 T 343

Water P<15.8 or T>177 P 15.8 T 177

Lubricating oil P<15.8 or T>204 P 15.8 T 204

Fuel oil P<10.5 or T>66 P 10.5 T 66

Hydraulic fluid P<15.8 or T>204 P 15.8 T 204

Lethal gas & liquids All - -

(3) KR & NK

Class 1 Class 2 Class 3Grade

Service Press. Temp. Press. Temp. Press. Temp.

Steam P>16 or T>300 716 or T>150 740 or T>300

(Only KR)16<P 40

200<T 300

(Only KR)P 16

T 200

(Only KR)

Primary

Refrigerant

( ammonia )

All All - - - -

Primary

refrigerant

(R12,R22)

- - - - All All

- 97 -



(4) U.S.C.G.

Service Class Pressure ( psig ) Temp (0F)

I Any and 0 and above

I-L Any and <0

II (3) (3) (3)

Class B&C

poisons

II-L (3) (3) (3)

I >150 or > 650

I-L >150 and < 0

II 150 and 0 to 650

Gases and

vapors

II-L 150 and <0

I >150 and 0

I-L >150 and <0

II 150 and 0

Liquefied

flammable

GassesII-L 150 and <0

I >225 or >330Molten sulphur

II 225 and 330

I >225 or >150

I-L >225 and <0

II 225 and 0 to 50

Cargo liquids

Grades A

Through DII-L 225 and <0

I >225 or >400

I-L >225 and <0

II 225 and 0 to 400

Cargo liquids

Grade E

II-L 225 and <0

I >225 or >350Water

II 225 and 350

I >150 or >150Fuel ( bunker

diesel, gasoline,

etc...)II 150 and 150

I >225 or >400Lubricating oil

II 225 and 400

I >225 or >400Asphalt

II 225 and 400

- 98 -



I >225 or >400Heat transfer

oil II 225 And 400

I >225 Or >400Hydraulic fluid

II 225 And 400

Flammable or combustible dangerous cargoes ..... Refer to specific requirements of Part 40

of this chapter.

Other dangerous cargoes .... Refer to specific requirement of part 98 of this chapter.

1. Where doubt exists as to proper classification, refer to the Commandant for resolution.

2. For definitions, see 46 C. F. R Part 30, 151. Note that the category “B” and “C” poison is

not used in the rules applying to self Propelled vessels ( 46 CFR Part 153 ).

3. Not permitted except inside cargo tanks approved for Class B and C poison.

( 5 ) D. N. V

Class I Class II Class IIIPiping

system p/bar t0C p/bar t0C p/bar t0C

Steam, Fuel

oil, Other

media

>16

>16

>40

Or >300

Or >150

Or >300

16

16

40

300

150

300

7

7

16

170

60

200

p: Design pressure, as defined in Sec. 6 A303

t: Design temperature, as defined in Sec.6 A303

1) For Class II and III piping both specified conditions are to be met, for Class I piping one

condition only is sufficient.

2) Air, Water, lubricating oil and hydraulic oil.

3) Cargo oil and open ended pipes ( drains, overflows, vents, boiler escape pipes, ... etc )

independently of the pressure and temperature, are pertaining to class III.

4) Thermal oil pipes independently of temperature and pressure are pertaining to class I.

5) Hyd’ oil piping in engine room with design pressure above 40bar are pertaining to class II.

- 99 -


section 4 piping system * Fabrication

4.2 Pipe fabrication Unit: mm


1)Dimension

(1) Straight pipe

(2) Bending pipe

(Two dimensional bending )

(Three dimensional bending )

(3) Branch pipe

(4) Penetration piece

d= 4

d= 5

d 010221

d= 5

d 01

d= 4

d 01

d= 4

d 01

Not defined

Not defined

Not defined

Not defined

Not defined

- 100 -



Unit: mm


2) Attachment of flange to pipe

(1) Angle of flange to pipe

(2) Distortion of flange face

D: out dia. Of pipe

(3) Distance between fillet and butt welding bead

(4) Distance between face to flange and welding toe

a 2

D>200

a 0.5

200 D≤450

a 1

D>450

a 1.5

L 5

a: max. 1.5

Not defined

<1

<2

<2.5

Not defined

Not defined

- 101 -



Unit: mm

ItemStandard

range

Tolerance

limits

Bending radiusBending

method

Pipe

materialDivision

3D R 4D 4D R

E(%) ≤10 ≤10

T(%) ≤20 ≤15Steek

pipeH H D

100

1

E(%) ≤10 ≤10

T(%) ≤25 ≤20Copper

pipeH H D

100

1

E(%) ≤10 ≤10

T(%) ≤20 ≤15

Cold or

hot

bending

Al-Br &

kunifer

pipe H H D100

1

3) Pipe bending

(1) Elliptically (E)

