Grse project vishal

IN PURSUIT OF EXCELLENCE AND QUALITY IN SHIP BUILDING

STATION: G.R.S.E (MAIN UNIT)

NAME: VISHAL DEBNATH

STREAM: MECHANICAL ENGINEERING

COLLEGE: BRAINWARE GROUP OF INSTITUTION

I

VOCATIONAL TRAINING REPORT

ACKNOWLEDGEMENT

I would like to thank G.R.S.E and its management for giving me the opportunity

to undergo vocational training at G.R.S.E (Main Unit), particularly, Mr. Arunava

Das Adhikary, my Training Officer who has been my guide and has helped me

with understanding all the processes and operations which I needed to know.

I had my training from 10th June, 2015 to 6th August, 2015 in Garden Reach

Shipbuilders & Engineers Ltd (GRSE). During my training I visited Plate

Preparation Shop, Ship Building Shop, and Modern Hull Shop etc. I am grateful

to Mr. S Naskar, Mr. M Basak, Mr. D K Prasad, Mr. S K Dutta, and Mr. S Das.

My sincere thanks Mr. S K Daw (AGM, MS, MAIN), Mr. K C Rai (Dy. Mgr. Dock

dept.), and Mr. V.R.S Sunil (mgr. Pipe shop) who guided me to their concerned

shop and to all other helping bodies for their valuable guidance, direction ant

intent supervision at every stage of my work.

VISHAL DEBNATH

ROLL NO. 10, 4TH YEAR

DEPT. OF MECHANICAL ENGINEERING

BRAINWARE GROUP OF INSTITUTION (WBUT)

TABLE OF CONTENT

SL. NO. SHOP NAME PAGE NO.

1. SAFETY SHOP 1 – 6

2. PLATE PREPARATION SHOP 7 – 14

3. SHIP BUILDING SHOP 15 – 20

4. MODERN HULL SHOP 21 – 25

5. MAINTENANCE SHOP 26 – 30

6. UTILITY SHOP 31 – 35

7. ICER SHOP 36 – 40

8. PIPE SHOP 41 – 46

9. MACHINE SHOP 47 – 52

10. PAINT SHOP 53 – 57

11. QUALITY ASSURANCE SHOP 58 – 60

12. FIRE FIGHTING DEPT. 61 – 65

13. DOCK DEPT. 66 – 71

Garden Reach Shipbuilders & Engineering Ltd

SAFETY PRECAUTIONS

Vishal Debnath BRAINWARE GROUP OF INSTITUTON

OBJECTIVE

To develop safety consciousness among employees and

to ensure safe and healthy work environment.

To be educated and ensure compliance and

implementation of statutory provisions and rules.

To ensure the procedures and standards laid down for

safe working environment towards self and others.

To make all concerned aware of their individual

responsibility to take responsible care for their own

health and adopt safety awareness for reduction of

accidents.

To ensure co-operation and suggestions from any

employees toward matter of safety

All suggestions towards improvement of Safety, Health

& Environment is a continuous process and shall be

considered for implementation.

PRECAUTION WHILE WORKING AT HEIGHTS

1. Defective wooden planks (weak, rotten, cracked, split, bent) should never

be used on staging. Staging plank should be checked thoroughly and

defective planks should be replaced prior to start of work.

2. Personnel while erecting staging must wear safety belts, when they have to

work on locations above ground level.

3. Flat tread ladders, connected with staging, for having access to the staging

platform and should be placed at an angle of 75 degree to the horizontal.

4. Work should not be done standing on the stage while storm / rains.

5. While working on fragile roofs, ladders safety nets should be provided for

arresting fall of the person from the roof.

6. For situations where normal arrangements for working on heights can’t be

provided (e.g. window cleaning , painting of roof structures etc.) , workers

should wear safety belts with life lines anchored to fixed structures.

7. The staging planks should be so arranged that there is no gap between

them.

HOT WORK SAFETY PRECAUTIONS

1. No hot work to be undertaken on-board ships without written clearance

from concerned officer.

2. Adequate ventilation is to be arranged, which should continue throughout

the hot work period.

3. Paint shop should monitor and declare safe zone after painting. As wet

paint is highly flammable.

4. Gas lines not to be entangled with electrical cables.

5. Damaged welding cables to be replaced immediately since they are the

potential source of short circuit and fire hazard.

SAFETY ASPECTS OF ELECTRICAL INSTALLATION

1. To check whether the circuit is alive or not, do not touch with bare fingers or hand.

2. Place warning board like “MEN WORKING – DO NOT TAMPER” on main switch before

commencing working.

3. Do not disconnect or connect a plug by pulling the cable or when the switch is on.

4. All portable appliances should be provided with 3- pin plug.

440/220/110 volts supply

should be provided with

distinguishing marks.

Hand lamp with max 110V to

be used on board the ships.

SAFETY GUILDLINES FOR WELDING

1. Never change electrodes with bare hands (or) wet gloves, (or)

standing on wet floors.

2. Ensure welding machines are properly earthed.

Cables to of minimum joints with proper cable joint @machine

identification at holder end.

Damaged welding cables should be replaced immediately as it is

the source of short circuit and fire hazard.

During rainy season welders should not use damaged hand

gloves and safety shoes.

PERSONAL PROTECTIVE EQIPMENT


PLATE PREPARATION SHOP


Plate Preparation Shop

A shipyard consists of a large number of shops in which various processes of

building of any ship are carried out. Plate Preparation Shop is one of them, where

plate is straightened, shot-blasted, painted and cut into various desired shapes

and sizes as per requirement & send to the vendors for fabrications. After it is

being fabricated (block) processed materials are being delivered to the GRSE ship

yard.

