Guddu Singh

INDIAN MARITIME UNIVERSITY Chennai

INDUSTRIAL TRAINING REPORT

Ship building process (Yard- 158 MT ANDAMAN)

(Yard -159 MT BHEEM)

At

TEBMA SHIPYARDS LIMITED MALPE

HIND INSTITUTE OF NAUTICAL SCIENCE &

ENGINEERING, SIKANDRA RAO

Under the guidance of

Mr. Paul Lincoln

Training coordinator

Prepared by- Guddu Singh

Roll No. 1435712007

Submitted To

Department of Shipbuilding

Hind institute of nautical science and engineering

Guddu Singh

DECLARATION

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

“INDUSTRIAL TRAINING REPORT” has been carried out entirely by me

in the TEBMA SHIPYARDS LIMITED MALPE UDUPI KARNATAKA, and

further state that it has not been submitted earlier wholly or in part to

any other University or Institution for the Subject Shipyard Attachment.

GUDDU SINGH

IMU Reg. No. 1435712007

Guddu Singh

CERTIFICATE

This is to certify that the thesis entitled “SHIPYARD INTERNSHIP TRAINING

REPORT” submitted by GUDDU SINGH to the College for Subject Shipyard

Attachment in 5th semester work carried out by his/her under my supervision. The

contents of this thesis, in full or in parts have not been submitted to any other

institute or University for Subject Shipyard attachment. . In our opinion, the

Internship training is up to the standard of fulfilling the requirements of the

Subject as prescribed by the regulations of this Institute.

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

Training Coordinator,

Mr. Paul Lincoln

Place Malpe Udupi Karnataka

Date: 29-08-2016

Guddu Singh

PREFACE

Practical knowledge means the visualization of the knowledge, which

we read in our books. For this, we perform experiments and get

observations. Practical knowledge is very important in every field. One

must be familiar with the problems related to that field so that he may

solve them and become a successful person.

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

professional life. According to this life, he has to serve an industry, may

be public or private sector or self-own. For the efficient work in the field,

he must be well aware of the practical knowledge as well as theoretical

knowledge.

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

and must know about management, working in the industry, labour

problems and many, so he can tackle them successfully.

Guddu Singh

ACKNOWLEDGEMENT

This training was a part of the curriculum of our 5th semester of B.SC

SHIP BUILDING AND REPAIR. Doing this Training over the past 01

month has been absolutely enriching experience not to mention the vast

amount of knowledge we gathered via experiencing some of the real

time difficulties in the field of SHIP BUILDING

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

Mr. Paul Lincoln and HR Mr. Mithun K for their constant guidance and

overwhelming support throughout my project.

I also wish to express thanks to the staff of Tebma Shipyard and My

Faculty in HIND INSTITUTE OF NAUTICAL SCIENCE AND

ENGINEERING for their help during the Training.

Finally, I would like to add my heartfelt gratitude to my parents, family

and friends for their support and guidance.

Tebma Shipyard Malpe Udupi GUDDU SINGH

Date: 29/09/2016 (1435712007)

Guddu Singh

QUALITY, HEALTH, SAFETY & ENVIRONMENT POLICY

OF SHIPYARD

Create value for shareholders and all other stakeholders by

making our shipyard an efficient, contemporary and integrated

yard for building/repairing ships and offshore structure.

Consistently meet and/or exceed customer’s need in India and

abroad whilst striving to place India on the map as major ship

building nation.

Prevent accident, ill health due to occupational hazards

and adverse impact on environment due to

construction/repairs related activities of Ship and Offshore

Vessel through continual improvement.

Ensure compliance of all applicable legal and other

requirements.

Ensure effective implementation of the system by achieving

well defined and set Quality, Occupational Health, Safety and

Environment objectives, which shall be reviewed from time to

time. Undertake all steps to communicate this policy to all

our employees & personal working under the control and to

make this policy available to the interested parties.

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These can be achieved by teamwork, innovation, total

organizational involvement, continual improvement, process

orientation and integration thereof to create a holistic

management system for world class performance par

excellence.

The Policy will be reviewed as and when required to ensure

continuing suitability.

Guddu Singh

The essentials Of Safety

Oxygen content in confined spaces should be 16% to 20.8%.

In the ship, especially in the engine room and tanks, the oxygen

content should be 19.5% to 23.5%.

23.5% is not considered as safe

.

If work is being in progress ( it may be any hot work, painting, shot

blasting, testing etc.), then lock out that particular area and tag out

a sign over there that “work is in progress please be clear off the

place”.

This process is called LOTO.

Hydrogen Sulphide (H2S) which is a dangerous gas gets

accumulated where ever oil is used.

Its content above 5 ppm can even cause death.

H2S gas has got an identification property, if this gas is in

between 1 to 3 ppm it produces a rotten egg smell.

Carbon Monoxide (CO) is produced mainly when cutting, welding

operations are being done and in particular when the tanks are

closed for more days.

In case of accumulation of these gases in any enclosed

compartment, they are removed through forced ventilation.

At the deck we provide a decik around the vent pipe to protect the

spread of fuel oil, in case any overflowing through vent pipe.

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Safety While working in confined spaces:-

Sufficient ventilation must be there.

Visual inspection and gas checks must be taken to allow

for a permit.

No electrical instrument or insulation or paint job should

be there near the hot work affected area.

Smoking is prohibited.

In confined spaces such as tanks the amount of lead content can be seen

which on smelling can even kill a person. So before entering in any

confined space :-

A person must have the permit of going in that region.

With the help of gas testing meter check the amount of oxygen

level.

One attendant should be there for immediate help and rescue Confined

spaces like ballast tanks should provide with explosion proof

lightening and adequate ventilation.

Before welding or cutting any material it is to be ensured that it is

certified.

While doing hot work it is to be ensured that :-

It is under permitted area.

There is no flammable material nearby.

There is an attendant.

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Always disconnect the gas connections / hoses before leaving.

Have a gas meter for checking the gas leakage.

Have adequate forced ventilation.

Before commissioning of any work risk assessment has to be done.

Permit to Work In Confined Spaces

A Permit Includes:-

Identification of the person.

Date and purpose of the entry in confined space.

Risk Percentage etc.

Permit To Enter

Toxic Gas Clearance Certificate

Permit To Hot Work

Environment Clear From Flammable Materials

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Scaffolding

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

will describe all the details fit working in that environment.

From the safety point of view there will be a tag provided in the

scaffolding area.

Color Coding:-

Green Tag represents that the area is safe for passage.

Red Tag represents that it is the restricted area.

When working at a height above 3.0 meters one must tie a belt

around his waist and tie it to a rigid structure so that if a person

slips that belt provides support to him and saves his life.

We also use safety nets from preventing a person falling down.

There Are 4 Point Of Contact While Climbing On Ladder.

We Careful While Work On Scaffolding.

Don’t Enter Between The Scaffolding While Work Is Going

On It.

A Permit Is Must Before Climb On Scaffolding

Always Wear All The PPE While Work On Height.

Never stand on unfinished scaffolding.

Slings must be tied.

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Hydraulic platforms are also used (as having a major safety

factor) to take someone to a particular height. Even in that case

also, safety harness is necessary to wear.

Scaffolding in Tebma shipyards ltd.

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Rigging Work

Hoisting and lowering equipment should have a periodic

checkup.

Rigging shackles, slings, chains, belts etc. after every one

year.

&

Crane, Hoist winch etc. after every 6 months.

Never stand below the cargo being lifted or lowered.

Never come in between the crane which is being rotated at

3600.

All the rules and regulations for a particular operation come under the

INDIAN FACTORY ACT & RULE (1948).

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. Shot Blasting and Painting

One must wear a “blasting hood” with airline respirator so as

to avoid inhale of abrasive impinges.

An apron must be wear which will cover the body fully.

Air purifier respirators may be used.

For painting also a similar apparatus is being used, when

painting a confined space.

Periodic medical checkup must be done of the personnel.

Don’t Enter In The Blasting Shop Without Prior Permission

No Hot Work Is Done During Painting

Smoking Is Not Allowed In The Area Of Painting

There Is Permit To Paint In Confined Spaces Is Must.

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Shot Blasting and Painting

Shot Blasting and Painting Shop In Tebma Shipyards ltd.

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Electrical Safety

Ensure that the installation should not be switched on without

your knowledge.

Check that the insulation is not live.

Ensure the insulation is earthed.

Remove or isolate potential conductors.

Cranes

The working area nearby the crane should always be

barricaded.

There should be one attendant also.

There should be audible signals.

There should be audible speakers with mike.

Insufficient planning and communication failure can lead to

the loss of life of a person.

One must ensure that before commissioning of any work he

must be aware of all safety measures

When working outboard PFD’s (Personal Floating Devices) must

be wear.