%100xD

DsDlE

D: Out dia of pipe

R: Bending radius

(2) Thickness reduction ratio ( T)

%100xt

trtT

t: Original pipe thickness

tr: Thickness after bending

D: Out dia. of pipe

(3) Wrinkle & swelling

H: Height

D: Out of pipe

- 102 -



Unit: mm


4) Sleeve joint

(1) Steel

(2) Copper , Al-Br

a: Min.1.5

l1:

Min.10(D≥65A)

Min.20(D≤80A)

(But max.1 only

for U.S.C.G)

0.05 a 0.15

Not defined

″

″

Not defined

5) Socket joint

a 1.0

b 0.2

a 1.5

b 0.8

- 103 -



Unit: mm


6) Welding of steel pipe

( 1 ) Edge Preparation

( 2 ) Back bead

( Class I, II pipe ) ( Other pipe )

( 3 ) Under cut

d 1.6

a = 2.4 ± 0.8

140

0 d1 2

d2 0.5

d 0.3

Not defined

Not defined

d 0.8

- 104 -


section 4 piping system * Installation

4.3. installation Unit: mm


1) Pipe hole cutting & penetration

( 1) Hole cutting

( 2 ) Pipe penetration

A-Type

D- type

100

Dd

l = 0.1D

But min.50

T T1

10 ~ 100A

b = 30 ± 5

125 ~ 500A

b = 40 ± 5

550 ~ 700A

b = 50 ± 5

D1 = D + Max.15

65A & below

L = 100

80a & above

L = 150

100

Dd

Not defined

Not defined

“

“

“

“

“

Not defined

“

- 105 -



Unit: mm


2) Alignment a 2

c – b 2

Not defined

3) Bolting

( U bolt ) ( Flange bolt )

a = 0 ~ 3

a2 + a3 = 0 ~ 3

b1 = 0 ~ 5

threads

b2 = 0 ~3

threads

H/coil only

a = 1 ~ 3

a1 = 0 ~3

a + a1 3

Not defined

4) Air vent pipe H = 10 Not defined

5) Sounding pipe H = 20 ± 5

t = 15

Not defined

6) Dresser coupling Short type

l = 40

d1 = ± 5

d2 3

Long type

l = 70

d1 = ± 30

d2 6

Not defined

d2 5

Not defined

- 106 -



4.4 Ship side line repair Unit: mm


7) Suction mouth ( hull part )

( 1 ) A – Type

( 2 ) B – Type

Pipe dia. (D) G

80A & below 20

100A<D<150A 25

200A 35

Pipe dia. (D) G

150A 40

200A 45

250A 55

300A 65

350A 65

400A 75

450A 85

500A 100

550A 110

600A 120

650A 140

Main suction

H = ± 10

Stripping

H = ± 5

Main suction

H = ± 10

Stripping

( Including

main &

stripping )

H = ± 5

- 107 -



4.5 Scupper pipe

ItemTolerance

LimitsRemarks

For ship side

Distance

Piece

C 3

L 15

D 500 ± 10

For boiler

Blow down

Distance

Piece

C 3

L 15

D 500 ± 10

For ship side

Distance piece

C 3

L 15

D 500 ± 10

For pad flangeL1 15

L2 15

For Echo

sound, Pad

flange

C 3

D 450 ± 5

- 108 -



BO

ILE

RB

LO

WD

OW

N( SovietR

ussiaShipyard, butrequiredclasssurveyorow

ner )

Sea c

hest o

n

the sea

side

Bo

iler b

low

do

wn

or

gen

era

l

ad

aptin

g

Gen

era

l

ad

aptin

g

Style

No

rm

al pipe

C¨

n b

Ö/ ®Öm

®ì

1)C

¨n

: 20t

2) §Öm

: Dµy b»ng hoÆc

h¬n chiÒu dµy èng

300

200

150

125

100

80 65 50 32

25A

17.4

12.7

11.0

9.0

8.6

7.6

7.5

7.0

t(min)

Pressu

re

Standard10K>

SCH

’80

Rem

ark

thic

kn

ess

1.flan

ge:

1) Existing using

2)Sam

e size use with valve

2.Ma

teria

l

Note :

1.The carbon content of the

material shall be

0.23% or less.