The machines that are being used in the Plate Preparation Shop are-

1. CNC – Plasma Cutting Machine.

2. CNC – Oxy Cutting Machine.

3. Hydraulic shearing Machine.

4. (a) Strengthening Machine.

(b) Short Blasting Machine.

(c) Painting Machine.

There are mainly three types of plate that are being processed in shop.

Types of plates

Carbon Percentage

Strength Longevity

DMR-249 A grade MS steel plates

Low High High

IS-2062 grade MS steel plates

High Low Low

Aluminum plates - Medium High

Now the two main classes of ships for which the plates are being prepared are:-

1. Anti-Submarine Warfare Corvette (ASWC)

For ex: YD: 3017, YD: 3018, YD: 3019

2. Landing Craft Utility (LCU)

For ex: YD: 2092, YD: 2093, YD: 2094, YD: 2095, YD: 2096

3. Water Jet Fast Attacker Craft (WJFAC)

For ex: YD: 2109, YD: 2110, YD: 2111

The uses of the machines are described as follows;

1. CNC – Plasma Cutting Machine

The machine here used is being made by the company named as

HYPERTHERM (series HT 2000). The word CNC here stands for Computer

Numerical Control programs. The design of the plate cutting which is done

through the software AUTO CAD, that design is being transformed into a

CNC program. This program is then sent to the plasma cutting machine

through wireless communication (CISCO-WAP 54G Switch).

The machine has two sub divisions mainly. They are the one number of

cutter and as well as one number of marker for each set. There are two sets

only for a machine. All are controlled by power thermistor and feedback

path via Master controller.

The plasma machine is being processed to make block, skid, flat bar types

of materials.

The plate thickness that is being maintained for cutting is in between 3.0

MM to 12.0 MM.

2. CNC – Oxy Cutting Machine

Same as Plasma cutting machine CNC here stands for Computer

Numerical Control programs. The design of the plate cutting which is

done through the software AUTO CAD, that design is being transformed

into a CNC program. This program is then sent to the Oxy cutting

machine through wireless communication.

Here both Oxygen and Acetylene is being used under certain pressure to

cut plates.

Material which are being processed or made like blocks, flat bars, flange,

PAD etc.

The plate thickness that is being offered through, maintains a range in

between 7 millimeter to 130 millimeter.

Flange is a special type of processed material which is used in ship.

Processed material having thickness of 15 mm to 130 mm. The materials

are being sent to the machine shop for machining work as per the

requirement.

3. Hydraulic Shearing Machine

This is a manual control machine where cutting teeth/ blades upper

portion only moves up and down and lower portion is fixed.

There are total six blades in this machine.

Among the six blades the guard distance could be maintained manually for

upper portion only as per the requirement.

Flat bar and sheet materials are being processed with the help of this

manual controlled distance.

The plate thickness that is being processed through it lies in between 3

millimeter to 12 millimeter.

4. (a) Strengthening Machine

The DMR or IS steel plates or aluminum plates may not be

straight. There may be some up and down in the plates but that tolerance is being

removed by the strengthening machine. When the plates become perpendicular

and straight fully.

(b) Shot Blasting Machine

This is actually the process after the

strengthening process with a continuous run of program. After the plates are

being made perpendicular and straight, it might be corrosive in nature or it

may have rust on it. To remove this rust or corrosiveness the plates are then

processed through shot blasting machines where steel shot are used. After the

process full corrosiveness is being removed.

(c) Spray- Painting Machine

After removing the corrosiveness, the plate are

being painted in the spray-painting machine. It is a quick and easier technique

to paint than the manual painting. There are two number of pointed guns up

and down portion which are moves horizontally so that all parts of both side of

the material must be painted. The pointed guns sprays paint at a constant

speed to cover all areas of it. It is a very important process ofcourse.


SHIP BUILDING SHOP


Ship Building Shop

Ships Nomenclature:-

1. Bitts – Strong iron post on ship’s deck for working or fastening lines; almost

invariably in pairs.

2. Bulkhead – One of the vertical wall-like structure enclosing a compartment.

3. Brig – Prison aboard ship or on shore.

4. Bollard – Wooden or iron post on pier or wharf to which mooring lines are

secured.

5. Cleat – A small deck fitting of metal with horns used for securing lines.

6. Deck – Aboard ship, it corresponds to a floor.

7. Compartment – Corresponds to a room in a building.

8. Overhead – Aboard ship, it corresponds to a ceiling of a building.

9. Head – Compartment of a ship having toilet facilities.

10. Superstructure – All equipments or fittings extending above the hull except

armaments.

11. Mast – Upright spar supporting signal yard and antennas in a naval ship.

12. Wardroom – Officer’s mess and lounge room aboard ship.

13. Yardarm – A spar attached to a mast and running athwart ship.

14. Rudder – Flat, vertical, movable, structure attached to the stern used for

steering the ship.

15. Lazarette – A storage compartment at the stern below deck.

16. Galley – The ship’s kitchen.

17. Cabin – The Captain’s living quarter.

18. Quarters – Living space, assembly of the new.

Ships are large, complex vehicles which must be self

sustaining in their environment for long periods with a high degree of reliability. A

ship is the product of three main areas of skill, those of the naval architect, the

navigating officer (deck officer) and the marine engineer (engineering officer). The

naval architect is concerned with the hull, its construction, form, habitability and

ability to endure its environment. The navigating officer is responsible for safe

navigation of the ship, and its cargo operations. The marine engineer is

responsible for the various systems which propel and operate the ship. More

specifically, this means the machinery required for propulsion, steering, anchoring

and ship securing, cargo handling, air conditioning, power generation and its

distribution.

There are two main parts of a ship: the hull and the

machinery. The hull is the actual shell of the ship including the superstructure.