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Safety during Hot Work

The following safety precautions must be taken before doing hot work

in a compartment or tank having water or any liquid:-

Pump out the liquid and sweep out and dry it out fully.

No welding hoses should get interrupt with accommodation

ladder.

There should be no electrical connection within 50 feet of

working area.

Always use explosion proof lights when working in dark.

Shipyard Different Departments Visit

Pipe Bending and forming shop.

Shot Blasting Shop.

Painting Shop.

Prefabrication workshop.

Winch Room.

Spare shop.

Slipway.

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Firefighting introduction

Introduction to Different Type of Extinguishing Medias

Dry Chemical Powder Type

Used for petrol, Gas and Electrical fires.

Fire extinguisher NO. TSL/m/339.

Inside pressure 30 kg/cm2

Standard IS 2171.

CO2 Extinguisher

Capacity 4.5 kg.

Fire extinguisher NO. TSL/BT/01.

Standard IS 2878.

Foam Type Fire Extinguishers

Capacity

Fire Extinguisher No.

Standard

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Fire fighting training

Procedure

It was done with the combination of processes used in PASS.

P = Plan, which extinguisher is to be used.

A = Aim, at the base of the fire.

S = Squeeze the valve.

S = Sweep the nozzle sideways.

When we operate those extinguishers they produce:-

DCP: - White powder with high pressure.

CO2 Type: - White gas and was cool in nature.

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After having a practicing hand on fire safety I saw some videos about

safeties for grinder.

Then I learnt about safety helmet and its parts,

Outer Shell.

Interior suspension.

Ventilation Space.

Helmet Belt.

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

Glass etc.

Guddu Singh

Day 02

Health Safety training

Purpose of training- To Understand the First aid given at the

time of sudden accidents in shipyard.

FIRST AID TRAINNING & CPR

Aim of Training

TO PRESERVE LIFE

TO PROMOTE RECOVERY

TO PREVENT FURTHER DAMAGE

QUICK TRANSPORT OF CASUALTY TO A MEDICAL

FACILITY

Defination First Aid is the immediate help or treatment given to a victim of

an accident, sudden illness or other injury before medical help is

obtained using materials.

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CPR

WHEN TO PERFORM CPR

No breathing

No pulse

Unconscious

HEART ATTACK/CARDIAC ARREST

Heart Attack –Reduced level of oxygen to the heart muscle.

Cardiac Arrest – Heart stops beating.

Signs and Symptoms – Pale, chest pain, pain moving to left arm,

upset stomach, shortness of breath, tired, denial.

Risk Factors – Age, cholesterol, weight, heredity, diet, smoking,

fitness, high blood pressure, stress.

The first important steps in giving CPR are….

The three C’s!!

CHECK

CALL

CARE

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CHECK

Is the scene safe?

Check to make sure that the scene is safe!!! Fire, wires, gas,

glass, spills, traffic, falling objects etc.

Make sure you are also taking care of yourself!

Assess what might have happened

Check for ABC

Is there anyone around who can also help? Ask others

around the scene for as much help as they can offer!

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Call

Calling for help is often the most important action you can take to help

an ill or injured person.

Call 100 or the local emergency number 108 (If there are other

people at the scene, ask someone else to call for you to help!)

If you’re by yourself, call 100/108 and/or get AED before you start

CPR

Give the 100/108 operator the correct information about your

location, victim, what happened and any other information you

can. Be the last to hang up!

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Care

Once you have followed the first two C’s, you may need to give care

until EMS personnel arrive. Follow these guidelines:

Do no further harm.

Monitor the person’s breathing and consciousness.

Help the person rest in the most comfortable position.

Keep the person from getting chilled or overheated.

Reassure the person.

Give any specific care

needed.

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Frist aid for electric SHOCK

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

second only to attending to obstructed breathing, stoppage of heart or

severe bleeding. It may lead to death if not treated in time.

a. Reassure the casualty (when conscious).

b. Put him comfortably on his back. Except in case of the injury of

the head, the chest, or of the abdomen, lower the head slightly

and turn into a side. In case of vomiting give fowlers position.

c. Loosen tight clothing, but do not remove clothing.

d. Wrap the light bed sheet or thin rug.

e. Never use hot water bottle or do not rub any part of the body

with anything.

f. Incase of injury to chest and abdomen do not give anything by

mouth as he may require operation or blood transfusion later on.

g. Observe all the above quickly in a minute if delayed death may

occur.

h. Shift to hospital as early as possible.

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Day 03

Planning Department Purpose of the training- The aim of the planning Department is to

provide a system to plan, monitor and evaluate the Ship building

activities to build and Deliver ships on time Meeting customer’s

requirements as per contract

Scope: All contracts For New Vessel construction & repair works.

Instructor: Mr. Gautham C and Mr. Shrinivas Rao

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Project Planning

On finalization Of The Shipbuilding/Ship repairing Contract

Project Planning Department Informs The Planning

Department Regarding approved Project Plans And Cardinal

Dates :

Date of Contract

Fabrication

Keel laying

Float out

Sea Trails

Delivery

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Project plan Development for Material

Planning department prepare the above plan for block Fabrication

& Block erection Dates with the Full Details for all the Major

Activities pertaining to each department indicating start & Finish

Date and Duration of the work along with the activities Linked,

as per Sequence so as to achieve the envisaged delivery Date.

As and when the details are released from the Design Department

the Project plane gets revised, accordingly.

The periodicity of revision of project Plane is kept flexible

depending upon Complexity of the project and guideline from the

top management.

In Tebma All Work Is Done On A Software Name As Microsoft

Project Plan MPP.

Other Software Use for Project Planning is Primovera6.

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

Sub project ID & Activity ID in Microsoft Project Plan MPP and

the Exported It into IFS (international Finance System).

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Activities are listed below:-

Milestone

Signing of contract

100% hull erection up to main deck

Superstructure erection without block 611

100% superstructure

Launching

Sea trails commencing

Ship delivery

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

whatever the Work is progress as per the Schedule.

Detailed activity/item wise list are prepared for each

department for all projects.

This is to analyze the completion of each activity, balance

work to complete, percentage completion and to prepare

fortnight schedule for production department.

Weekly progress summary for each department is also

prepared from the database on weekly basis.

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Data Base Preparation Detailed activity/item wise lists are prepared for each

department for all projects as given at next page. This is to

analyze the completion of each activity, balance work to

complete, percentage completion and to prepare fortnight

schedule for production Department.

The weekly progress summery of each department is also

prepare from the database.

Achieved steel tonnage report is also prepared from the

database on weekly Basis.

Weightage of 100% is distributed to the activities according to

the quantum and intensity of the work to each project.

The general distribution of weightage is shown on next pages

of each department.

The weightage distribution will vary from project to project

depending on the complexity of the project.

Planning department decides the weightage distribution while

creating data base for the project.

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Weightage Distribution in Tebma

Design- Drawing Being Outsourced In Tebma Shipyards

Ltd. And in house made are monitored group wise with respect

to operation departments. Activity Drawing Released

weightage 100%

Purchase- Material Procurement Activities are monitored at

various levels and weightage as noted below.

Activity BOM&PRQ Purchase Order Material Receipt

Weightage 25% 25% 50%

Hull- Fabrication And Erection Of Blocks Are monitored

in block wise with respect to weight of block and weightage

as noted below: 1) Block Fabrication

Activity Steel Cutting Fabrication Dry Survey

Weightage 5% 50% 5%

2) Block Erection

Activity Erection&

Alignment

Fairing Welding Dry

Survey

Weightage 5% 15% 15% 5%

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(SOF) Structural Outfit – Structural Work of outfit

items and fitment of deck items are Detailed with quantity

giving weightage as noted below:

Activity Fabrication Erection Dry Survey

Weightage 45% 45% 10%

Piping- Piping work is Monitored For Fabrication,

Erection, Pressure test And Is Detailed With Quantity Giving

Weightage As Noted below:

Activity Fabrication Erection Dry

Survey

Pressure

Test/Flushing

Weightage 45% 25% 15% 15%

Machinery- Machinery Work is monitored in Quantity

wise with Weightage as noted below: Activity Shipping Bolted down

Weightage 30% 70%

Electrical-Electrical work is monitored in the quantity Wise

with Weightage As noted below. Activity Hot Work Equipment

installation

Cable

laying

Cable

Termination.

Weightage 30% 15% 25% 30%

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Accommodation- Accommodation work is monitored in the

quantity Wise with Weightage As noted below. Activity Hot

Work

Flooring Furniture

Fitment

HVAC Insulation Paneling

Weightage 15% 10% 15% 20% 15% 25%

Painting- Painting work is monitored in Area Wise with

Weightage As noted below.

