Lloyds -- Hull New Construction - SNC06 -

Ship New Construction Training Course: 

Ship New Construction Training Course Hull New Construction

AIMS : 

AIMS The aims of this session are to: Describe the methods used in modern hull new construction Identify key processes, controls and practical considerations Give practical guidance relating to hull construction supervision

LEARNING OBJECTIVES: 

LEARNING OBJECTIVES At the end of this session you will be able to: Describe hull construction methods Describe the key processes and controls Prepare effectively for hull supervision inspections

Safety first!: 

Safety first! S top T hink O bserve P lan

CAUSES OF SAFETY FAILURES: 

CAUSES OF SAFETY FAILURES Unsafe places Unsafe people Unsafe systems

KEY DOCUMENTS FOR HULL NEW CONSTRUCTION: 

Quality standards e.g. IACS Shipbuilding and Repair, Ship Yard Quality Manual Rules e.g. Classification Rules for Ship Structures Approved structural drawings Approved weld procedures Approved NDE plan Approved tank testing plan Block division drawing KEY DOCUMENTS FOR HULL NEW CONSTRUCTION

QUALITY STANDARDS: 

QUALITY STANDARDS Welding and Structural details National Standards Construction Monitoring procedure

KEY DATES IN HULL CONSTRUCTION: 

KEY DATES IN HULL CONSTRUCTION Steel cutting Keel laying Launch (float out) Delivery

STOCKYARD CONTROL AND STEEL PREPARATION: 

STOCKYARD CONTROL AND STEEL PREPARATION

STOCKYARD CONTROL AND STEEL PREPARATION: 

STOCKYARD CONTROL AND STEEL PREPARATION Verify certification Random thickness checking Inventory Shipyard checks Surveyor’s checks Tolerance

SHIPYARD CHECKS – RECEIVING PROCESS: 

SHIPYARD CHECKS – RECEIVING PROCESS Receive steel & shipping documents QC check 1. Documentation data verified. 2. Steel mill data & shipyard host data comparison. Quarantine area To Materials Control Department Pass Fail

SHIPYARD CHECKS – RECEIVING PROCESS: 

SHIPYARD CHECKS – RECEIVING PROCESS Material Control Dept. Visual Inspection ID ok Allocate Location & Pile No. & transport Deliver to production Quarantine 1. Input: Hull no., Mark no., Plate no., Grade 2. Output: ID no 3. Confirm ID no on steel plate No Delivery Inspection Location & pile Design department generate work order Yes

MATERIALS - Inspectors and surveyors should:: 

MATERIALS - Inspectors and surveyors should: Confirm stock yard materials handling procedures followed Spot check materials scantlings and measuring equipment Confirm use of quarantine area Confirm clarity and accuracy of markings throughout fabrication Request sample materials certificates, mill sheets and nesting plans and verify against plate ID Confirm correct handling of special materials

BLASTING AND PRIMING: 

BLASTING AND PRIMING Prior to Blasting and Priming After Shot Blasting and Priming

BLASTING, PRIMING AND RE-IDENTIFICATION: 

BLASTING, PRIMING AND RE-IDENTIFICATION Confirm correct plate to process Blasting standards Approved primer Identification marking and re-confirmation Calibration of equipment Non-conforming material

PRIMERS AND HIGH TENSILE STEEL: 

PRIMERS AND HIGH TENSILE STEEL Are primers important? Can they affect weld quality? Can they affect subsequent application of paints? High Tensile Steel and Special Grade Steels? Why are they used? What if Mild Steel is accidentally used instead?

IDENTIFICATION MARKERS: 

IDENTIFICATION MARKERS Typical Automatic Markings Typical Manual Markings

FABRICATION AND ASSEMBLEY: 

FABRICATION AND ASSEMBLEY

MARKING AND STEEL CUTTING: 

MARKING AND STEEL CUTTING Profiles and sections generated using CAD/CAM Plate cut and marked using NC cutting Edges prepared Slots and openings cut in panels Reference lines marked Piece parts cut from parent plate

PLATE AND PROFILE FORMING: 

PLATE AND PROFILE FORMING

Maximum Heating Temperature on Surface for Line Heating for Plate Forming (IACS Standard).: 

Maximum Heating Temperature on Surface for Line Heating for Plate Forming (IACS Standard). Item Standard Conventional process AH32 to EH32 & AH36 to EH36 Water cooling just after heating Under 650°C TMCP type AH32 to EH32 & AH36 to EH36 (Ceq.>0.38% High Carbon) Ceq = C+(Mn/6)+(Cr+Mo+V)/5 +(Ni+Cu)/15 (%) Air cooling after water Under 900°C Air cooling and subsequent water cooling after heating Under 900°C (starting temperature of water cooling to be under 550°C) Low Carbon TMCP type AH32 to DH32 & AH36 to DH36. (Ceq ≤0.38%) Low Carbon TMCP type EH32 & EH36(Ceq.≤0.38%) Water cooling just after heating or air cooling Water cooling just after heating or air cooling Under 1000°C Under 900°C

BLOCK ASSEMBLEY: 

BLOCK ASSEMBLEY Block break-up criteria Sub-assembly Assembly Pre-erection

FLAT PANELS FABRICATED FROM PLATES USING SUBMERGED ARC WELDING (SAW): 