The machinery includes not only the main engines

required to drive but also the auxiliary machinery (boilers, generators etc.) used

for maneuvering purposes, steering, mooring, cargo handling and for various

other services, e.g. the electrical installations, winches and refrigerating plant.

The rear portion of the ship is called after end or stern. When moving stern first,

the vessel is said to be moving astern. The front portion of the ship is called the

fore end, whilst the extreme forward end is called the bow. When moving bow

first, the vessel is said to be moving ahead. Fore and aft are generally used for

directional purposes. The area between the forward and aft portions of the vessel

is called amidships. The maximum breadth of the vessel, which is found in the

amidships body, is known as the beam.

Many modern cargo and passenger liners have a

transverse propulsion unit or bow thruster in the bows. Its purpose is to give

greater maneuverability in confined waters, e.g. ports, and so reduce or eliminate

the need for tugs. The rudder, which enables the vessel to maintain its course, is

situated right aft. The bulbous bow can improve passenger and crew comfort, as

it can reduce pitching in heavy seas and has been provided in tankers, bulk

carriers and modern cargo liners to increase speed when in ballast.

The modern tendency is to have large unobstructed

holes with mechanically operated hatch covers, both for the speedy handling of

cargo, and to reduce turn-round time to a minimum.

7 General arrangements plan- a bulk carrier. A

ship’s actual design and number of decks depend on the trade on which the ship

will ply. A tramp, carrying shipments of coal or core, will be a single desk vessel

with large unobstructed hatches to facilitate loading and discharge. A cargo liner

carrying a variety of cargo in relatively small consignments would have tween

desk to facilitate stowage. It such a vessel also conveyed wood and other

commodities of high stowage factor, a shelter deck would be provided.

Additionally, container ships are equipped with

specially designed holds with cells or slots to facilitate speedy container handling

using shore-based lifting gear.

Three principal types of machinery installation

are to be found at sea today. Their individual characteristics change with

technological advances and improvements and economic factors such as the

change in oil prices. The three layouts involve the ship’s propulsion machinery

using direct-coupled slow speed diesel engines (the main engine), medium speed

diesels with a gearbox, and the steam turbine with a gearbox drive to the

propeller.

A propeller, in order to operate efficiently, must

rotate at a relatively low speed. Thus, regardless of the rotational speed of the

prime mover, the propeller shaft must rotate at about 80 to 100 rev/min. the

slow-speed diesel engine rotates at this low speed and the crankshaft is thus

directly coupled to the propeller shafting. The medium speed diesel engine

operates in the range 250-750rev/min and cannot therefore be directly coupled

to the propeller shaft. A gearbox is used to provide a low-speed drive for the

propeller shaft. The steam turbine rotates at a very high speed, in the order of

6000rev/min. Again, a gearbox must be used to provide a low-speed drive for the

propeller shaft.


MODERN HULL SHOP


MODERN HULL SHOP

This shop is almost similar to ship building shop having almost same space for

working. Although building of block is more frequently done here.

MAIN ACTIVITY- Building and assembling of ship block.

Machine & Equipment used-

As this shop is similar to the ship building shop. However process of welding is more

frequently done here. So it is essential to describe the processes of welding done

here.

ADVANTAGES OF WELDED JOINTS

DISADVANTAGES OF WELDED JOINTS

The welded structure is normally lighter than riveted or bolted structures.

It provided maximum efficiency.

A welded joint has a great strength of the parent metal itself.

Since there is an uneven heating and cooling during fabrication, therefore the members can be distorted or additional stress may develop.

It requires highly skilled labor and supervisor.

No provision is there for expansion or contraction in frame, so holes may form.

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MIG WELDING

MIG welding is an abbreviation for Metal Inert Gas Welding. It is a process considered semi-automated. This means that the welder still requires skill, but that the MIG welding machine will continuously keep filling the joint being welded.

MIG welders consist of a handle with a trigger controlling a wire feed, feeding the wire from a spool to the weld joint. The wire is similar to an endless bicycle brake cable. The wire runs through the liner, which also has a gas feeding through the same cable to the point of arc, which protects the weld from the air.

GAS CUTTING Oxy-fuel cutting are processes that use fuel gases and oxygen to weld and cut metals, in

oxy-fuel cutting, a torch is used to heat metal to its kindling temperature. A stream of oxygen

is then trained on the metal, burning it into a metal oxide that flows out of the kerf as slag

Oxy-fuel cutting may use a variety of fuel gases, the most common being acetylene. Other fuel are- 1) Acetylene 2) Gasoline 3) Hydrogen

TUNGSTEN INERT GAS ARC WELDING (TIG) In tungsten arc welding, the heat is produced from an arc between the non-consumable tungsten electrodes and the work piece. The Welding zone is shielded by an atmosphere of inert gas supplied from the suitable source. The gas nozzle surrounds the tungsten electrode. When gas leaves the nozzle, it completely involves the tip of the electrode and the work under it.