2.The m

aterial of S20C

shall be

heat treated.

pad

flan

ge

pipe

co

mpo

nen

t

SM41, SF45

or S20C

STPG

38ST

PT38

ma

teria

l

rem

ar

k

- 109 -


Section 4 piping system * Scupper piping

1) Deck penetration

2) Ship side discharge penetration the hull

3) PCLE deck or weather deck installation

- 110 -


Section 4 piping system * hull piping

4.6 Hull piping in accommodation

4.6.1 Detail of welding method

1) Butt weld

No. Methods Dimension Application

t 3.2

t=t1

S=2 1

10201 S=2 1

0202 B=1.6 0.8

t >3.2

Pipe to pipe

0

0

5

0

0301

t=t1

S=2 1

t >3.2

20101 S=2 1

0

0

5

0

0302

B=1.6 0.8

t = t1

t >3.2

Pipe to fitting ( Elbow,

reducer, tee )

3

t < t1 S = 2 1

a 1.6 B =1.6 0.8

: Refer to 1 or 2

Specified above.

t >3.2

a>1.6

: Refer to 1 or 2

Specified above

t >3.2

Pipe to pipe or

Pipe to fitting

- 111 -



4.6.2 Weld profiles and tolerance limit for piping

( 1 ) Jointing and welding shall be carried out to have satisfactory weld profiles.

( 2 ) Tolerance limits and repair procedures are as follows.

Item MethodsTolerance

LimitRepair procedure

Under cutD 0.8 mm

When the depth of under

cut exceeds the limitation,

to be repaired by welding

with small dia, electrodes.

All pipes

10

When the tolerance

exceeds the limitation,

flange to be refitted.

Alignment D: Pipe N/D

D<200:

a 0.1mm

200 D 450:

a 2.0mm

D>450:

a 2.5mm

When the tolerance

exceeds the limitation,

flange to be renewed.

Dimension L 5mm

- 112 -



4.6.3 Filet weld

( 1 ) Pipe to flange

W: 1.5t but not less than 5mm.

C: Maximum 2mm ( not to be tight fit ), but sum of the clearances diametrically

opposite is to exceed 5mm.*t1 : but need not to exceed 0.3T

( 2 ) Pipe to sleeve

W : Refer to page 52/86.

C : See “ C “ value of pipe to flange weld.

* Mark part to be at least 9.5mm

( 3 ) Welding to structure ( for pipe penetration piece ).

- 113 -



4.7 PVC A/B class penetration piece type in accommodation

* Application : A/B – class steel deck/ bulkhead penetration for PVC pipe.

Pipe Steel sleeve

N.D O.D D d t N.DH L e

50 60 89.1 78.1 5.5 50 60 89.1 78.1

65 76 114.3 102.3 6.0 65 76 114.3 102.3

75 89 139.8 126.6 6.6 75 89 139.8 126.6

100 114 165.2 151.0 7.1 100 114 165.2 151.0

Note : 1) “ PANDA-90” fire sleeve transit device for the penetration of A or B class division for

PVC pipe.

2) Noncombustible material certificate of PANDA -90 fire sleeve.

LR: SVG/F91/355

DNV: F-11314

ABS: 91-BK-27245-X

KR: BU-02901/03

BV: 5031/5042/A1/0

GL: 67951 HH

3 ) *** Mark : PANDA-90 length 180mm, steel sleeve 200mm.

- 114 -



4.8 Pipe support for steel and PVC pipe in accommodation

1) Standard distance of steel and PVC pipe

( 1 ) Distance ( interval ) of pipe supports to be based on the flowing table, but may be

increased up to the maximum 1.2 times of the standard distance in consideration of hull structure.

Steel pipe PVC pipe

Nom. dia

(A)

Out dia.

(mm)

Distance

(m)

Nom. dia.

(A)

Out dia.

