26
Internship Report [Type the document subtitle] 7/27/2012 Indian Maritime University Dhruv Prajapati

MDL Report

Embed Size (px)

Citation preview

Page 1: MDL Report

Internship Report[Type the document subtitle]

7/27/2012Indian Maritime UniversityDhruv Prajapati

Page 2: MDL Report

2 | P a g e M D L

INTRODUCTION

I have undergone summer internship in MDL (Mazagon Dock Limited) situated in Mumbai, a leading Shipbuilding Company of INDIA with ISO 9001:2000 accreditation. It is a profit-making Central Government Schedule ‘A’ PSU under the Ministry of Defense, Department of Defense Production, engaged primarily in the construction of Warships and Submarines for the Indian Navy.

Main activities are ship building, ship repair and fabrication of offshore structures with facilities situated at Mumbai and Nhava. MDL have the capability to build warship, merchant ship, submarines up to 30,000 deadweight and fabrication of wellhead platforms and jack up rigs. For outfitting work the company has a large number of workshops with sophisticated equipment and machines specific to hull fabrication and ship construction work.

Our training was mainly conducted in design department. Our training schedule is planned as two weeks in structural department (sdo) , two weeks in outfit department (odo) , two weeks in forward design group (fdg), one week in engineering department (edo) and one week in electrical department (ldo).

We were basically focused on the design aspect of the ships, on which software it is made and how the material flow works etc. We were taken to the ships to study the interior of the engine room of a naval ship of INS KOCHI and MSV II (multipurpose service vessel)

2012 |INTERNSHIP REPORT IMU

Page 3: MDL Report

3 | P a g e M D L

ABOUT MDL

Mazagon dock Limited Mumbai is an ISO 9001:2008 company is one of the leading shipbuilding and offshore fabrication yards in India. The yard was established in the 18th century , and over the 200 odd eventful yards , has earned a reputation for quality work and established a tradition of skilled and resourceful service to the shipping world in general and the Indian navy , Coast guard and ONGC in particular. In its varied history MDL passed through varied ownerships like the P&O lines and the British India Steam Navigation Company. It was incorporated as a Public Limited Company in 1934.

After its takeover by the government in 1960, Mazagon Dock grew rapidly to become the premier war-shipbuilding yard in India, producing sophisticated warships for the navy and offshore structures for ONGC. It has grown from a single unit, small ship repair company, into a multi-unit and multi-product company with significant rise in production, use of modern technology and sophistication of products. The company’s current portfolio of design spans a wide range of products for both domestic and overseas clients.

The company has qualified manpower to implement CAD/CAM/CIM using the latest ship design software’s ,operating from a number of work stations having the latest computer hardware to provide , up to date design and production support, commensurate for the yard’s capabilities.

It manufactures warships and submarines for the Indian Navy, as well as offshore platforms and associated support vessels for offshore oil drilling. It also builds tankers, cargo bulk carriers and passenger ships and ferries.

The shipyards of MDL were established in the 18th century. These yards have over two centuries of experience in shipbuilding. Ownership of the yards passed through various entities, including the P&O Lines and the British India Steam Navigation Company. Eventually, MAZAGON DOCK LIMITED was registered as a public company in 1934. The shipyard was nationalized in 1960, and is now a PSU of the Government of India.

2012 |INTERNSHIP REPORT IMU

Page 4: MDL Report

4 | P a g e M D L

PROJECTS

COMMERCIAL PROJECTS

1. Offshore platforms

MDL builds offshore oil drilling platforms. It operates facilities at Alcock, Mumbai and at Nhava Yard for construction of platforms with wellhead, water injection and production separator and glycol process capabilities, as well as jackup rigs, SBMs and other offshore structures.

Repair and maintenance jobs on offshore rigs are also undertaken at Alcock, Jackets up to 80 m. length and 2200 T. weight can be constructed. At Nhava, Jackets up to 80 m. length and 2300 T. weight, Main Decks up to 550 T. weight and Helipads of 160 T. weight

The yard also builds specialist vessels with capability to clean oil spills and fight fires on offshore drilling platforms.

A welding training school develops and maintains welding techniques and procedures to acceptable standards and continuous update of welding techniques.