Area Block Tanks External

Hull

Superstructure

Ext. & Int.

Hull

Marking

Weightage 25% 25% 15% 25% 10%

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

the Completion of tank testing with weightage as noted blow:

Activity Penetration Air Test Dry Survey

Weightage 40% 20% 40%

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Reporting In Tebma

Production Progress- Production Progress is Prepared in

every week to get the work progress in activity wise for the

project. Required data for this will be forwarded by the

Department to the respective department to the planning

department who will feed the data to the data base.

Constraints Analysis- It is observed that many a times,

delay could be due to any constraints which are beyond the

control of the production dept. concern. Hence identification

the constraints for non-achievement becomes essentials to

resolve constraints and also measuring performance of the

production dept. against what can be achieved

The performance of the particular dept. is monitored Vis a Vis

planned for after knocking off constraints beyond its control.

Constraints are identified, recorded and analyzed for corrective

action during review.

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Weekly Progress Report – The weekly progress report

is prepared from the summary obtained in the data base file.

This is the presented in the weekly Production Review

Meeting (In Tebma at Every Thursday of the month). PRM

is attended by all the HOD to review the progress and take

corrective action. Also the work progress of each project is

calculated to see the percentage of the completion of the

project.

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Day 04

Ship movement

Ship Launching in Tebma at malpe yard

Purpose

To Transfer ships from build bay/repair bay to the sloping

cradle and to launch the same trough an efficient and safe

process.

The ship during construction stage is erected on ground block

supports. For movement of the ship, these ground supports are

removed and trolleys are instructed as per trolley insertion plan,

Document Required

Block Support Plan.

Ships Docking Plan.

Ship Load Distribution Chart

Trolley insertion plan.

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Ship Launching Procedure Flow Chart

Plan schedule for movement and launching

Remove ground supports and insert trolleys

Rig up for pulling

Move ship from build bay to transfer cradle

Rig up for side movement of transfer cradle

move transfer cradle in line with sloping cradle

Rig up for pulling on sloping cradle

Move ship from transfer cradle to sloping cradle

Pre-Launch prepration

Launch

Berthing of ship

Retrieval of sloping cradle and trolleys

Preservation of trolleys and associated equipments

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Ship Docking Procedure Flow Chart

Plan Schedule for docking

Positioning trolleys on sloping cradle

Set dock block support

Lower the cradle to required Depth

Rig up for side movement of transfer cradle

Move transfer cradle in line with repair bay

Rig up for pulling on repair bay

Move ship from transfer cradle to rapair bay

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Tool Required

Sledge Hammer

Buffing M/C

Cleaning gears& Grease/oil.

Shifting trolley Toe Jacks.

5T/10T hydraulic jacks.

Roller Pipes.

Wooden Blocks and wedges of assorted sizes (lower the

trolleys and to erect the block supports)

Butter Paper

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Procedure

Remove the ground support as per trolley insertion plan

and clean the area.

Buff, clean and Grease the rails.

Shift and insert the trolley to the required position with the

help of shifting trolley/ toe jacks and roller pipes. Lower

the trolley on the rails with the help of hydraulic jacks and

wooden blocks.

Arrange block support on the trolley as per block

arrangement plan.

Hammer tight, Block supports and take load (Block

supports to be covered with butter paper on top to avoid

damage to hull paint)

Repeat the above procedure for all trolleys and transfer

ships load.

Some ground supports are not disturbed to share ships

load till movement.

Precautions Or General notes:

Thoroughly clean and wash the area before trolley

insertion

Give Prior information to the project manager regarding

support removal and trolley insertion.

Wear proper PPE For Safety

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Use proper and calibrated shifting and lifting equipments

to avoid injury to personnel and damage to the trolley and

rollers.

Use experienced Riggers for the work.

Work should be carried out under staff supervision only.

Avoid sudden Jerk while removing ground supports

Take precaution to avoid the damage of hull paint.

Do not use crow bars on roller surface.

Use of Transfer Cradle

The ship is pulled with the help of eye pads welded either on

trolley or under the ship’s hull which is depends upon the size

of the ship and load on the trolleys.

Document Required

Trolley loading plan.

Wire rope routing and layout plan

Pulling eye pad location

Procedure

Align the transfer cradle with building bay and connect

rails.

Connect the forward eye pad through bow shackles Wire

slings and pulleys.

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Rig rope through pulleys and forward anchor point to

auxiliary winch.

Clean the trolley Movement area.

Clean and grease the rails.

Evacuate all personnel and remove gangway cable and

hose connections from the ship.

Inform the safety department to cordon off movement area

to ensure the sefty during movement.

Start auxiliary winch to the required speed to pull the ship.

Observe the rope movement to avoid any obstacles

Record the winch parameter start stop and duration of

movement

Side Movement of the transfer cradle

Procedure

Disconnect ropes and pulleys connecting ship to the aux.

winch

Remove rail interconnection between new building shed

and transfer cradle.

Rig the side movement of transfer cradle.

Clean transfer cradle rails and clean obstacle in cradle

movement area.

Move the transfer cradle with aux. winch and align with

the sloping cradle

Ships pulling on sloping cradle

Procedure

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Connect the aft eye pads through the bow shackles.

Rig rope through pulleys eye pads on sloping cradle

Forward anchor points to the auxiliary winch

Start auxiliary winch for required speed and pull the ship.

Observe the rope movement to avoid any obstacles

Depending on the ship movement winch speed is

increased or decreased as required and necessary

instruction are given to the winch operator.

When ship in water then disconnect the bow shackles,

wire slings, pulleys and rope connecting ship to the

auxiliary winch

Remove the eye pads and painted eye pad area.

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Day 05

Ship Design

Purpose of training- the purpose of this training is to

understand the Basic Design (Approved Drawings By

Classification Socity) and Detailed Drawings used in shipyard at

various stage of shipbuiding.

Tebma Shipyard doesn’t have A Design Office So It Outsource

The Design From Various Ship Design Companies .The Design

Depart of Tebma only check the drawings.

Instructor: Mr. Shrinath /Mr. Mouraly C /Mr. Lingeshwaran

Tebma Design Department with Projects.

DESIGN

CHENNAI

PROJECT

TUG

DREDGER

SURVEY LAUNCH

MALPE

PROJECT

MPSV

TUG

KOCHI

PROJECT

PSV

AHTS

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DESIGN ROLE IN PROJECT

PROJECTS

SMALL SHIPL <40 m

PREPARING DWG

SENT TO APPROVAL

CO-ORDINATION TO

PRODUCTION

CLEARING COMMENTS

AS FITTED

DREDGER

PREPARING DWG

SENT TO APPROVAL

CO-ORDINATION TO

PRODUCTION

CLEARING COMMENTS

AS FITTED

OFFSHORE VESSEL

CO-ORDINATION TO PRODUCTION

CLEARING COMMENTS

AS FITTED

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Design Department Tebma

Machinery Design

DESIGN

HULL

Mr. Lingeshwaran

MACHINERY

Mr. Shrinath

ELECTRICAL

Mr. Mourly C

MACHINERY

EQUIPMENT SELECTION

REUIREMENTSSUITABILITY

MATERIALSELECTION

Depend on fluid

STD(BIS,DIN)

DRAWING

CLASSDRAWINGS

PRODUCTIONDRAWINGS

SPOOLGENERATION

CO-ORDINATION

ARRANGEMENTDWG

PENERATIONLIST

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Hull Design

HULL

HULL FORM

LINES PLAN

PRELIMINARYT&S BOOKLET

SOUNDING TABLE

INCLININGEXPERIMENT

FINAL T& SBOOKLET

STRUCTURES

GENERAL ARRANGEMENT

LONGITUDINALPROFILE PLAN

W.T.BHDS

FRAMING SECTION

SUPER STRUCTURES

OUTFIT & STATUTORY

DECK MACHINERYFOUNDATION

BULWARK/GUARD RAIL

FCP

LSA

INSULATION &PANELLING

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Machinery Equipment by Mr. Shrinath sir

Introduction to various machinery used in a ship

1) Main Engine And propulsion

1.1. Main Engine.

1.2. Gearbox

1.3. Thrust Block

1.4. Bearings

1.5. Propeller

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3. Engine Room Auxiliaries 3.1. Auxiliary Generator.

3.2. Air Compressor

3.3. Fuel oil Separator.

3.4. Lube Oil Pump

3.5. Air Conditioning Plant Compressor

3.6. Starting Air Compressor.

3.7. Hydrophore Pump.

3.8. Main Sea Water Pump.

3.9. Other Pumps and Equipment’s.

4. Deck machinery and cargo handling Crane

Mooring Winch

Capstan

Windlass

Anchor Handling equipment’s

Rope Reel Drum

Life Raft

Life Boat

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Electrical Power generation & Distribution

To meet all the power requirement of the equipment’s discussed

above, Main Generators are available which have mostly diesel

engines as prime movers. Also Emergency Generators are

available, to power essential loads of the ship.