(mm)

Distance

(m)

Remark

15 21.7 1.0

20 27.2 1.5

25 34.0 1.5

32 42.7 1.5

40 48.7 2.5 40 48 1.0

50 60.5 2.5 50 60 1.0

65 76.3 2.5 65 76 1.2

80 89.1 3.2 75 89 1.2

100 114.3 3.2 100 114 1.5

125 139.8 3.2 125 140 1.5

150 165.2 3.9

L=1.2S

(L: Maximum

allowable

distance of pipe

supports.

S: Standard

distance of pipe

supports )

Note: Theoretical criteria is guided by a limitation of about 3mm deflection with piping filled

fully between pipe supports one another.

( 2 ) Stays for pipe supports to be fitted on or close to stiffening beam as far as possible.

( 3 ) Stays for pipe supports to be sniffed to avoid sharp ends and to be paint finished.

- 115 -


Section 4 piping system * Hyd-line design

4.9 Pipe grade of hyd-line

Symbol Grade/ name Range of applicable Remark

JIS G 3452 SGPLOW PRESS SYSTEM

* Pump suction pipe

JIS G 3454 STPG

MIDDLE PRESS SYSTEM

HIGH PRESS SYSTEM

* SEAM LESS PIPE

- W.P≤100kg/cm2

- W.T≤3500

JIS G 3455 STSHIGH PRESS SYSTEM

* SEAM LESS PIPE- W.P≥100kg/cm2

JIS G 3459SUS ( stainless )

(304, 306 TP)

HIGH PRESS SYSTEM

CORROSION

RESISTANCE

HIGH TEMPERATURE

SERVICE SYSTEM

SPECIAL REQUEST

ONLY BY OWNER

- 116 -


Section 4 piping system * Hyd-line design

4.10 PIPING JOINTS

KIND OF JOINTS MATERIALPIPE DIA.

(mm)

WORK PRESS

(kg/cm2)

MATERIAL

RANGE

Socket welding and

threaded fitting

SF45

S25C

SUS

6A~100A Max.500* STEEL OR

SUS PIPE

Sliver brazing fitting

BsTF4

BsBF

CNTF1

6A~50A Max.210*AL- BRASS

* Cu –Ni PIPE

Square flange SF45 15A~80A Max.210 * STEEL PIPE

S25C

SUSMax.210

* STEEL OR

SUS PIPETween ferrule

compression fittingBrass

6A~25A

Max.20* COPPER

TUBE

S25C

SUSMax.250

*STEEL OR

SUS PIPEMulti bite type fitting

Brass

6A~25A

Max.100* COPPER

TUBE

S25C

SUSMax.210

Flared fitting

Brass

6A~25A

Max.20

* STEEL OR

SUS PIPE

* COPPER

TUBE

6A~25A Max.210

25A~40A Max.180Quick coupling

50A Max.140

* STEEL PIPE

IF

NECESSARY

- 117 -


SECTION 5 PAINTING PART

5.1 PRIMAY SURFACE ................................................................................... 118

5.2 preparation grade…………………………………………………119

5.3 shop priming.......................................................................................... 119

5.4 D.f.t control ( new shipbuilding ) ............................................ 120

5.5 D.f.t control ( repair ship )........................................................... 120

5.6 pre- treatment.................................................................................... 121

5.7 treatment of weld part................................................................ 122

5.8 damage part ......................................................................................... 125

5.9 Management ( pre- coating ) ....................................................... 129

5.10 environmental ( temp/ humidity ) .......................................... 129

5.11 final coat condition ..................................................................... 130

- 118 -


section 5 painting part * steel surface

5.1 PRIMARY SURFACE PREPARATION

ITEM Method Surface preparation grades

6 t Shot blasting

Sa22

1

When shot blasting is considered

impracticable, sand blasting may be

applied.

Rolled hull

structural steel

6>t Sand blastingSa2

2

1

Pipe

250 d

Sand blasting or

hand/ power tooling

pickling

Sa22

1 or St2-St3

250>d

Hand/ power tooling

pickling

( Blasting at yard’s

convenience )

St2-St3 or Sa22

1Outfitting,

pipes, supports,

seat, etc...

Support,

seats, aux.

mach. Etc.

Hand/ power tooling

( Blasting at yard’s

convenience )

St2-St3 or Sa22

1

- 119 -


section 5 painting part * steel surface

5.2 PREPARATION GRADE

IT is assumed that prior to treatment the steel surface has been cleaned of dirt and grease and

that the heavier layers of rust have been removed by chipping.

( 1 ) Sa2 1/2 : Blast cleaning.