HULL BLOCK BUILDING METHODS The basic component of ship building is steel plate. The plates are cut, shaped, bent or otherwise manufactured to the desired configuration specified by the design .Typically the plates are cut by an automatic flame cutting process to various shapes. These shapes may be then welded together to form I and T beams and other structural member a hull is the watertight body of a ship or boat. Above the hull is the superstructure and/or deckhouse, where present. The line where the hull meets the water surface is called the waterline. The structure of the hull varies depending on the vessel type. In a typical modern steel ship, the structure consists of watertight and non-tight decks, major transverse and watertight (and also sometimes non-tight or longitudinal) members called bulkheads, intermediate members such as girders, stringers and webs, and minor members called ordinary transverse frames, frames, or longitudinal, depending on the structural arrangement. The uppermost continuous deck may be called the "upper deck", "weather deck", "spar deck", "main deck", or simply "deck". The particular name given depends on the context—the type of ship or boat, the arrangement, or even where it sails. Not all hulls are decked (for instance a dinghy). In a typical wooden sailboat, the hull is constructed of wooden planking, supported by transverse frames (often referred to as ribs) and bulkheads, which are further tied together by longitudinal stringers or ceiling. Often but not always there is a centerline longitudinal member called a keel. In fiberglass or composite hulls, the structure may resemble wooden or steel vessels to some extent, or be of a monocoque arrangement. In many cases, composite hulls are built by sandwiching thin fiber-reinforced skins over a lightweight but reasonably rigid core of foam, balsa wood, impregnated paper honeycomb or other material.


MAINTENANCE SHOP


Maintenance Shop

`Maintenance’ means activities required or undertaken

to conserve as nearly, and as long as possible the original condition of an asset or

resource while compensating for normal wear and tear. Actually it includes a

group of actions, which are necessary for restoring a piece of equipment, machine

or system to the specified operable condition to achieve its maximum useful life.

In maintenance shop in GRSE, mainly overhead crane and

EOT (Electric Traveling Crane) are being checked for maintenance.

An overhead crane, commonly called a bridge crane, is a

type of crane found in industrial environments. An overhead crane consists of

parallel runways with a traveling bridge spanning the gap. A hoist, the lifting

component of a crane, travels along the bridge. If the bridge is rigidly supported

on two or more legs running on a fixed rail at ground level, the crane is called a

gantry crane or goliath crane.

Overhead cranes are commonly used in the refinement

of steel and other metals such as copper and aluminum. At every step of the

manufacturing process, until it leaves a factory as a finished product, metal is

handled by an overhead crane. Almost all paper mills use bridge cranes for regular

maintenance needing removal of heavy press rolls and other equipment.

EOT is most common type of overhead crane, found in

most factories. As obvious from name, these cranes are electrically by a control

pendant, radio/IR remote pendant or from an operator cabin attached with the

crane itself.

Maintenance can be divided in three parts:

1) Preventive Maintenance,

2) Predictive Maintenance,

3) Breakdown Maintenance.

1) Preventive Maintenance

It’s a daily maintenance (cleaning, inspection, oiling and

re-tightening), design to retain the healthy condition of equipment and prevent

failure through the prevention of deterioration, periodic inspection or equipment

condition diagnosis, to measure deterioration. Just like human life is extended by

preventive medicine, the equipment service life can be prolonged by doing

preventive maintenance.

It is a time-based maintenance consists of periodically

inspecting, servicing, cleaning equipment and replacing parts to prevent sudden

failure and process problems.

In this type of maintenance, mainly materials go through

lubrication process. It is also called oiling process for smoothing of machine’s

operation speed in work. As mentioned above, preventive maintenance is a

periodical job. It can be happen after one week or 15 days or one month

depending on the parts. Normally, it is done at Sunday. So, Sunday is not a holiday

for at least maintenance department of GRSE.

2) Predictive Maintenance

This is a method in which the service life of

important part is predicted based on inspection or diagnosis, in order to use the

parts to the limit of their service life. Compared to periodic maintenance,

predictive maintenance is condition based maintenance. It manages trend values,

by measuring and analyzing data about deterioration and employs a surveillance

system, designed to monitor conditions through an online system.

Workers can get signal from the machine by

which they can understand that there something wrong in the machine and it

have to go through predictive maintenance. The signals can be an abnormal

sound which is not suitable for perfect condition or it can be the sense of heat,

which will insist that may be the cooling system is not working properly or any

other disturbance occurs.

3) Breakdown Maintenance

Breakdown maintenance means that people waits

until equipment fails and repair it. Such a thing could be used when the

equipment failure does not significantly affect the operation or production or

generate any significant loss other than repair cost.

So, it is the repairing process actually. And of

course, it is a very important type of maintenance. But, yes it is unfortunate that

when we have to do this that means the preventive and predictive maintenance

have not gone perfectly or an accident just occurs. But, then workers have to go

through the whole method and of course it is not a short process. A lot of time,

money and hard work will require.


UTILITY SHOP


MATERIAL HANDLING EQUIPMENTS

Material handling is the art and science of conveying, elevating, positioning,

transporting, packing and storing of materials. Material handling equipment is

generally classified in four main categories: storage and handling equipment,

engineered systems, industrial trucks, bulk material handling.

PLATFORM TRUCK

HAND LIFT TRUCKS

These hand trucks are provides with a

mechanism of lifting its platform, which

can be rolled under the pallet or skid with

load to clear the ground and then move

the load from place to place. And have

hydraulic or mechanical lifting mechanism

with a fork for holding the load.

These hand trucks consists of

platform mounted on 4 wheels

and provided with handle for

pushing or pulling operation. A

platform truck or hand trolley cart

is an essential tool for moving

heavy boxes to and from the

mailroom, warehouse or receiving

area.

FIXED PLATFORM TRUCK

FORK LIFT TRUCKS

The forklift truck is used for, lifting lowering stacking, unstacking, loading and

unloading and maneuvering of medium to large weights. It has a low speed of

about 10kmph.

The body of the truck is purposely built heavy which act as a counter load while

lifting loads on fork.

Solid rubber tires are provided for operations in different floor conditions.

These are battery powered

industrial truck having a fixed

level, non-elevating platform for

carrying load. Materials to be

moved have to be loaded and

unloaded to and from the

platform by hand hoist and crane.

The capacity of truck in GRSE is 1

ton.

It is the most versatile, useful and

widely used industrial lifting truck.