Generator

Box battery

Main distribution Board

DPS (Dynamic Positioning System)

Satellite systems

Other Navigation units and etc…

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Piping design By Mr. Mouraly c

Piping system

Piping includes pipe, supports, flanges, fittings, bolting, gaskets,

valves and the pressure containing portion of the equipment and

supports. Therefore the pipe when joined with fittings, valve and

equipments, supports are called PIPING.

System is the process how we are handling the fluids

Piping System in a Ship

Bilge System.

Ballast System.

Fire Fighting System.

Air Vent System.

Tank Sounding System.

Cargo Piping System

Hydraulic piping System.

Pipe Fittings

Welded.

Threaded.

Flanged.

Also Classified As,

Bends.

Branches.

Reducers.

Flanges.

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Piping drawings

Layout Arrangement Drawings.

Process flow Diagrams.

Equipment Drawing.

Isometric Drawings.

Coordination Drawings.

Process Instruments drawings.

Symbols Used In Piping Drawings

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Day 07/08

Hkt

Pre Fabrication yard at hkt

Propose of training- to explain the procedure of pre fabrication

of sub assembly nesting welding and plate bending.

Drawing required

Nesting plan

Block fabrication drawing with part list

Procedure

1. Marking/cutting

The various parts and elements are required for the sub-

assemblies of the block are marked/cut on plates and sections as

per nesting plan either manually or CNC cutting according to

part list of sub-assemblies required for block.

A control register is to be maintained showing the heat no.

and grade of the plate.

2. Edge Preparation

Edge preparation of required beveling of plate required for

various skin plates and panels viz. Bottom/side shell tank top

and bulkhead panels are prepared by either automatically by

CNC machine or manually by semi-automatic bug cutter (gas

cutter).

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3. Forming

Cold forming is done for sections and bilge strakes as per

templates prepared from lofting table.

Hot forming is done for higher thickness plates like stem bar and

nose plate I fore peak, Bulbous bow shell plates and also plates

to be formed in multiple shape by rolling and bending.

After forming Yard no. block no. and part no. is to marked for

identification

4. Palletisation

Various part and elements cut as per nesting plan are segregated

identification no. marked and kept in pallets block wise and yard

wise.

Each part/elements is marked the yard no. block no. part no.

Each palate is marked the pallet no, yard no. block no. of

elements contained in it. This is done to prevent from misplaced

or loss, Register is to be maintained for the details of such

pallets.

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Pre Fabrication of sub assembly

Fit up of intercostal floors brackets to girder stiffener to

continuous floors etc.

The root gap for plates fit ups and vertically of profiles to

be ensured.

Welding of these assemblies in down hand position.

Distortion if any is removed by the line heating

Join the tank top panel plates together bottom side upward

Weld seam by SAW or CO2 preferably with the ceramic

backing as per approved WPS.

Mark punch all the frame .girder line including check line

of entire girder fit up check line. Check line is the line

marked either port or starboard of the center line of the

girder to ensure whether the half thickness of the center

girder is falling exactly on either side or two lines parallel

to center line showing the thickness of girder.

Weld temporary guide cum stopper for automatic

alignment while placing sub assembly.

All Sub Assembly fillet or butt joint should start from the

Centre to outward of the panel or sub assembly

Welding schedule to be followed to avoid excess or under

fill weld and to ensure correct reinforcement

Block Fabrication flow at hungercatta yard

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Block Fabrication Process Flow Chart

Relese of Drawing

Identify the material required for panels, plates profile etc.

Nesting, Marking, Cutting

Identify welding process

Fit Up Of plates

Fit Up Inspection by IQC

Welding of Panels

Inspection by IQc

Shift to block Assembly

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Welding By Mr. Paul Lincoln Sir

Definition- Welding is a process of joining material, usually

metals, often by melting the work piece and adding a filler

material to form a molten material, which when cools will

become a strong joint

Classification of welding

Fusion welding Union of parts is accomplished by melting the two parts to be

joined, in some cases adding filler metal to the joint

Examples: arc welding, resistance spot welding, oxyfuel gas

welding

Solid state welding Heat and/or pressure are used to achieve coalescence (union), but

no melting of base metals occurs and no filler metal is added

Examples: forge welding, diffusion welding, friction welding

Arc welding

An electric arc struck between the electrode and the base metal

to melt the metals.

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The power supply can be DC or AC In welding, the positively charged anode will have a greater

heat concentration and, as a result, changing the polarity of

the electrode has an impact on weld properties.

If the electrode is positively charged, it will melt more

quickly, increasing weld penetration and welding speed.

A negatively charged electrode results in more shallow welds.

AC supply results in medium penetration welds.

AC machines less expensive to purchase and operate, but

generally restricted to ferrous metals.

DC equipment can be used on all metals and is generally

noted for better arc control.

The electrode can be consumable or non-consumable

Common consumable electrode welding are: SMAW -

shielded metal arc welding, also called as MMAW (Manual

metal arc welding) - the most common type of welding. An electric current is used to strike an arc between the base

material and a consumable electrode rod or stick

(producing around 5500 C). The electrode rod is made of a

material that is compatible with the base material being

welded and is covered with a flux that gives off vapors that

serve as a shielding gas and provide a layer of slag, both of

which protect the weld area from atmospheric

contamination. The electrode core itself acts as filler

material, making a separate filler unnecessary

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An electric arc is a discharge of electric current across a

gap in a circuit

To initiate the arc in AW, electrode is brought into contact

with work and then quickly separated from it by a short

distance

It is sustained by an ionized column of gas (plasma)

through which the current flows

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A pool of molten metal is formed near electrode tip, and as

electrode is moved along joint, molten weld pool solidifies in

its wake

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Shielded Metal Arc Process:

–Intense heat at the arc melts the tip of the electrode.

–Tiny drops of metal enter the arc stream and are deposited on the

parent metal.

–As molten metal is deposited, a slag forms over the bead which

serves as an insulation against air contaminants during cooling.

–After a weld ‘pass’ is allowed the cool, the oxide layer is

removed by a chipping hammer and then cleaned with a wire

brush before the next pass.

At high temperatures in AW, metals are chemically

reactive to oxygen, nitrogen, and hydrogen in air –Mechanical properties of joint can be degraded by these

reactions

–To protect operation, arc must be shielded from surrounding air

in AW processes

•Arc shielding is accomplished by: –Shielding gases, e.g., argon, helium, CO2

–Flux

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GMAW – Gas Metal Arc Welding

Constant voltage, direct current power source is most

commonly used with GMAW, but alternating current are

also used. –MIG (Metal Inert Gas) - a continuously fed consumable wire

acting as both electrode and filler metal, along with an inert or

semi-inert shielding gas flowed around the wire to protect the

weld site from contamination. Argon and Helium are mostly

used as shield gas, sometimes as a mixture too.

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

shield, it is called Metal Active Gas welding

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Applications of MIG and MAG: Mostly used for aluminum welding

Also used for non-ferrous and ferrous material

Widely used in automobile industry

Good quality and speed achieved -

No slag formation

Because of the need to maintain a stable shroud of shielding gas

around the weld site, it can be problematic to use the GMAW

process in areas of high air movement such as outdoors

Better arc time because of continuous wire electrode –Sticks must be periodically changed in SMAW

Better use of electrode filler metal than SMAW –End of stick cannot be used in SMAW

Higher deposition rates

Eliminates problem of slag removal

Can be readily automated

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Submerged Arc Welding Consists of an electrode fed from a spool. The molten weld and

the arc zone are protected from atmospheric contamination by

being "submerged" under a blanket of granular fusible flux

consisting of line, silica, manganese oxide, calcium fluoride, and

other compounds. When molten, the flux becomes conductive,

and provides a current path between the electrode and the work.

This thick layer of flux completely covers the molten metal thus

preventing spatter and sparks as well as suppressing the intense

ultraviolet radiation and fumes.

SAW is normally operated in the automatic or mechanized

mode, however, semi-automatic (hand-held) SAW guns with

pressurized or gravity flux feed delivery are available. The

process is normally limited to the flat or horizontal-fillet

welding positions

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TYPE OF WELDING JOINTS

Butt Joint A joint between two members aligned approximately in the

same plane

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Lap Joint

A joint between two overlapping members

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T Joint

A joint between two members located approximately at right

angles to each other.

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Corner Joint

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

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Edge Joint

A joint between the edges of two or more parallel or nearly

parallel members

Intermittent welding

Weld geometry and

dimensions.