2. Commercial vessels

The yard has built a wide range of vessels for the commercial sector, including offshore supply vessels (OSVs), harbor utility vessels and crafts such as tug boats, dredgers, tankers, passenger ships and cargo ships. It has also built and supplied commercial trawlers and barges, support vessels, a floating jetty and floating cranes.

2012 |INTERNSHIP REPORT IMU

Page 5: MDL Report

5 | P a g e M D L

Naval Projects1. Warships

a. Nilgiri   class frigate

The first warship built by MDL was the 2,900-ton displacement, INS Nilgiri, the lead ship of her class. She was launched on 15 October 1966 and commissioned on 23 June 1972. Five more frigates of this class were built over the next nine years for the Indian Navy.

b. Godavari   class frigate

While construction of the Nilgiri-class was being completed, the Indian Navy proposed requirements for an indigenously designed and built frigate. This new frigate was to be of wholly Indian design and manufacture. To address these requirements, MDL designed and built the Godavari class guided-missile frigates with a 3800 tons diplacement, and ability to embark two helicopters. Three ships of the class were built by MDL - the lead ship, INS   Godavari , the INS   Ganga  and INS   Gomati .

c. Khukri   class corvettes

MDL designed and built the first two vessels of the Khukri class corvettes for the Indian Navy. The lead vessel of the class was commissioned on 23 August 1989, and the second, INS   Kuthar , on 7 June 1990. The remainder of the class were built at Garden Reach Shipbuilders and Engineers (GRSE) following a transfer of technology from MDL, in order to diversify warship building capabilities to other yards, as well as to make room at MDL for the larger projects to follow.[5]

d. Delhi   class destroyers

The next class of vessels designed and built by MDL were the Project-15 Delhi   class  guided-missile destroyers. These were powered by gas turbines and displaced 6,200 tonnes. The first of the class, INS   Delhi , was launched in February 1991 and commissioned on 15 November 1997. The second, INS   Mysore , was commissioned on 2 June 1999 followed by the last ship in the series,INS   Mumbai , on 22 January 2001.[6]

2012 |INTERNSHIP REPORT IMU

Page 6: MDL Report

6 | P a g e M D L

e. Shivalik   class frigates

The 6000 tons Shivalik   class  (Project-17) frigates are the first warships with stealth features to be designed and built in India. These multi-role, guided-missile frigates have reduced radar signature and are due to enter service starting in 2010. At least 3 of this class are under construction at MDL. The lead vessel of the class commissioned on 29 April 2010.

f. Kolkata   class destroyers

Kolkata   class  vessels are the next-generation of guided-missile destroyers in the 6,800 tonnes range to be designed and built at MDL. They incorporate stealth features. The lead vessel of the class was launched on 30 March 2006. At least three vessels of the class are planned.

2. Coast Guard vessels

The yard also builds offshore patrol vessels (OPVs) for the Indian Coast Guard. These vessels are specialized ships built for patrolling, policing, search and rescue operations in India's Exclusive Economic Zone. Each of these ships carries a helicopter on board. Seven such ships have been delivered to the Coast Guard.

3. Floating police stations

Based on the order by the BSF the yard started construction of floating Border Out Posts (BOPs). Essentially these BOPs are floating police stations, each with four high-speed boats. The yard has delivered 9 out of an order for 14 BOPs.

4. Other vessels

Among other ships, the yard has built three fast missile boats, a cadet training ship, and various other utility ships for the Indian Navy.

Submarines

Shishumar class submarine

The Shishumar class submarines are a variant of the Type 209 diesel-electric submarine designed by Howaldtswerke-Deutsche Werft. Two vessels of this class were constructed at MDL. These were the first two indigenously built submarines in India. INS Shalki was commissioned on 7 February 1992 and INS Shankul was commissioned on 28 May 1994.

2012 |INTERNSHIP REPORT IMU

Page 7: MDL Report

7 | P a g e M D L

Scorpène class submarine

MDL is presently building six diesel-electric submarines of the Scorpène class under a technology-transfer agreement with DCNS.

2012 |INTERNSHIP REPORT IMU

Page 8: MDL Report

8 | P a g e M D L

DESIGN DEPARTMENT

Shipbuilding is an activity that requires integration of all forms of technology known to man into a vessel that floats in water. It has evolved greatly over the centuries and become more and more sophisticated with every passing century.