Very thorough blast cleaning, Mill scale, rust and foreign matter shall be removed to the

extent that only traces remaining are slight stains in the form of sports or stripes.

Finally, the surface is cleaned with a vacuum cleaner, clean dry compressed air or a

clean brush. It shall then correspond in appearance to the prints designated Sa 2 1/2.

( 2 ) St2 : Power tool cleaning

Thorough scraping and wire-brushing, machine brushing, grinding –etc. The treatment shall

remove loose mill scale, rust and foreign matter. Finally, the surface is cleaned with a vacuum cleaner,

clean dry compressed air or a clean brush. It should then have a faint metallic sheen. The appearance

shall correspond to the prints designated St2.

( 3 ) St3 : Power tool cleaning

Very thorough scraping and wire-brushing, machine brushing, grinding-etc. Surface

preparation as for st3, but much more thoroughly. After removal of dust, the surface shall have a

pronounced metallic sheen and correspond to the prints designated St3.

5.3 SHOP PRIMING

Item D. F. T Surface preparation

Shop primer

( Pre- treatment )15 5

Shop or sand blasting

Sa2 1/2

- 120 -


section 5 painting part * D. F. t Control

5.4 Dry film thickness control ( New ship building )

Item Standard

Tanks One point/ five square metersMeasuring

pointsOutside

shellOne point/ ten square meters

1. Average dry film thickness of the paint to be attained

as the specification.

2. At least 85% of the measuring points to meet the

specified film thickness.

3. Min. 85% of the specified film thickness to be

attained on remaining 15% measuring points.

5.5 Dry film thickness control ( General repair ship )

Item Standard

Tanks One point/ Ten square metersMeasuring

pointsOur side

shellOne point / 50 square meters

D. F. T Control

1. Average dry film thickness of paint to be attained as

the specification.

2. At least 80% of the measuring points to be met the

specified film thickness.

3. Min 80% of the specified film thickness to be

attained on remaining 20% measuring points.

- 121 -


section 5 painting part * Pre- treatment

5.6 PRE- TREATMENT FOR PAINTING

Kind of paint

Item Inorganic zincEpoxy resin conventional

MOISTURE Not to be visible to the naked eye

Salt “”

Oil/ grease Not to be visible. Trace of thinner wiping is permitted

Fat “”

Soap solution White deposits are not to be visible

Zinc saltTo remove white deposits, but the remaining trace may be visible

after sweep-blasting or power tooling

Fume by welding or

cuttingNot to be remained.

Chalk/ slate pencil

markTo be wiped with rags or brush. The trace be visible

Marking paint

In general,

not be

removed

In general, not to be removed.

But if highly sophisticated special

coating system to be applied,

usage of marking paint will be

advised by paint manufacturers.

Remaining trace may be visible.

Not to be

removed

Dust/ mud

contamination

Dust or mud contaminants to be removed with rags, broom or

vacuum cleaner to the possible extent.

Flying or suspension properties of fine-dust which could be excluded

by self-pressure of spray – gun may be accepted in the normal

shipbuilding practice.

- 122 -



5.7 TREATMENT AT WELDING PART

Item Remarks

1) Spatters Stable spatters

Stable spatter contracted surface with mother

plate more than two-third of spatter width not

to be removed.

Stable spatter ( O )

Unstable spatters

Removable or unstable spatters to be removed

with grinder, disc-sander or chipping hammer.

Unstable spatter ( x )

For non-exposed

areas. ( Cargo hold

spaces, C. O. tanks,

W. B tanks, void

spaces, covered parts

of superstructures,

etc... )

Remain welding beads

2) Repair welding

bead of notches

For exposed areas.

( Exposed deck,

outside shells, engine

room passageways

etc... )

Welding and grind flush

- 123 -



Item Remarks

3) Slag

Slag to be removed with grinder or disc-sander up to the

standard. But if not completely removes, trace or stain may be

left.