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Welding positions. Fillet welds •1F – down hand

•2F – Horizontal

•3F – Vertical

•4F – Overhead

Groove welds •1G – down hand

•2G – Horizontal

•3G – Vertical

•4G – Overhead

•5G - for fixed horizontal pipes

•6G - for inclined fixed pipes

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Welding Defects Crack

Incomplete fusion

Porosity

Incomplete join penetration

Undercut

under fill

Overlap

Spatter

Slag inclusion

Excess penetration

Convexity

Concavity

Lack of fusion

Face Reinforcement

Throat crack

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Nesting by Sunil Sir

Definition-The process of planning to optimally accommodate

Maximum components to be cut from a plate with minimum

material wastage and effort is called “nesting”

Nesting can be done manually by trial and error method Needs skill and expertise for good result

Time consuming

Software are available to do nesting like Sigma nest Expensive, but saves lot of time

Scrap factor: wastage of plates in the form of scrap.

Limiting it to 10 to 12 % is considered good.

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Day 09

Rigging and lifting equipments

Purpose of the training- to understand the all rigging and lifting

equipments used in shipyard.

Training instructor- Mr. Anandan V

List of rigging and lifting equipments used in shipyard

1. The ‘D’ lugged joining shackle is used extensively for

joining the cable to the anchor in more modern vessels. In

the past this type of shackle was used, as the Kenter lugless

joining shackle is used today, in the joining of the shackle

lengths of cable together. If it is to be used for this purpose,

the rounded crown part of the shackle should always face

forward, so that it does not foul the anchor when letting go.

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Lifting belt- 6T capacity, (polyester material)

Lashing belt

Bow shackle

Vertical lifting clamp

Wire slings

After that he took me for a round to show the lifting

equipment present in the shipyard.

Hydraulic crane-15T capacity

Lifting Beam- it is used to lift the blocks and place it by

turning it at any direction.

Transporter- for taking the blocks and placing inside the

shot blasting chamber.

Crawler crane- for lifting heavy blocks of ships and

placing it where the overhead gantry crane cannot reach.

Its SWL is 30T.

Gantry Girder crane- 4 nos. each of 30T

Sir said that for lifting any block eye pad must be welded

on the block rigidly through which hooks of the chain block

from the overhead gantry crane or the crawler crane passes.

After finishing all these sir explained about the terms

related to rigging and seamanship.

Whipping- the binding round the bare end of the rope

for preventing the strands from unlaying.

Mousing- a length of line or small wire rope between the

point and shank of a hook to prevent unhooking. This

can also be done for a D-shackle.

Lashing- two crossed spars can be secured together

either with a square lashing or a diagonal lashing.

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Seizing- it may be defined as being a method of

fastening together two parts of rope sufficiently strongly

to stand a required strain.

Then sir showed me an:-

Eyebolt- which is used for securing an eye to a wooden

structure.

Block- is a portable pulley made of wood or steel.

Turn Buckle- these are also called rigging screw .

various kind of rigging screws are used to set up i.e. to

adjust for length or tension, any rigging equipment.

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Day 10/11

Hull Fabrication

Purpose of training- the purpose of this training is to

understand the work flow and operation procedures of

production process of hull fabrication.

Hull fabrication is done in the new building shed of the Tebma

shipyard malpe.

List of Document and Drawing require in hull fabrication

1. Set of production drawing issued by drawing department

of TSL.

2. Project Schedules.

3. Technical Specification.

4. TSL Quality standards for hull.

5. Welding Schedule Given By Welding Department.

6. Approved welding procedure specification WPS copy

from QA/QC.

7. Approved Quality Assurance Plane (QAP) copy from

QA/QC.

8. Welder Qualification copy from QC/QA.

9. Material test Certificate.

Tools Used in Shifting of Hull Blocks.

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1. EOT in New Building Shed.

2. Hydraulic Jacks.

3. Hydraulic jacks for push and pull.

4. Bottle screw and turn buckle.

5. Chain locks

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Hull Block Fabrication flow chart

Recipt Of Drwing

Qualification of welder

Verify material grade as per drawing

Nesting Marking and cutting

Pre fabrication of sub assembly

Pre Fabrication Survey

Fabrication Of Hull Block

Block Dry Survey

Grand Assembly

Block Eraction Fit-up

Dry survey of block erection

Non destructive test

Air pressure test/vacuum test

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Pre-fabrication of sub assembly:-

The parts of sub-assemblies as per sub assembly part list

drawing are marked on plate/sections. The marking and

cutting of plates are done as per nesting plan by using CNC

Plasma Cutting Machine in Hungerkatta Yard.

Prefabrication of sub-assemblies are done ensuring

dimension control as per drawing and work instruction

(MPE/HUL/WI/007) and distortion control during various

stages of welding is done as per work instruction

(MPE/HUL/WI/05).

Pre fabrication Survey

Pre Fabrication survey of sub assembly is done to

check the dimension of sub assembly and welding defects

if any

This survey is done as per rule if the classification

society.

It is done By Internal Quality Control Manager.

Fabrication of Hull Block

A. Fabrication of double bottom blocks.

Tebma Follows the Process Of Block Fabrication And

erection

Block Fabrication is done As per block drawing in two

operation as per work instruction MPE/HUL/WI/007

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First align and fit up all sub-assemblies on top of tank top

panel upside down condition on the skid.

Fit up Inspection by QC department as per check list fit up

MPE/QC/F/CLF and dimension report (MPE/QC/F/DR).

After clearance from QC department, Complete the

welding I down hand position as per Welding procedure

Specification WPS., Welding Sequence, Follow the Correct

Welding sequence.

Next turn this tank top assembly and place it on bottom

shell panel, align, fit up and weld.

Rectify weld distortion, angular deformity if any by line

heating and fairing.

B. Fabrication of other blocks including super structure.

All bulkheads are fabricated and welded as sub-assemblies

as per drawing and lifting capacity of the crane.

Align the deck panel on the skid upside down. Fit up all

stiffening members.

Align and fit up all the pre-fabricated bulkheads and

assemblies on top of the deck panel as per drawing.

Fit up Inspection by QC department as per check list fit up

MPE/QC/F/CLF and dimension report (MPE/QC/F/DR).

After clearance from QC department, Complete the

welding I down hand position as per Welding procedure

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Specification WPS., Welding Sequence, Follow the Correct

Welding sequence.

Rectify weld distortion, angular deformity if any by line

heating and fairing.

Block Dry Survey:-

Dry Survey is first carried by Internal Quality Control

Department

The final survey is carried by Owner and Classification

Society.

Results are recorded as the inspection report.

Grand assembly of blocks:

Small Blocks are joined together aligned, fit up done as a

grand assembly of blocks as per work instruction

This is limited to the capacity of EOT crane in the new

building shed.

Fit up Inspection by QC department as per check list fit up

MPE/QC/F/CLF and dimension report (MPE/QC/F/DR).

After clearance from class, welding carried out as per

approved WPS, welding schedule and follow weld

sequence.

Rectify weld distortion, angular deformity if any by line

heating and fairing.

Erection of hull blocks and grand assembled blocks.

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After dry survey of blocks and grand assembled blocks

erection of hull blocks and grand assembled blocks are

carried out as per drawing.

Block erection sequence is as per block erection schedule

issued by planning dept.

Double bottom unit block is erected first as a keel laying

block.

Then bilge/side shell blocks are positioned, aligned. Fit up

done.

Finally deck units are erected, aligned and strapped to

complete the ring construction.

Erection joints fit up inspection of blocks and grand

assembled blocks are offered to QC/Class/Owner after

verification by production as per check list fit up and

dimension report.

Results are recorded in the inspection report.

After clearance from class, welding carried out as per

approved WPS, welding schedule and follow weld

sequence.

While erection fit up is cleared and welding is progressing,

adjacent blocks are erected and attached to this ring on

forward and aft direction, For stability and maintaining

accuracy in half breadth, height and center line Further

erection should be also Completed ring wise,

Welding is done by using Ceramic backing strip, If

ceramic backing strip is not used then after root run

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welding of erection joint back gouging and DP test is

carried out,

Subsequently block erection joints fit up and dry survey

inspection is carried out.

Dry Survey of block erection:-

On completion of block erection joints Stiffening members

welding and removal of temporary supports and grinding

dry survey is carried out. Dry survey by visual inspection is

carried out by production department

Results are recorded in the inspection report.

Non Destructive Testing NDT:-

After clearance of dry survey by class NDT of weld Seams

and butts as per class approved NDT plan is carried out.

Weld defects if any found during NDT are rectified and the

weld joint is re checked.

NDT report is submitted to class for review and held with

QC.