Today, it is the realm of the professional naval Architect to design and to ensure that its manufacture conforms to the various specifications and the need of the

user. Every shipbuilder in the world requires a ship designer and that is what the Design Department at MDL basically

functions towards.

All the sophistication and detailing that is required to manufacture is provided by the Design Department. Each section in the Design Department has its own role to play. Apart from the various sections of mentioned below, there is an electrical department that takes care of the various electrical wiring throughout the ship.

These are as follows:

1. Forward Design Group (FDG)

2. Structural Department (SDO)

3. Outfit Department (ODO)

4. Engineering Department (EDO)

5. Electrical Department (LDO)

2012 |INTERNSHIP REPORT IMU

Page 9: MDL Report

9 | P a g e M D L

FORWARD DESIGN GROUP

The forward design group can be sub divided into 3 sections:

1. Basic Design Group2. Cost Estimation Cell3. Contract and Marketing Cell

The general progression of any typical order follows the following sequence:

THE PRE CONTRACT STAGE:

The owner (NAVY/Private) gives a basic briefing about the required product consisting of the following documents:

1. Naval Architecture Specifications 2. Basic Drawings3. Electrical and Other requirements 4. General Arrangement (If Available)5. Machinery Specifications

The first threshold within the pre contract stage consists of THE TECHNICAL SPECIFICATION BID it consists of the technical specifications the yard is able to provide the owner including the speed, dead weight, etc.This bid is formed by taking inputs from the STRUCTURAL, OUTFIT AND ENGINEERING DEPTs.

2012 |INTERNSHIP REPORT IMU

Page 10: MDL Report

10 | P a g e M D L

It is then simultaneously forwarded to the owner and the cost estimation cell.The cost estimation cell with the help of past records, vendors/OEMs and other methods estimates the cost of the ship. It also estimates the PROFIT MARGIN, MANPOWER, MATERIAL, LABOR, TIME etc.All the above terms including the final cost constitute the final FINANCIAL BID which is also then submitted to the owner.

THE ORDER STAGE:Once the financial and technical bids are approved by the owner the legal dept and the marketing cell form the final contract which includes even the minutest details of the ship required.

THE POST CONTRACT STAGE:

This stage is primarily concerned with the detailed design of the ship and is taken care by the structural, engineering depts. Etc. Once the bare hull is made the FDG dept. once again comes into picture. It conducts the following activities:

1. THE INCLINING EXPERIMENT2. LAUNCHING AND DOCKING CALCULATIONS3. TRIM STABILITY BOOKLET4. WEIGHT MONITERING etc.

2012 |INTERNSHIP REPORT IMU

Page 11: MDL Report

11 | P a g e M D L

Structural Department

Structural design group mainly deals with the modelling of the ship in the software tribon. However the whole department is being upgraded to aveva marine for detailing of the modelling and the structural details. Basic requirement of Navy are met with a basic design. After approval from the navy detail designs are drawn. Tribon M3 modelling is carried for hull detailing and sheeting, bulkheads, stiffeners, etc. based on the lifting capacity of assembly units available in the shop, until erection plan is prepared. Erection plan consists of typical unit drawings. Optical section will prepare nesting and cutting plans using faired hull surface designs and curvature requirements. Planning section prepares the part list and cutting document to be sent to material requisition store and production shops. Plate PreparationPlates are subjected to shot blasting and various and various layers of coat are painted on to prevent rusting while storing.The store will provide required plates and stiffeners and welding and cutting starts at the production and assembly shops (P&A)

Production and Assembly Shop (P & A SHOP)Pressing, bending, rolling, bevelling and cutting are the major activities carried out in the production shop of the shipyard. Assembly carries out welding, hammering, grinding and bolting.Production Machinery Cutting

CNC Cutting Machine Plasma of 2-30 m thickness Plasma Cutting Gases used include oxygen hydrogen and air

Gas Cutting machine Pug machine Plates up-to 8 inches thickness Semi automatic Uses acetylene and(C2H2) and oxygen

Plano Shear Machine (bevelling) Bevelling is used for plate preparation in the case of welding

together plates of different thickness Employs mechanical cutting Hydraulic jacks are used to hold the plate in position

2012 |INTERNSHIP REPORT IMU

Page 12: MDL Report

12 | P a g e M D L

Roller shears the plateRolling

300t rolling machine Small plates

600t rolling machine Larger plates

Pressing / Bending 350t and 600t pressing machines

Manually done Experienced labour force required to obtain required shape

of plates Templates made of wood to compare and assist Blocks and support prices used to assist

Folding Machine 300t Knuckles 90 deg bends and wedges Chalk /marker used markline to be bend Heavy weight used to put pressure on plate and bend it

according to needAssembly Major activity in assembly is welding together components to make sub assembly units and assembly units.