4) Rust and Heat scale

Rust and heat scale

- 124 -



Item Remarks

5) Weld fume

Weld-fume

6) Repair of welding defect

After secondary surface preparation at each stage, the welding

defects found are to be repaired as follows

Grade Area DefectsRepair

Method

1

Butt & Seam lines

of side shell

Air, Water tight

boundaries

Blow hole

pin hole

Welding and

Grinding

Blow hole

pin hole

3 < D

“

2Major structural

members Blow hole

pin hole

3 D

Fill up with

epoxy putty

3

Common members

(Bracket, Stiffeners,

rolled angle, flat

bar)

Blow hole

Pin hole

“

( Not welding)

Repair

- 125 -


section 5 painting part * damage part

5.8 DAMAGED PART

Item Remarks

Preparation

and

Feathering

( Wire brushing and/ or disc-sweeping etc... )

1) Rusted part and

block joint

Touch-up

The surface between coat and touch-up to be treated

with an elaborate workmanship as smooth as possible.

Roughness

Roughness of the profile after feathering to be treated

with an elaborate workmanship as smooth as possible.

- 126 -



Item Remarks

2) Mechanical

damage on painted area.

( 1 ) In case damage reaches to bare steel:

- Adequate cleaning to bare steel according to the standard

referred.

- Repair coating as original system.

( 2 ) In case damage dosen’t reach to bare steel:

- adequate cleaning by appropriate methods to the paint film

affected.

- Repair touching-up as damaged film.

3) Wooden block boundary

area.

( New ship building )

Repair criteria of paint film damages.

Profile view of typical.

- 127 -



Item Remarks

A’ Detail Repair method

Flat Bottom

- Squeezes

- Compression

1. Scraping

2. Fine papering

3. Touch up as

specified delicately.

* To be repaired as it is.

4) Spot rusted areaSpot-rusted part

- 128 -



Item Remarks

5) Burnt part

- 129 -


section 5 painting part * environmental

5.9 MANAGEMENT OF PAINTING WORKS

1) pre-coating

( Stripe coat )

2) Overrall coating Airless spraying or air spaying ( if necessary ) to be applied

5.10 ENVIRONMENTAL STANDARDS

1) Temperature

1) Substrate temperature to be kept above 50C

2) Surface temperature to be kept more than 30C above the dew

point.

2) Humidity Relative humidity to be kept below 85%

- 130 -


section 5 painting part * final condition

5.11 SURFACE CONDITION OF FINAL COATING

Item Check Points

Where appearance of

special importance

( Exposed superstructure,

cabin, passages, etc...)

a ) Sagging, missing, brush mark, cracking, wrinkling and

holiday are not to be visible.

b) color of final coating is not to be different from the

specified.

c) Spray dust is not to be visible.

For visible parts other than

above ( inside of engine

room outside shell,

exposed part of decks,

stores and cargo hold,

etc...)

a) Missing, cracking, wrinkling and holiday are not to be

visible remarkably.

b) Sagging and brush mark not to be continued to large extent

on the surface.

c) Final color is not to be different from the specified color but

difference of color by aging at working stage which will be

equal in the end is permitted.

For invisible part, void

spaces and cofferdams,

cargo tanks, W. B. tanks,

etc...

a) Missing, cracking and holiday are not to be visible

remarkably.

b) Heavy sagging are not to be continued to large extent on the

surface.

c) The difference of the appearance is not to be severe.

- 131 -


Section 6 Electrical part

6.1 CABLE INSTALLATION…………………………………………………………………….132

- CABLE WAY

- UNDER FLOOR METHOD

- CABLE TIE & BAND TAPE

- CABLE STAIR

- ROUND STAIR

- STAIR HEIGHT

- CABLE PIPE/ DUCT

- CABLE RADIUS ACCEPTANCE

- CABLE PENETRATION

- METHOD OF ENTERING CABLE INTO EQUIPMENT

- DETAIL OF CABLE THROUGH WITH M. C. T

6.2 WEATHER DECK FITTINGS ………………………………………………………………148

6.3 CABLE EXPANSION METHOD ……………………………………………………………150

6.4CABLE CONDUCT EARTH METHOD…………………………………………………… 150

6.5 STANDARD OF OPENING THE HULL ……………………………………………………151

- 132 -


SECTION 6 ELECTRICAL PART * CABLEINSTALLATION

Item

6.1. Electric cable installation

1.1 Turning method of main cable ways

1.1.1 In case of same height.

* In case of same height in relation to one and another way.

1.1.2. In case of different height

* In case of different height in relation to one and another way.

- 133 -



Item

1.1.3. In case of curved way

* The cable shall be installed on adequate supporter as shown on following

figure.