Air Pressure testing/Vacuum testing:-

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

work instruction

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All weld seams and butts of underwater hull tank top

external hull up to

Main deck side shell of sponsoon and all bulkheads

forming watertight boundaries up to main deck are

requirement to be checked.

Vacuum testing is carried for weld seams butts which is a

part of watertight integrity and not covered under APT as

per QC work instruction.

Inspection results are recorded in inspection report.

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Day 12/13

SOF (structural outfitting)

Definition- Outfitting is the process of installing parts and

various subassemblies (e.g., piping systems, ventilation

equipment, electrical components) on the block prior to joining

the blocks together at erections

Outfitting at each stage of construction is planned to make

the process flow smoothly throughout the shipyard:

Unit outfitting

On-block outfitting

On-board outfitting

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Unit outfitting Unit outfitting is the stage where fittings, parts, foundations,

machinery and other outfitting materials are assembled

independent of the hull block.

Unit outfitting allows workers to assemble shipboard

components and systems on the ground, where they have

easy access to the machinery and workshops.

Outfitting materials come in varying sizes, shapes and

complexities. In some cases, units are as simple as a fan

motor connected to a plenum and coil. Complex outfitting

are mainly composed of components in machinery spaces,

boilers, pump rooms and other complex areas of the ship.

Unit outfitting involves assembling piping spools and other

components together, then connecting the components into

units.

Outfitting units on the ground increases safety and

efficiency by reducing the work hours that would otherwise

be allocated to on block or on-board work in more confined

spaces where conditions are more difficult.

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On-block outfitting

On-block outfitting is the stage of construction where

most of the outfitting material is installed onto the

blocks.

Outfitting materials installed on block consist of

ventilation systems, piping systems, doors, lights,

ladders, railings, electrical assemblies and so on.

Many units are also installed at the on block stage.

Throughout the on-block outfitting stage, the block

can be lifted, rotated and moved to efficiently facilitate

installing outfitting materials on the ceilings, walls and

floors.

All of the shops and services in the shipyard must be

in communication at the on-block stage to ensure that

materials are installed at the right time and place.

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On-board outfitting On-board outfitting is performed after the blocks are

lifted onto the ship under construction (i.e., after

erection). At this time, the ship is either at a building

position (building ways or building dock), or the ship

could be berthed at pier side.

The blocks are already outfitted to a large extent,

although much more work is still needed before the

ship is ready to operate. Onboard outfitting involves

the process of installing large units and blocks on

board the ship. Installation includes lifting the large

blocks and units on board the new ship and welding

or bolting them into place. On-board outfitting also

involves connecting the shipboard systems together

(i.e., piping system, ventilation system and electrical

system). All of the wiring systems are pulled

throughout the ship at the on-board stage.

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List of Post outfitting Items • Mast and Sampson post erection

• Cranes and derricks

• Doors, hatches, ramp doors

• Ventilation refrigeration, insulation

• Firefighting equipment

• Lifesaving equipment

• Steps, ladders, lifts

• Guard rails

• Flooring

• Interiors, furnishing • Galley equipments

• Bathrooms, toilets

• Navigation, communication equipment

• Engine control

• Lighting

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Day 13/14 Painting

Surface preparation of metals for painting

Factors affecting performance of paint

Surface contamination including salts, oils, grease, drilling

and cutting compounds

Rust and mill scale

Surface profile

Objective of surface preparation

The main objective of surface preparation is to ensure that all

such contamination is removed to reduce the possibility of

initiating corrosion so that a surface profile is created that allows

satisfactory adhesion of the coating to be applied. Methods of surface preparation Degreasing: It is essential to remove all soluble salts, oil, grease, drilling

and cutting compounds and other surface contaminants prior

to further surface preparation or painting of the steel.

The most common method is by solvent washing, followed

by wiping dry with clean rags. The wiping clean is critical,

because if this is not carried out thoroughly the result of

solvent washing will simply spread the contamination over

a wider area.

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Proprietary emulsions, degreasing compounds and steam

cleaning are also commonly used.

Hand tool cleaning:

Loosely adhering mill scale, rust and old paint coatings

may be removed from steel by hand wire brushing,

sanding, scraping and chipping.

However, these methods are incomplete, and always leave

a layer of tightly adhering rust on the steel surface.

Power tool cleaning: Generally more effective and less laborious than hand tool

cleaning for the removal of loosely adhering mill scale,

paint and rust.

However, power tool cleaning will not remove tightly

adhering rust and mill scale.

Power wire brushes, impact tools such as needle guns,

grinders and sanders are all commonly used.

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Care should be taken, particularly with power wire brushes,

not to polish the metal surface as this will reduce the key

for the subsequent paint coating.

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Blast cleaning: By far the most effective method for removal of millscale,

rust and old coatings, using abrasives such as sand, grit or

shot under high pressure.

The grade of blasting suitable for a particular coating

specification depends on a number of factors, the most

important of which is the type of coating system selected.

Prior to blasting, steelwork should be degreased and all

weld spatter removed. If salt, grease or oil is present on the

surface it will appear to be removed by the blasting

process, but this is not the case. Although not visible, the

contamination will still be present as a thin layer and will

affect the adhesion of subsequent coatings

Weld seams, metal slivers and sharp edges revealed by the

blasting process should be ground down, as paint coatings

tend to run away from sharp edges, resulting in thin

coatings and reduced protection.

Weld spatter is almost impossible to coat evenly, in

addition to often being loosely adherent, and it is a

common cause of premature coating failure.

The surface profile obtained during blasting is important,

and will depend on the abrasive used, the air pressure and

the technique of blasting. Too low a profile may not

provide a sufficient key for coating, while too high a profile

may result in uneven coverage of high, sharp peaks

possibly leading to premature coating failure, particularly

for thin film coatings such as blast primers

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The following table gives a brief guide to typical roughness

profiles obtained using various types of abrasive:

HYDROBLASTING (hydro jetting)

Hydro blasting is a technique for cleaning surfaces, which

relies entirely on the energy of water striking a surface to

achieve its cleaning effect. Abrasives are NOT used in

hydro blasting systems.

Consequently the problems caused by dust pollution and by

the disposal of spent abrasives are eliminated.

Two different hydro blasting operating pressures are

commonly encountered:

High pressure hydro blasting, operating at pressures between 680

bar (10000 psi.) and 1,700 bar (25000 psi.).

Ultra high pressure hydro blasting, operating at pressures above

1700 bar (25000 psi.).

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The steel surfaces produced by hydro blasting do NOT look

the same as those produced by dry abrasive blasting, or

slurry lasting.

This is because water on its own cannot cut, or deform steel

in the same way as abrasives. Hydro blasted surfaces

therefore tend to look dull, even before they “flash rust”.

Hand wire or bristle brushing to remove heavy flash rusting

may be acceptable for small areas, but will generally

produce an inadequate surface. Mechanical rotary wire

brushing can however produce acceptable surfaces for large

areas.

When large areas are hydro blasted, flash rusting which

obscures the original blast standard may occur, before an

inspection can be carried out.

Establishing the required standard by blasting a small test

area prior to the main blast may help, providing the rest of

the job is blasted to the same standard.

Methods for ensuring the rest of the job is blasted to the

same standard will vary from project to project.

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Nonferrous metal, Aluminum: The surface should be clean, dry and grease‐free (see under

Steel‐Degreasing). If any corrosion salts are present they

should be removed by lightly abrading.

Before painting, apply one thin coat of a proprietary acid

etch primer to provide a key for further coats. If this

reaction does not take place, adhesion will be found to be

poor. The surface should be scraped clean, and treated with

a proprietary aluminum pretreatment solution, and the acid

etch primer then re‐applied

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International Standards of surface preparation Followed by International ISO 8501‐1 and Swedish SIS 05 5900

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Painting

No paint can perform all the desired functions

Separate paint scheme required for underwater (u/w) hull,

boot top area, above water hull, deck, hold, tanks, bilges,

compartment, superstructure, Engine Room etc.

Paint areas of external hull

Underwater hull should resist corrosion and fouling

Boot top is susceptible to heavy corrosion, fouling and

aberration

Above water hull should resist corrosion, and aberration

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Function of paint on ship structure Each type of paint applied to specific areas on ships have

a different role to play.

Almost all paints on ship structure should provide

anticorrosive protection.

Underwater paints should provide anticorrosive as well as

anti-fouling protection.

Above water paints should provide anticorrosive as well

should be visually appealing.

Paints of Engine Rooms should provide resistance to

corrosion, heat and oil.

Deck paints should resist corrosion and well as be non-

skidding.

Flight deck paints should have high impact resistance and

have high friction.

All external paints should resist effect of sun’s rays.