Welding –major activity Arc for steel plate Plasma for aluminium plates

Bolting Huge nuts and plates used to join

Grinding Preparing edges of plate for welding without defects arising from

impurities Hammering

Bends may arise due to temperature variation and thermal stresses arising due to welding

Hammering flattens those ends

Unit assembly at dry dock

Unit installation starts from amidships and extends both ways .To compensate for losses and expansion during welding green material is employed.

2012 |INTERNSHIP REPORT IMU

Page 13: MDL Report

13 | P a g e M D L

Standard Structural Details (SSD)

Detail design about each unit like with structural component like bulkhead, transverse and longitudinal, collision, minor, WT and NWT, compartments, decks, side shells, stiffeners, pads ,collars and plates.

OUTFIT DEPARTMENT2012 |INTERNSHIP REPORT IMU

Page 14: MDL Report

14 | P a g e M D L

To start with the hull outfit, first drawing should be prepared is an Access Plan of the whole ship. Access means to enter /move through openings. So, key plan of Hatches, Manholes, emergency Escape Scuttles (EES) and various types of Ladders, Doors, Windows and Side Scuttles are finalised. These are prepared based upon the General Arrangement Plan (GA) of a particular ship. Next, the detail production drawings of individual items covering above systems are prepared.

Hull outfit section is also design and specifies the location of the various equipments that are fitted in the ship. The outfitting items which remain on the deck and inside of the ship are mainly as follows:

1) SHIP’S FITTINGS (excluding machinery and electrical)

2) BOLLARDS

3) FAIRLEADS

4) ACCESS

DOORS, HATCHES ,MANHOLES AND EES

STAIRS AND LADDERS

BROW AND GANGWAY

5) BOOMS & DAVITS

6) WINDOWS AND SIDE SCUTTLES

7) DECK EQUIPMENTS

ANCHOR – Different types of anchors are used in ship :

a. BOWER ANCHOR – A ship’s main anchor are called bower anchor used for anchoring the ship and stowed on both sides of bow.

b. STERN ANCHOR – This anchor is used by some ships as a stern anchor, stowed in a stern region. These are mainly used for beaching purpose.

LSTL is having one stern anchor and two bower anchors.

ANCHOR CAPSTAN

2012 |INTERNSHIP REPORT IMU

Page 15: MDL Report

15 | P a g e M D L

ANCHOR CUM GENERAL PURPOSE WINCH

CRANES

VEHICLE LASHING ARRANGEMENT

8) LIGHT & SOUND SIGNAL ARRANGEMENTS

9) FIRE FIGHTING ARRANGEMENT

10) MOORING AND BERTHING ARRANGEMENT

11) CARGO ACCESS EQUIPMENT such as

BOW RAMP

BOW DOOR

VEHICLE RAMP

WETHER DECK HATCH COVER

INNER BOW DOOR

HYDRAULIC EQUIPMENT ( including pipes, fittings, flexible hoses etc.)

2012 |INTERNSHIP REPORT IMU

Page 16: MDL Report

16 | P a g e M D L

ENGINEERING DEPARTMENT

This Engineering Design group deals with various mechanical systems fitted in a ship, such as:

1. PROPULSION AND POWER GENERATION SYSTEM

2. ENGINE FITTINGS AND ACCESSORIES

3. REFRIGERATION SYSTEM

4. FIRE MAIN SYSTEM

5. BILGE AND BALLAST SYSTEM

6. FRESH WATER SYSTEM

7. FILLING AND LUBRICANT SYSTEM

8. SEA WATER COOLING SYSTEM

9. CIRCULATING WATER SYSTEM

10. AVCAT SYSTEM

11. FIRE AND DECK WASHING SYSTEM

12. SCUPPER DRAINAGE & SANITARY SYSTEM

13. SEWAGE TREATMENT PLANT WITH VACCUUM TOILET

SYSTEMS

1. AIR ESCAPE & SOUNDING

2. EMERGENCY DG EXHAUST SYSTEM

3. STEERING GEAR SYSTEM

2012 |INTERNSHIP REPORT IMU

Page 17: MDL Report

17 | P a g e M D L

4. FIN STABILIZER SYSTEM

5. CO2 SYSTEM

6. SHIP’S COMPRESSED AIR SYSTEM

7. COMPRESSED AIR SYSTEM IN MAIN & AUX. ENGINE ROOM

8. DD COMPRESSOR SYSTEM

9. A/C AND VENTILLATION SYSTEM

10.DOMESTIC ARRANGEMENT

11.LAUNDRY

12.LOGISTIC ARRANGEMENT

13.HOT AND COLD FRESH WATER SYSTEM

14.DRAINAGE ARRANGEMENT

15.FLOODING AND SPRAYING

ELECTRICAL DEPARTMENT

Electrical group designs the electrical, electronics and weaponry systems of ships. The Various systems which are being dealt by them are as follows:

1. POWER GENERATION & DISTRIBUTION

2. LIGHTING SYSTEM

3. NAVIGATION SYSTEM

4. SIGNAL AND COMMUNICATION SYSTEM

5. INTERNAL COMMUNICATION SYSTEM

2012 |INTERNSHIP REPORT IMU

Page 18: MDL Report

18 | P a g e M D L

6. EXTERNAL COMMUNICATION SYSTEM

7. ARMAMENT SYSTEM

8. AVIATION SYSTEM

9. ALARM, MONITORING & CONTROL SYSTEM

10.GENERAL

a) LOAD CHART

b) MAIN CABLE ROUTE PLAN (WITH GLAND LIST)

c) SEPARATE CABLE ROUTE PLAN (WITH GLAND LIST)

d) AERIAL LOCATION PLAN

e) BOOK OF JUNCTION BOXES

Load chart is a table for calculating electrical power requirements for operating various systems used in a ship. On the basis of the same the capacity of power outputs for generators is determined.

MAJOR ELECTRICAL SYSTEMS

1. Automated Power Management Systems (APMS)2. Integrated Machinery Control Systems (IMCS)3. ATM Based Integrated Ship Data Network (AISON)4. Lighting Systems5. Navigational Aids6. Internal Communication System7. External Communication System

OTHER ELECTRICAL SYSTEMS

1. LAN Systems2. VCS3. MK-III

2012 |INTERNSHIP REPORT IMU

Page 19: MDL Report

19 | P a g e M D L

4. SICADS5. Upper Air Sounding6. V-UHF7. Auto plotter8. ACS9. ICCP10.Steering Gear11.Degaussing System

WEAPONS DEPARTMENT

The weapons and the weapons system also come under the electrical department. The procurement of the systems and their installation also carried out under the supervision of the electrical department.

MAJOR WEAPON SYSTEMS

1. Surveillance System2. Close –IN Weapon System3. Surface To Surface MISSILE System4. Surface To Air MISSILE System5. Under Water Weapon System

WEAPONS

1. Surface To Surface Missile2. Surface To Air Missile3. Close –IN Weapon System

UNDER WATER SENORS1. SONAR ATAS2. SONAR HUMSA

UNDER WATER WEAPONS

1. Rocket Launcher RBU 60002. PURGA

ACKNOWLEDGEMENT

2012 |INTERNSHIP REPORT IMU

Page 20: MDL Report

20 | P a g e M D L

This summer training has given me an opportunity to have an overall idea of vast shipbuilding activities. I would like to convey my gratitude to MDL Personnel with high regards for their co-operation and guidance received from the design department.

CONCLUSION

2012 |INTERNSHIP REPORT IMU

Page 21: MDL Report

21 | P a g e M D L

An overall knowledge on practical Shipbuilding will definitely become an asset in my life. This practical knowledge gathered from here will be whole heartedly utilised in my future service life.

2012 |INTERNSHIP REPORT IMU