1.2. Branch cable way ( for example )

- 134 -



Item

1.3. Vertical main cable ways

- 136 -


SECTION 6 ELECTRICAL PART * CABLE Band

Item

1.5. Cable tie and binding tape

1.5.1. Cable tie

* The cable tie to be applied inside of switch board, control console, etc cable

fastening.

Symbol L Remark

CT- 100 100 MIL – S – 23190 D MS 3367 – 4

Ct – 175 175 MIL – S – 23190 MS 3367 - 1

- 137 -


SECTION 6 ELECTRICAL PART * CABLE Band

Item

1.5.2 Cable binding tape

* These binding tapes shall be used for cable securing and selected in accordance

with cable kind and / or their location. P. V. C coated BTN – 3, 4 type shall be used for

non-metallic sheath or non-armoured cable others ( BTM-1, 2 ) shall be used for metallic

sheath or armoured cable. For cable which are exposed to weather or installed in

refrigerated rooms, laundry, etc.. stainless steel tape shall be applied.

Symbol w t remark

BTN-1 15 0.5 elec.’ glav. ‘ steel

BTN-2 - “ stainless

BTN-3 “ “ elec. ‘ glav. ‘ steel ( PVC coating )

BTN-4 “ “ Stainless ( P. V. C coating )

- 138 -


SECTION 6 ELECTRICAL PART * cable stair

Item

1.6 Cable stair

1.6.1 Single stair combined method

H < 300 = 50 x 6. F. B H > 300 = 40 x 40 x 5 ANG.

WType Hanger Runner bar L

H < 300 H > 300

LA – 2 L- 2 25x 6 F. B 200 224 292

LA – 3 L – 3 “ 300 324 392

LA – 4 L – 4 38 x 6 F.B 400 424 492

LA – 5 L – 5 “ 500 524 592

LA – 6 L – 6 “ 600 624 692

LA - 7 L – 7 “ 700 724 792

LA – 8 L – 8 “ 800 824 892

LA – 9 L – 9 “ 900 924 992

LA – 1m L – 1m “ 1000 1024 1092

- 139 -



1.6.2 Double stair combined method

1.6.3. Reversible single stair combined method.

- 140 -



1.6.4 Round type stair

1.6.5 Adjustment of stair height

- 141 -


SECTION 6 ELECTRICAL PART * penetration

Item

1.7 Deck and wall penetration

1.7.1 Collar and coaming

Coaming dimension.

COAMTING COAMTINGNOA B

n TYPE NOA B

n TYPE

1 100 60 30 1 23 350 200 50 22 ″ 80 40 1 24 400 60 30 13 150 60 30 1 25 ″ 80 40 14 ″ 80 40 1 26 ″ 100 50 15 ″ 100 50 1 27 ″ 160 ″ 26 200 60 30 1 28 ″ 200 ″ 27 ″ 80 40 1 29 450 80 40 18 ″ 100 50 1 30 ″ 100 50 19 ″ 160 50 2 31 ″ 160 ″ 210 250 60 30 1 32 ″ 200 ″ 211 ″ 80 40 1 33 500 80 40 112 ″ 100 50 1 34 ″ 100 50 113 ″ 160 50 2 35 ″ 160 ″ 214 300 60 30 1 36 ″ 200 ″ 215 ″ 80 40 1 37 600 80 40 116 ″ 100 50 1 38 ″ 100 50 117 ″ 160 50 2 39 ″ 160 ″ 218 ″ 200 50 2 40 ″ 200 ″ 219 350 60 30 1 41 700 80 40 120 ″ 80 40 1 42 ″ 100 50 121 ″ 100 50 1 43 ″ 160 ″ 222 ″ 160 50 2 44 ″ 200 ″ 2

- 142 -



Item

1.7.2 Substantial for cable penetration

a. Substantial for non-watertight penetration

i) In case of no heat resisting steel wall, beam, girdes and long etc... to depend the

substantials as shown below.

ii) In case of heat resisting.

to be fitted to put about 10mm from the heat resisting surface a shown below.

- 143 -



Item

b. Substantial for watertight penetration

i ) In case of fitting of one by one gland

ii) Assembly fitting stuffing gland.