External paints of warships should be radar absorbent type.

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Conditions during paint application

The most important factors are to consider the

condition of the substrate, the surface temperature, and

the atmospheric conditions at the time of painting. Painting should not be undertaken When the air temperature falls below the lower drying or

curing limit of the coating

As a guideline surface temperature should be 3 deg. Above

due point and RH<85%

During fog or mist conditions or when rain or snow is

imminent

When the surface to be painted is wet with condensation

or when condensation can occur during the initial drying

period of the paint

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Components of a paint scheme

Primer: This is the layer that adheres to the substrate. It

is most important that the primer is applied with great

care as it has a definite effect on the overall life of the

paint scheme.

Anticorrosive paint: The primary aim is to prevent the

corrosion of the substrate. Anticorrosive properties are

obtained by barrier protection, which means that the water

vapour transmission of the system should be very low.

Polyurethene (PU) or Coal Tar Epoxy (CTE) were very

popular. Several countries have imposed ban on these now.

Vinyl or Chlorinated rubber paints are also used.

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

adhesion of two otherwise incompatible paint types

Antifouling paints: Aim is to prevent marine organisms

to attach themselves to the hull. Copper and Tri-butyl Tin

paints were used. By regulation Tin and Copper Free

paints are to be used.

Antifouling paint, being the outermost layer of the u/w hull

paint scheme influences the skin friction of the hull.

SPC (Self polishing co-polymer) prevents marine growth as

well as ensure a smooth hull surface by wearing off with

the water flow, leaving a smooth surface at all times.

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Methods of paint application Brush For small areas

For decorative parts

Slow

Roller application Faster than brush application

Thickness control difficult

Air spray (conventional) Paint atomized by low pressure air stream

Paint introduced to air stream under suction or gravity

Simple and inexpensive equipment

High build paints are to be thinned

High loss of paint Air spray (pressure pot) Paint introduced into air stream under pressure

Better performance than conventional air spray

Airless spray Atomization of paint achieved by high hydraulic pressure

High build paint application possible

Low loss of paint

Costlier equipment

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Components of a paint scheme

Nonskid paints used on decks have sand or similar particles

embedded in it to increase friction.

Typical u/w paint scheme

Surface preparation by blasting to recommended standard

Three coats of anti-corrosive

alternate colours.

Two coat of anti-fouling alternate

colours.

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Machinery

Purpose of training- To Understand all Machinery Fitted in

the ship onboard and the procedure of the installation and

commissioning of main engine and other machineries

Instructor- Mr. Arvind/Mr. Sachin

Introduction to Machinery installed in Yard-158

Main Engine-An engine room will usually contain 02

engines, either diesel or heavy fuel. The engines are used to

provide mechanical power for the propulsion through

propeller. The engine use in YARD-158 are manufacture

by YANMAR having power 1180 KW. The driven Rpm Of

the engine is 900 RPM.

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Propeller- A propeller is need to move ship and turn from

one place to other through thrust. A thrust is creating

according pitch position of the propeller.

A propeller that turns clockwise to produce forward thrust,

when viewed from aft, is called right-handed. One that turns

anticlockwise is said to be left-handed

YARD- 158 contains SRP (Steerable rudder propeller) and

YARD-159 equipped with Voith propulsion system.

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Engine Room Auxiliaries

An engine room is where the main engine, generators,

compressors, pumps, fuel/lubrication oil purifiers and other

major machinery are located. It is sometimes referred to as the

"machinery space" Auxiliary generator

Air Compressor

FO separator

Fi-Fi pump

Lube oil cooler

Hydrophore System

Sewage Treatment plant

Bilge purifier

Harbor Diesel Generator

Fresh Water generator

Main Generators

Emergency generator

Fuel Transfer pump

Sea water pump

Other pumps and equipments

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Deck Machinery & Cargo Handling

To raise/ lower ships boats (for life safety and harbour use),

winches are provided. To raise/lower ships anchor, capstans or

windlass are provided. For cargo handling, cranes are provided.

All these equipment are electric or electro hydraulic.

Crane

Mooring/Towing winch

Life raft

Life Boat

Rope Reel Winch

Windlass

Derrick

Main Fi Fi Pump on the top of wheel house

Capstan

Anchor

Anchor handling unit

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STP (Sewage Treatment Plant)

A sewage treatment plant for use aboard ship comprises a vacuum

assisted fresh water flush system delivering sewage to a collection

tank for treatment. Disposal of sewage from ships alongside or in

coastal waters is a considerable current problem. Some harbours

have sewage collection facilities, however, these are not always

available. Thus sewage collection and treatment plant is required

where port facilities are unavailable.

Sewage treatment plant

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Installation of main engine

Engine is specified by the owner and some time by shipyard

and owner both.

Shipyard placed an order for the new engine to the engine

manufacturing company.

Engine manufacturer send a copy of the engine foundation

drawing to the shipyard

Shipyard makes a foundation of the engine before the engine

receipt.

The engine receipt in The shipyard with the copy of

registration

Shipyard Done a trail of engine in shop in presence of OEM

The machinery department take the engine to the engine room

of a new build ship by means of crane and other machinery.

Put the engine on the main engine foundation and start

alignment of the engine with respect to the propeller shaft

After the alignment the engine is bolted down to the

foundation.

When installation is complete the trail of the engine is done in

presence of internal quality control. If quality control found

any fault or excessive noise and vibration the It need to be

corrected.

Then a trial is done on front of class surveyor and owner

representive.

The Final Trail is done on the time of Final Sea trail.

Same Procedure is followed for all other machinery

installation

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Accommodation

Purpose of the training-To understand the procedure of

construction of the accommodation space in a ship with full

human comfort

Training instructor- Mr. Nidhin Das

Definition- Accommodation space in a ship must have adequate

ventilation and supply of the air and it is free from the outside

condition

Insulation in Accommodation-

There are three type of insulation used in accommodation

1. Fire Insulation.

2. Noise Insulation.

3. Vibration Insulation.

Fire insulation:

There are four Class of Fire insulation used in ship

A60

A30

A15

A0

A60- It is mostly used in high fire risk areas. It can hold the

fire for 60 Minutes

For bulkhead there are Two Layers of A60 Of thickness

30mm+30mm are used

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A30- It is used in medium fire risk areas. It can hold the fire

for 30 minutes.

It is mostly in celling of the accommodation room. There is a

layer of class A30 insulation of thickness 45mm is used.

A15 and A0 Is used in low fire risk areas. These are used in a

ship at very low level.

Sound Insulation:

It is used in accommodation space to prevent the noise

disturbance from one compartment to other compartment

It is only used in the compartments where running machinery

having greater noise. So it creates a comfort for a person for

easy to sleep.

It have a sheet of 50mm is fitted with bulkhead shell.

Thermal insulation:

50mm thickness Sheet used with celling.

100mm Thickness Sheet Used with Bulkhead

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Procedure to install the Insulation

On the time of fabrication the insulation holding pins are

welded with the bulkhead by using stud welding

Insulation holding pins have a distance of 300mm from

each other.

Check all the pipelines are passing for the area

Take clearance from all departments for remaining hot

work or work with bulkhead.

If Any work is pending then no insulation work can be

done

Check final paint of the insulation area bulkhead by pain

survey for DFT.

Put the insulation on the bulkhead on the insulation

holding pins.

Protect the Insulation by using Aluminum Foil.

Tight It with the mesh.

Post insulation survey is done by IQC.

Paneling

Panels are used in Accommodation space for giving the shape

to the room.

There are three type of panels used in ship

1. Wall Panels:

It is used with the bulkhead side

50mm thickness panel used with partition bulkhead.

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25mm thickness panel used with bulkhead side.

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

Bottom Profile- It is used in bottom to lock to lock

the wall panel.

2. Stainless Steel Panels:

It is only used in galley of the ship.

3. Celling panels:

It is used in the celling of the room.

Furniture used in accommodation space

Wardrobe

Double bed decker

Tea table

Table with wardrobe

Sofa

2 chair

Book self

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Day12/22/23

Electrical

Purpose of training- To understand the all equipment and wiring

and panels fitted in a ship.

Training instructor- Mr. Vijay

He started me with the basics of electrical and electronics:-

The power generation and distribution onboard ship.

Various control systems

Various signaling system

He then explained me about installation of panels, cables,

MCB’S, generation units and electrical accessories.

Then he send me to Mr. Guru Prasad SP who was in the wheel

house of the vessel.

He asked me some concepts about the electrical equipments

and systems and then explained them in detail:-

- Power Distribution system (PDS)

Five power generating units are on the vessel i.e. 2

auxiliary generators, 2 shaft generators and 1

emergency generator.

Power is distributed to various systems using

MSB’S, LDB’S, EDB’S etc.