These are self-loading,

counterbalanced, diesel powered,

wheeled vehicles, with operator

seating on the vehicle, designed to

raise, move and lower the load on

forks.

GOLIATH CRANE

GRSE has one Goliath Crane of 250 Ton capacity covering the Module Hall.

Goliath Gantry Crane provides enormous flexibility in hook configuration,

with up to 8 m hook traverse and 100% load unbalance and accuracy to a 4-

millimeter tolerance.

The unique single-girder design of Goliath Gantry Cranes combines low

total weight and high rigidity.

The goliath crane moves on rails supported on the floor levels instead of

rails placed at elevated levels as in case of EOT cranes. This eliminates the

need for workshop building and hence reduction in capital cost. Outdoor duty goliath cranes are also checked for stability under storm

conditions. Special storm anchors are provided to prevent toppling of crane

under storm condition.

ELECTRIC OVERHEAD CRANE

TRACTORS

An overhead crane, commonly

called a bridge crane, is a type of

crane found in industrial

environments. An overhead crane

consists of parallel runways with a

traveling bridge spanning the gap.

A hoist, the lifting component of a

crane, travels along the bridge.

Most of EOT in GRSE have max

load of 10 ton.

It is used a prime mover to

give motion to another or

group of vehicles e.g. trailers,

semitrailers, transfer cars etc.

A front-loader or loader is a

tractor with an engineering

tool which consists of two

hydraulic powered arms on

either side of the front engine

compartment and a tilting

implement


Internal Combustion Engine Repair

Shop


ICER SHOP It deals with repair and proper functioning of Air compressor and various DG Sets that are used for different operations in ships and in different shops.

Air Compressor

DG SET

Air Compressor

In GRSE two types of air compressor are used

1. Engine operated Air Compressor 2. Battery operated Air Compressor

APPLICATIONS To supply High pressure clean air to fill gas cylinders. To produce large volume of moderate pressure air for large scale

industrial processes Machine cooling, use of air pressure in robots, removal of debris

from cutting processes (metal fragments, metal powder, etc.). Generation of starting air for marine diesel engines

COOLING The different types of cooling system are used are:-

1. Air cooled 2. Water cooled 3. Oil cooled

Listed below are some of the common engine problems or troubles

and their possible causes

a) ENGINE does not starts

Empty fuel tank. Fuel pump not working. Fuel supply hose damaged, distorted, or improperly attached. Inappropriate, clogged, or faulty spark plugs Loose plug wires Broken ignition switch Faulty wiring and connection problems in the ignition system. Battery is undercharged. Ignition coil not functional. Fuel is old, dirty, or contaminated. Starter motor is not operational.

Possible causes: Engine stalls

Fuel filter is clogged up

Fuel is old, dirty, or contaminated

Fuel supply hose damaged, distorted, or improperly attached

Closed fuel tank vent

Inoperative, or clogged thermostat

Wrong engine oil Spark plugs defective, wrong, plugged, or incorrect spark-plug

gap

Fuel supply hose damaged, distorted, or improperly attached

DG SET

A Diesel Generator (DG) is a combination of diesel engine with electrical

generator (often called an alternator) to generate electricity. DG sets are used in

places that have no connection to power grid, and as emergency power-supply if

the grid fails. In other words DGs remain the number one choice for standby and

emergency power systems. DGs are selected based on the electrical load they

are intended to supply.

These can be water-cooled or air-cooled.

Compact, sleek, manual/automatic

Sound proof and weather proof enclosure.

Specially designed sound attenuators are provided to control sound at air entry and exit

points inside the enclosure


PIPE SHOP


Pipe Shop

Pipe bending methods:

There are two types of pipe bending method.

1. Hot Bending-

In this type of bending one end of the pipe is packed with jute

and the pipe is then filled with sand called sand packing.

In sand packing sand is filled and pipe made vertical and

hammered to make tighter and as other end is jute packed sand doesn’t escape.

The bending is done as per template.

Big bore pipes (nominal volume above 80) are being bend by

hot bending process.

2. Cold Bending-

(a) Hydraulic Bending:

Pipes with more thickness are bend by this method. No

sand packing or Jute packing is required the pipes are bended by Hydraulic press

machine.

(b) Fabricate Bending:

Templates and layout are produced and pipes are

forged into them.

Small bore pipes like NV 15, NV 20, NV 25 (nominal

volume smaller than 100) are being bend by cold bending process.

Types of pipes:

1. Ms Pipe-

(a) Ms Black Pipe, always uses to supply oil.

(b) Ms Galvanizing Pipe, it is zinc coated ms pipe.

2. Copper-Nickel Pipe-

This pipe is always uses to supply fresh water only.

Valves which are directly exposures to water means

underwater walls will be done shop floor as a testing before on board treatment.

Tools used in Pipe shop:-

Caliper

A caliper is a device used to measure the distance between two

opposite sides of an object. A caliper can be as simple as a compass with inward

or outward-facing points. The tips of the caliper are adjusted to fit across the

points to be measured, the caliper is then removed and the distance read by

measuring between the tips with a measuring tool, such as a ruler.

Punch

In traditional typography, punch cutting is the craft of cutting

letter punches in steel from which matrices were made in copper for type

founding in the letterpress era. Cutting punches and casting type was the first

step of traditional typesetting. The cutting of letter punches was a highly skilled

craft requiring must patience and practice. Often the designer of the type would

not be personally involved in the cutting.

Spirit Level

A spirit level is an instrument designed to indicate whether a

surface is horizontal (level) or vertical (plumb). Different types of spirit level may

be used by carpenters, stonemasons, bricklayers, other building trade’s workers,

surveyors, millwrights, and other metalworkers, and in some photographic or

video graphic work.

Alcohol such as ethanol are often used rather than water.