- 144 -


SECTION 6 ELECTRICAL PART * method ofentering cable

Item

1.7.3. Method of entering cable into equipment

a. For water tight gland

b. For coaming

- 145 -


SECTION 6 ELECTRICAL PART *wall collar

Item

1.7.4 Detail of cable through deck & wall

a. A and B class steel Wall

i) Rectangular collar type

ii) Round collar type

Cable

- 146 -


SECTION 6 ELECTRICAL PART * coamings

Item

b. A class deck

i ) Rectangular coaming type

ii ) Round coaming type

- 147 -


SECTION 6 ELECTRICAL PART * M. c. t

Item

c. Multi cable transit

For A class deck in electric cable trunk shall be supplied.

- 148 -


SECTION 6 ELECTRICAL PART * fittingsinstallation

6.2 WEATHER DECK FITTINGS

2.1 Distance between steam pipe to cable

2.2 Cable grand install

2.3 Cable pipe thickness range for on deck and W.T or F.O tank penetration parts.

PIPE INTERNAL DIAMETER ( I. D ) MINIMUM THICKNESS

ID < 57.0 4.0

57.0 ID <152.4 4.5

152.4 ID <304.8 5.5

304.8 ID UNACCEPTABLE

- 149 -


SECTION 6 ELECTRICAL PART * fittingsinstallation

- 150 -


SECTION 6 ELECTRICAL PART * cableexpansion

6.3 CABLE EXPANTION METHOD

* MINIMUM RADIUS: CABLE O.D x 12 Times

3.1. CABLE HANGER TYPE

3.2. CABLE PIPE TYPE

6.4 CABLE CONDUCT EARTH METHOD

- 151 -


SECTION 6 ELECTRICAL PART * HULL OPENINGMETHOD

6.5 STANDARD OF OPENING

5.1 TYPICAL

“A” SPACE “B” SPACESPACE

CONPENSATION

POSITIONWITHOUT WITH WITHOUT WITH

REMARK

CARGO OIL

TANK

d 1/5D

MAX=300

d 1/2D

MAX=300

d 1/10D d 1/4D

CARGO HOLD

ENGINE ROOM

d 1/4D d 1/2D d 1/8D d 1/4D

GIR

DE

R, W

EB SUPER

STRUCTURE

d 1/3D d 1/2D d 1/6D d 1/4D

SOILD FLOOR,

CONFFERDAM WEB

d 2/5D d 1/2D d 1/5D d 1/4D

DOUBLE BOTTOM

SIDE GIRDER,

DIAPHRAGM

d 3/5D d 2/3D- -

* NOTE:

GENERALLY IN “ C” SPACE, OPENING SHOULD NOT BE CUT, IF

UNAVOIDABLE FOR PIPING, ETC.. OPENING COMPENSATION SHOULD BE DESIGNED

AFTER CONSIDERING TYPE OF STRUCTUAL MEMBER AND ITS SIZE OF LOAD, ETC.

IF TO BE FITTED DOUBLING PLATE COAMING ( RING )

S1 = ( S – 1/2h ).

- 152 -


section 6 electrical part * hull openingmethod

5.2 MIN. DISTANCE BETWEEN HOLE & HOLE, HOLE & END OF STRUCTURE MEMBER

A SPACE B SPACE C SPACE

1) HOLE AND HOLE

2

21 ddS

S=d1+d2

2) HOLE AND DECK

dS2

1 S=d

3) HOLE AND FACE BAR

S=d

(Min.75mm)

S=2+d

(Min.75mm)

4) HOLE AND SCALLOP

2

rdS

(Min.50mm)

S=d+R

(Min.50mm)

5) HOLE AND SLOT

2

dBS

S=B+d

IF2

dBS

S=B+d

TO BE FITTED

COLLAR PLATE

* NOTE:

GENERALLY WHEN DOUBLING PLATE OR F.B COAMING HAD SAME AS

HULL THICKNESS TO BE DESIGENED, “S” MAY BE REDUCED BY HALF OF DOUBLING

PLATE OR F.B COATING.

HOWEVER “ S” IS NOT TO BE LESS HALF OF STANDARD.

- 153 -


section 6 electric part * hullreinforcement

5.3 HULL STRUCTURE OPENING HOLE REINFORCEMENT METHOD

5.3.1 DOUBLE PLATE INSTALL

a b/2

t1 t

5.3.2 RING STIFFENER INSTALL

5.3.3 PARTIAL INCREASING OF WEB DEPTH.

a b/2

t1 t

d Min. 25

a 1.5h

b L

h 3d-H

Documents

HALONG SHIPYARD QUALITY STANDARD BOOK 1