- Dynamic Positioning system (DP)

It is an integrated automation system in which all the

systems onboard ship are combined together which

will work simultaneously on the basis of feedback

from a reference unit.

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Used to place the ship in a particular pre-defined position with

the help of GPS, side thrusters, propellers, steering gear, anti-

heeling system etc. keeping in mind the reference line of the

voyage of the ship and alterations occurred due to winds and

wave action

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Day 24/25

Piping Purpose of the training- to understand the piping system

used in ship and all the valve and pumps used in ship

Training instructor- Mr. A.R Ravi/ Mr. Sarath P.V

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

of water, gas, steam, petroleum etc.

Purpose of pumping and piping arrangement:-

- Cargo loading and discharging.

- Tank washing

- Bilge drainage

- Blasting

- General services.

Piping consist of :-

- Piping

- Valves

- Pumps

- Flanges/Couplings

- Elbows

- Sleeves

- Expansion joints

- Reducer

- Gasket etc.

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Piping

Copper-Nickel-Iron alloy piping is used for the piping of

the salt water main and its branches, sanitary system, hull

and fire, fire and bilge, overboard discharge from

water/fuel displacement system, salt water supply to and

overboard discharges from bathroom ejectors, bathroom

drains.

Galvanized mild steel piping is used for all suctions to

compartments, overboard discharge of salvage pump

system, suction pipes within fresh water storage tanks, oil-

fuel residue suctions.

Steel pipes below 3/2 inch bore are connected by screwed

sleeves and large pipes by flanges welded to the pipes.

No non-ferrous piping is introduced into any part of the

ship so low as to come in contact with the bilge water.

Pipes connected to the other bottom or to protective

bulkheads are worked with generous bends or alternatively

with weaken shearing joints, so that they cannot act as

struts in the event of deflection of the structure

Air and Sounding pipes

Air pipes are provided for all tanks to prevent the air being

trapped under pressure in the tank when it is filled, or a

vacuum being created when it is emptied. The air pipes may

be fitted at the opposite end if the tank to the filling pipe

and/or at the highest point of the tank.

From oil fuel and cargo oil tanks, cofferdams, and all tanks

that can be pumped up, the air pipes are led to an open deck,

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in a position where no danger will result from leaking oil

or vapors.

Sounding pipes are provided to all tanks and compartments

not readily accessible and are located so that soundings are

taken in the vicinity of the suctions, i.e. at the lowest point

of the tank.

Each sounding pipe is made as straight as possible and is

lead above the bulkhead, deck except in some machinery

spaces where this might not be practicable.

Valves

- Seacock

- Screw down valve

- Screw down non return valve

- Screw down non return and flood valve

- Butterfly valve

- Screw down and non-return drain valve

- Reducing valve

Manifold

A manifold is a wide and/or bigger pipe or channel, into

which smaller pipes/channels lead.

Types of manifold:-

I. Exhaust manifold

It is used to collect the exhaust gases from multiple

cylinders into one pipe.

II. Hydraulic manifold

It is used to regulate the fluid flow in a hydraulic

system, thus controlling the transfer of power between

actuator and pumps.

III. Inlet manifold

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It is used to supply the air or fuel/air mixtures to the

cylinders.

IV. Manifold scuba

In a scuba set it connects 2 or more diving cylinders.

Valve actuator

A valve actuator is a mechanism of opening and closing the

valve.

Manually-operated valve require someone in attendance to

adjust them using a direct or geared mechanism attached to

the valve stem.

Power operated actuators, using gas pressure, hydraulic

pressure, electricity allow a valve to be adjusted remotely

or allow rapid operation of large valves.

Power operated valve actuators may be the final elements

of an automatic control loop which automatically regulates

some flow, level or other process.

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Day 26

Quality control Purpose of the training- to understand the quality control

system used in shipyard.

Training instructor- Mr. Praveen K/Mr. Srinivasn K/Mr.

Ganesh Samaga

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

To meet the quality requirement of classification

societies.

To ensure safety and reliability of ships during

construction and during service.

To minimize defects and reworks during production

process.

To meet production within reasonable variation.

To ensure prompt and effective response of action and

receipt customer complaints

From the time of plates received at the yard till the delivery

of the ship QC plays an important role at each step. For

e.g.:-

Material inspection

Block fabrication

Block erection

Installation of machineries

Piping

Painting

Accommodation etc.

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I was then told to go with Linesh sir who was the quality

control of machinery department.

He said that the commissioning and trials of the machinery

is checked by the QC but when trials will be commenced

QC of the shipyard, class surveyor and owner’s

representative will be present.

During survey if any deflection occurs it should be within

permissible limit may be upto 2-3mm. After then only QC,

owner and class surveyor signs on the satisfactory survey

sheet of that particular department.

There are two types of trials being commenced for a ship:

I. Dock trials

The trials which can be done while the ship is at the

dock for e.g. running the Main DG set, pumps,

compressors, emergency generators etc. are known as

dock trials.

II. Sea trials

The trials which need to be done at sea like

Speed trials

Endurance trials

Crash trials

Astern trials

Maneuvering trials

Anchorage trials

After that sir gave an example of ballast tank trials

According to the rule book the whole procedures will be

followed.

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The ballast pump will be started and the valve present in

the manifold on the discharging line to the particular tank

will be opened while other will be closed.

All the ballast tank

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Day-27

Materials

Purpose of the training- to understand the activities in

procurement and material inspection.

Training instructor- Mr. Maheshwer S/ Mr. Pawan S

He explained me the procedure followed by material

department from the time of receiving material from the supplier

to the delivery of the same to the production department:-

Project planning department will send purchase order to the

supplier according to the design and production requirements.

After the material is released from the supplier it arrives to

the material department.

Firstly, gate entry pass is made by the security at the gate

after verification of address on delivery challan.

Then, material comes to the material inward section.

Physical inspection of the logs will be done to check the:-

- Quantity

- Bill

- Delivery challan

- Tested certificates

All provided by the supplier.

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During physical inspection we will compare the PRQ

(Purchase Requirement) with the quantity received.

If any difference is there, we will make a material discrepancy

note (MDN).

If no discrepancy, inform QC for quality inspection.

After inspection, QC gives a quality inspection report.

On the basis of it, we make Goods Receipt Note (GRN).

GRN bill is then handed over to the accounts department.

In case any discrepancy in GRN and bill provided by the

supplier we will make a debit note (DN).

Material is stored at designated location according to:-

- Nature i.e. heavy/medium/light

- Groups with necessary preservation

- Space availability and storage facility.

Storage and preservation

To maintain the quality of the material, stores does the

preservation activity.

For e.g.:-

i. Rust and corrosion prevention of machinery parts → apply

light coat of grease or rust preventive oil.

ii. Rubber seal is given to prevent the moisture.

iii. Cushioning material is inserted to prevent them from

getting dents, indentations etc.

iv. Shelter is provided from the sunlight and rain.

v. In some areas, A.C. rooms are also introduced so as to

maintain minimum temperature which will procure electrical

and electronic equipments paints etc.

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Material delivery from material department to production

department:-

Shop order will be given by the project planning

department to the material department and in consolation with

the production department.

Material issue slip will be made and passed to the material

department through production department.

Dispatch of material will be done from the material

outward section and an out-pass is made at the gate.

This out-pass can be in two-ways:-

i. Returnable basis

ii. Non-returnable basis

Cannibalization:- In few cases, production department

requests material from one project due to design

change/modification/defects noticed during working etc.

to meet the production schedule as alternative material

from OEM having a long lead time.

For the delivery of the final product, the approvals

and permissions are obtained by head stores from

statutory agencies.

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CONCLUSION

As a student of HIND INSTITUTE OF NAUTICAL SCIENCE AND

ENGINEERING, I have to undergo the industrial training for one month from 29

August to 29 Sept. 2016. I had chosen to do my practical training in one of the

famous SHIPYARD TEBMA SHIPYARD LIMITED MALPE in India.

As A student of B.sc Shipbuilding and repair course, I have been briefed and

introduced to current and most used shipbuilding techniques in the industry.

Although I was not familiar with the practical knowledge, I don’t know how the ship

exactly made.

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

shipyard in here, I had finally understood every process how a ship is build, I was

given the opportunity to do the simple task such as ship design welding cutting and

electrical line looping and many more. During the practical I had gain lot of

knowledge as well as working experience.

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

shipbuilding I had been exposed to the shipbuilding working environment, which

may help me in my future career. During the period of practical, I learned to be

discipline and punctual.

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

by engineers

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

all the student from HIND INSTITUTE OF NAUTICAL SCIENCE AND

ENGINEERING should undergo industrial training. So the student can gain much

more experience in shipbuilding field