Alcohols have low viscosity and surface tension, which allows the bubble to travel

the tube quickly and settle accurately with minimal interference with the glass

surface. Alcohols also have a much wider liquid temperature range, and would

not break the vial as water could due to ice expansion. A coolant may be added to

increase the visibility of the bubble.

Pipe Wrench

The pipe wrench is an adjustable wrench used for

running soft iron pipes and fittings with a rounded surface. The design of the

adjustable jaw allows it to lock in the frame, such that any forward pressure on

the handle tends to pull the jaws tighter together. Teeth angled in the direction of

turn dig into the soft pipe. They are not intended for use on hardened steel hex

nuts or other fittings because they would ruin the head; however if a hex nut is

soft enough that it becomes rounded beyond use with standard wrenches, a pipe

wrench is sometimes used to break the bolt or nut free. Pipe wrenches are usually

sold in the following sizes: 10, 14, 18, 24, 36 and 48 inches, although smaller and

larger sizes are available as well. They are usually made of cast steel.

Snips

Snips, also known as shears, are hand tools used to

cut sheet metal and other tough webs. There are two broad categories: tinner’s

ships, which are similar to common scissors, and compound-action snips, which

use a compound leverage handle system to increase the mechanical advantage.

Pipe Bending Machine

Cnc pipe bending machine is very important in pipe shop. It is require to

bend long iron pipes as requirements while, flanges are used to join two different

pipes in a single point. Flange are of three type generally as: Plane flange, Spigot

flange and conical flange. There are plushing method, which is actually a cleaning

process of pipe from oil. It takes time from 20 minutes to 3 hour.

Roller Pipe Bending Machine

Actually the pipe bending operation, pipe collaring

process and pipe branching operation is done properly at the FOJ unit of GRSE.


MACHINE SHOP


MACHINE SHOP

A machine is a tool containing one or more parts that uses energy to perform an intended

action. Machines are usually powered by mechanical, chemical, thermal, or electrical means,

and are often motorized.

LATHE Lathe is a machine tool which rotates the work piece on its axis to perform various

operations such as cutting, knurling, drilling, or deformation, facing, turning, with tools that

are applied to the work piece to create an object which has symmetry about an axis of

rotation. The main component of Lathe are Head stock, Tail

stock,4 or 3 jaw chuck, carriage, cross slide, hand slide, gear box etc.

Different type of production Lathe is:-

1) Non automatic Lathe- Centre Lathe 2) Semi automatic Lathe- Capstan lathe, turret lathe, multiple lathe, copying(hydraulic)

lathe, relieving lathe 3) Automatic- automatic cutting off lathe, single-spindle automatic lathe, Swiss type

automatic lathe, multiple spindle automatic lathe

Fig-1

GRINDING MACHINE A grinding machine, often shortened to grinder, is any of various power tools or machine tools used for grinding, which is a type of machining using an abrasive wheel as the cutting

tool. Each grain of abrasive on the wheel's surface cuts a small chip from the work piece via shear deformation. Grinding is used to finish work pieces that must show high surface quality (e.g., low

surface roughness) and high accuracy of shape and dimension. As the accuracy in

dimensions in grinding is on the order of 0.000025 mm, in most applications it tends to be a

finishing operation and removes comparatively little metal, about 0.25 to 0.50 mm depth.

However, there are some roughing applications in which grinding removes high volumes of

metal quite rapidly. Thus, grinding is a diverse field.

A grinding depends upon the blade is to be used for and the material from which blade

is made. Knife manufacturers may offer the same model of knife with different grinds on the

blade and owners of a blade may choose to reshape it as a different grind to obtain different

blade property.

A grinding disc is made mainly of silicon carbide or artificial carborundum. The grinding disc

turns and removes material along its face or circumference.

BORING MACHINE

In machining, boring is the process of enlarging a hole that has already been drilled (or cast),

by means of a single-point cutting tool (or of a boring head containing several such tools).

Boring Machine specified according to- 1) Type of the machine (Horizontal and vertical) 2) Maximum diameter of the boring bar which can be held by the machine 3) Maximum travel of the table in the longitudinal and cross direction. 4) Spindle speed available and feed available. 5) Maximum allowable weight of work piece. 6) Net weight of the machine.

HORIZONTAL BORING MACHINE

A horizontal boring machine or horizontal boring mill is a machine tool which bores holes in a

horizontal direction. . There are three main types — table, planer and floor. The table type is

the most common and, as it is the most versatile, it is also known as the universal type.

A horizontal boring machine has its work spindle parallel to the ground and work table.

Typically there are 3 linear axes in which the tool head and part move. Convention dictates

that the main axis that drives the part towards the work spindle is the Z axis, with a cross

traversing X axis and a vertically traversing Y axis. The work spindle is referred to as the C

axis and, if a rotary table is incorporated, its centre line is the B axis

.

VERTICAL BORING MACHINE

Vertical boring is a machining process whereby a part to be machined is clamped to a bed

and a machining tool is rotated to produce some cylindrical, internal feature in the work

piece. The cylindrical surface to be produced is oriented in the vertical direction and the tool

is typically fed down into the work piece.

Many vertical boring operations can be performed by a conventional mill and boring

attachment, so in general vertical boring machines are used to machine large castings and

blocks of metal too heavy for a regular mill.

One of the advantages of carrying out the boring operation in the vertical position is the ease

of clearing cuttings from around the cutting tool. Another key advantage is that the need for a

large amount of power to rotate a very large block of steel and the associated dangers are

avoided.

Another variation on the vertical borer is the vertical lathe. With this type of machine, the

work piece is rotated instead of the cutting tool, but the general operation and application is

similar but the application is for smaller, lighter work pieces.

Typical applications for vertical boring are:

1) Line boring of large machine tool casings and engine blocks. 2) Machining internal bearing diameters in large castings. 3) Finish machining of cylindrical surfaces on very large work pieces.

FLOOR TYPE BORING MACHINE Floor type boring machine uses a stationary T-slotted floor plate instead of moving table for supporting the work piece, horizontal transverse, perpendicular to the spindle axis, is obtained by moving the column in guide ways. Floor type boring machine are employed for machining very large work piece.

PLANO MILLING MACHINE

Plano milling is widely used in industries for precise shaping of metals & various solid

material. These entire machine are ideal for various processes such as slot cutting, routing,

welding & turning in metallurgy industry. We make the range of machines available to the

client in various configurations as per their application requirement.


PAINT SHOP


Paint Shop

Paint shop is a very important department in any industry.

Because, it takes care about the looks of the parts and also looks after problems

of safety hazzards with those materials.

In paint shop, mainly three types of work or

operation is done by the workers, which are as follows:

1) Surface Preparation Process

2) Powder Coating Process

3) Spray-Painting Process

1) Surface Preparation Process

It is also named as polishing method. It is done actually

for removing of unwanted scratches or junks. The material have to take an

amount of heat firstly, then they will go through some acid and after that have to

polish by costic soda.

Surface preparation is the essential first stage treatment

of a steel substrate before the application of coating, and is generally accepted as

being the most important factor affecting the total success of a corrosion

protective system. The surface preparation process not only cleans the steel, but

also introduces a suitable profile to receive the protective coating.

2) Powder Coating Process

Surface coating by means of spray of powder is a dry

finishing process that has become extremely popular since its introduction in

North America over 40 years ago. More and more companies specify powder

coatings for a high-quality, durable finish, allowing for maximized production,

improved efficiencies, and simplified environmental compliance.

Powder coating are based on polymer resin systems,

combined with curatives, pigments, leveling agents, flow modifiers and other

additives. These ingredients are melt mixed, cooled and ground into a uniform

powder similar to baking flour. A process called electrostatic spray deposition is

typically used to achieve the application of the powder to the metal substrate.

After application of the powder coating, the parts

enter a curing oven where, with the addition of heat, the coating chemically

reacts to produce long molecular chains, resulting in high cross-link density. These

molecular chains are very resistant to breakdown. This type of application is the

most common method of applying powders.

3) Spray Painting Process

It is a technique where a device sprays a

coating (paint, ink, varnish etc) onto the surface.

In electrostatic spray painting, the atomized

particles are made to be electrically charged, thereby repelling each other and

spreading themselves evenly as they exit the spray nozzle. The object being

painted is charged oppositely or grounded. The paint is then attracted to the

object giving a more even coat than wet spray painting and also greatly increasing

the percentage of paint that stick to the object.


Quality Assurance Shop


QUALITY ASSURANCE SHOP

The function of the QA department is following:

1. Hull inspection

2. Machinery inspection

3. Plumbing inspection

4. Electrical inspection

Standards Used for inspection:

1. NES 147 standard

2. ABS standard (American bureau of shipping)

3. IRS STANDARD (Indian register of shipping)

Parameters for skid inspections:

1. Distance between props

2. Height of props

3. Length of skid

4. Width of skid

5. Diagonal check of skid.

Leak inspection of components of ships:

1. Water pressure test

2. Air pressure tests

3. Hose test

DRY SURVEY AND CORRESPONDING TESTS

DRY SURVEY OF UNITS/COMPTS/TANKS

Dry survey checks is carried out for completion of units/ compartments / tanks

prior to commencement of installation work.

All the items indicated in the drawing are checked for their location and size as

per the drawing. Report will be made if found satisfactory in relevant format.

HOSE TESTING

CHALK IMPRESSION TEST

Hose testing for welding of the

seats for fitting to the hull (such

as ICCP anodes, ‘A’ brackets,

Echo sounders, logs, stabilizers

etc.) and checked for leakage

Checks for item having

rubber gaskets to close the

opening for water tightness

or air tightness like doors and

hatches, emergency escapes,

cold room. It is carried out

before hose testing.


Fire Fighting Department


FIRE EMERGENCY ACTION PLAN

1) Officer in charge(As Nominated)

2) (Nominated officer) would act as nodal officers during emergency in their

respective disciplines.

3) Personal noticing fire or smoke within the ship is to inform bridge by

telephone indicating location of fire.

4) Bridge will give orders through main broadcast for firefighting party to

muster at near fire post & proceed with equipment to the location of the

fire.

5) Personnel closed up at the location are to remain at their watch stations to

avoid overcrowding at firefighting zone.

6) Pressure on the fire mains is to be maintained at 7 kg/cm² 24*7.

7) All ventilations in the vicinity of the fire should be stopped/ switched off.

8) Two personnel will form fire patrol in all shifts.

ALARM IN CASE OF FIRE EMERGENCIES IN UNIT

In Case Of Fire Or Explosion

Siren / Hooter blast for 10 secs on, then 5 secs off This cycle for 3 min time.

All Clear Signal Continuous Siren / Hooter blast for 3 min period.

PRINCIPAL CAUSES OF FACTORY FIRE

1. Gas cutting / welding or Arc welding fire.

2. Electrical equipment – Short circuit/ Overheating/ Sparking.

3. Fuel oil / lubricant / hydraulic oil / inflammable gas related

equipment like pumps, compressor etc. – accidental surge heating

4. Naked light in restricted zones.

5. Carelessness / ignorance or deliberate infraction of rules such as

unauthorized heaters in shops / dept. for cooking / tea making.

6. Arson.

TYPES OF FIRE

Fire can be classified under the following categories:-

1) Class “A” fire: ordinary combustible solid material like wood,

cloth, paper etc.

Extinguishing media: water jet or spray, soda acid

extinguishers and water extinguishers.

2) Class “B” fire: inflammable liquids like kerosene, petrol and paint varnish, all liquid petroleum products. Extinguishing medium: foam type extinguisher and dry chemical powder extinguisher but both not be used at a same fire.

3) Class “C” fire: Combustible gaseous substance under pressure like LPG, Acetylene, hydrogen. Extinguishing media: Dry chemical powder and CO² extinguisher.

4) Class “D” fire: combustible metal like magnesium, calcium, aluminum. Extinguishing media: Special type dry chemical powder.

FIRE FIGHTING PROCEDURE

1) Cut off power and gas supplies to all machines/ other utilities.

2) To inform the fire fighter when he arrives.

3) To apply first aid, potable extinguisher on the fire spot according

to class of fire.

TABLE FOR USE OF EXTINGUISHER ON CLASS OF FIRE

EXTINGUISHERS CLASS “A” CLASS “B” CLASS “C” CLASS “D”

Soda Acid S US US US

Water type S US US US

Foam S S US US

DCP(BC) US S S US

DCP(ABC) S S S US

Carbon- Dioxide US S S US

US- Unsuitable; S- Suitable ; DCP- Dry chemical powder;


DOCK DEPARTMENT


DOCK DEPARTMENT

DOCKING If ship come to the ground from water then it is known as docking.

UNDOCKING If ship come to water from ground then it is known as Undocking. NOTE- If ship come to the water first time then it is known as launching.

If the ship is going to water from ground or vice versa, then it should be kept in mind that, a

ship does not steer like a car, it pivots on its axis. So every step should be in scientifically

approach, so that heavy impact on the ship doesn’t harm.

DRY DOCK-

A dry dock is a narrow basin or vessel that can be flooded to allow a load to be floated in,

then drained to allow that load to come to rest on a dry platform. Dry docks are used for the

construction, maintenance, and repair of ships.

The classic form of dry dock, properly known as graving dock, is a narrow basin, usually

made of earthen berms and concrete, closed by gates or by a caisson, into which a vessel

may be floated and the water pumped out, leaving the vessel supported on blocks.

To launch ship from dry dock, first valves are opened, the chambers fill with water, causing

the dry dock to float lower in the water, and then it is slowly pull into the water with the help

of small boat.

INCLINED BERTH A berth, somewhat inclined plane on the land, where ship is being built and set out to the

water. During launching, first wax and grease is applied on the wooden rail of about 8 mm

thickness at the bottom portion of the ship hull, then valves are opened through which water

fill the chamber. After, it is slowly allowed to come inside the water.

SIGNALING SYSTEM OF SHIP The system of international maritime signal flags is one system of flag signals representing

individual letters of the alphabet (A-Z) and the letter from 0-9 in signals to or from ships. It is

a component of the International Code of Signals (ICS).

DOCKING EQUIPMENT

CAPSTAN

Capstan is a mechanical device used chiefly on board ships or in shipyards for moving

heavy weights by means of ropes, cables, or chain A capstan consists of a drum, driven

either manually or by steam or electricity, that rotates about a vertical axis to wind in a line

(rope, cable, or chain) that has been wrapped around it.The grip between the line and the

drum depends on friction and on the number of times the line is wrapped around the drum.

Speed of drawing in the load can be controlled by allowing partial slippage of the line around

the capstan. A notched track (ratchet) on the base plate and pawls attached to the drum

prevent backward motion.

WINCH

A winch is a mechanical device that is used to pull in (wind up) or let out (wind out) or

otherwise adjust the "tension" of a rope or wire rope (also called "cable" or "wire cable"). In

its simplest form it consists of a spool and attached hand crank. In larger forms, winches

stand at the heart of machines as diverse as tow trucks, steam shovels and elevators. The

spool can also be called the winch drum. More elaborate designs have gear assemblies and

can be powered by electric, hydraulic, pneumatic or internal combustion drives. Some may

include a solenoid brake and/or a mechanical brake or ratchet and pawl device that prevents

it from unwinding unless the pawl is retracted.

BOLLARD

A bollard is a short vertical post. Originally it meant a post used on a ship or a quay,

principally for mooring. The word now also describes a variety of structures to control or

direct road traffic, such as posts arranged in a line to obstruct the passage of motor vehicles.

The term can also be used to describe short, post-like light fixtures.

PANAMAX Panamax ships are travelling through the Panama Canal. They strictly follow the size

regulations set by the Panama Canal Authority, as the entry and exit points of the Canal are

narrow. A Panamax vessel can't be longer than 294,13 m (965 ft), wider than 32,31 m (106

ft) and her draught can't be more than 12,04 m (39.5 ft). These vessels have an average

capacity of 65,000 DWT, and are primarily used in transporting coal, crude oil and petroleum

products.

SUAZEMAX Suezmax is a naval architecture term for the largest ship measurements capable of

transiting the Suez Canal in a laden condition, and is almost exclusively used in reference to

tankers.

CONCLUSION

During my training in G.R.S.E I learnt the processes and functions of different

shops in building a ship.

1. The metal sheet required are brought from SAIL.

2. The sheets are then collected in SSY(Steel Stock Yard)

3. The sheets are then taken to plate preparation shop where sheets are

prepared to the required dimensions.

4. The prepared plates are then transferred to SBS (Ship Building Shop) And

MHS (Modern Hull Shop) where the plates are welded and then formed

to a block which is fabricated in this shop.

5. After a block preparation the block are sent to yards where they are

erected and welded to other blocks.

6. By this process block are welded one after another and it forms the

structure of the ship.