FLAT PANELS FABRICATED FROM PLATES USING SUBMERGED ARC WELDING (SAW) SAW Gantry - Tandem wire

FILLET WELDINGS OF LONGITUDINALS TO FLAT PANELS: 

FILLET WELDINGS OF LONGITUDINALS TO FLAT PANELS Gantry fillet welding Location of panel stiffeners

SUB ASSEMBLEY PANELS WELDED TO FLAT PANELS: 

SUB ASSEMBLEY PANELS WELDED TO FLAT PANELS

BLOCK ASSEMBLEY: 

BLOCK ASSEMBLEY

PATROLLING, MONITORING SURVEYS & FINAL SURVEYS OF BLOCKS: 

PATROLLING, MONITORING SURVEYS & FINAL SURVEYS OF BLOCKS

PRODUCTION PROCESSES: 

PRODUCTION PROCESSES Welding Pre heating

COMMON WELDING PROBLEMS: 

COMMON WELDING PROBLEMS Solidification Cracking

COMMON WELDING PROBLEMS: 

COMMON WELDING PROBLEMS Correct angle Correct heat input Good bonding Lack of Fusion

COMMON WELDING PROBLEMS: 

COMMON WELDING PROBLEMS Lack of Root Fusion Material Thickness Joint Design Process Available Current Choice of Electrode

COMMON WELDING PROBLEMS: 

COMMON WELDING PROBLEMS Slag detachment Interpass cleaning Slag Inclusions

COMMON WELDING PROBLEMS: 

COMMON WELDING PROBLEMS Clean and degrease joints Primer coatings Gas shielded processes Baking of electrodes Porosity

LAMELLAR TEARING: 

LAMELLAR TEARING

COMMON WELDING PROBLEMS: 

COMMON WELDING PROBLEMS Hydrogen (Cold) Cracking

BLOCK STAGE PAINTING: 

BLOCK STAGE PAINTING

PRE-OUTFITTING: 

PRE-OUTFITTING Extent of outfitting Access for inspections

BLOCK PRE-ERECTION: 

BLOCK PRE-ERECTION

BLOCK PRE-ERECTION: 

BLOCK PRE-ERECTION Pre-erection Dimensional control Alignment and gaps Surplus material Welding Deformation Critical joints, high stress areas Surveys and NDE control

PRE-ERECTION – alignment and gaps: 

PRE-ERECTION – alignment and gaps

PRE-ERECTION – surplus material: 

PRE-ERECTION – surplus material

PRE-ERECTION – welding and NDE: 

PRE-ERECTION – welding and NDE

PRE-ERECTION – deformation: 

PRE-ERECTION – deformation

PRE-ERECTION – critical joints, high stress areas: 

PRE-ERECTION – critical joints, high stress areas

BUILDING DOCK ERECTION: 

BUILDING DOCK ERECTION

KEEL BLOCKS AND BLOCK ALIGNMENT: 

KEEL BLOCKS AND BLOCK ALIGNMENT

LONGITUDINAL & TRANSVERSE BULKHEAD INSTALLATION: 

LONGITUDINAL & TRANSVERSE BULKHEAD INSTALLATION

Median line alignment & fit-up method for a hopper joint: 

Median line alignment & fit-up method for a hopper joint

EXAMPLE CRITICAL LOCATIONS CONTAINER SHIPS: 

EXAMPLE CRITICAL LOCATIONS CONTAINER SHIPS Bilge Area Watertight & non-watertight bulkheads Deck, hatch corners and coamings

ALIGNMENT AND FIT-UP: 

ALIGNMENT AND FIT-UP Shipyard Practice Heel method using 100 mm line markings Easy for yard to measure Median method converted to heel method

HATCH COAMING ALIGNMENT AND FIT-UP: 

HATCH COAMING ALIGNMENT AND FIT-UP Alignment and fit-up Final welding and NDE

TYPICAL ERECTION SEQUENCE: 

TYPICAL ERECTION SEQUENCE v v v v

TANK TESTING: 

TANK TESTING Air leak testing Vacuum testing Hydrostatic testing Testing plan & record

ERECTION JOINTS – points to consider: 

ERECTION JOINTS – points to consider Longitudinal distribution of building stresses Ease of welding No pre-marking of NDT points Correct alignment Gap control Block welding of load carrying members Regular checks by keel and deck sights

RUDDER AND PROPELER FITTING: 

RUDDER AND PROPELER FITTING

DECKHOUSE INSTALLATION: 

DECKHOUSE INSTALLATION Alignment Container ship Deckhouse openings

DRAUGHT MARKS – Verification: 

DRAUGHT MARKS – Verification Check latest keel sightings Agree base datum line Verify draught marks

DIMENSION AND LOAD LINE MARKING VERIFICATION: 

DIMENSION AND LOAD LINE MARKING VERIFICATION Ship’s dimensions Verification of load line marks Change of flag/class

ANCHORING AND MOORING EQUIPMENT: 

ANCHORING AND MOORING EQUIPMENT

HULL COMPLETION AND FLOAT OUT: 

HULL COMPLETION AND FLOAT OUT

HULL COMPLETION AND SLIPWAY LAUNCH: 

HULL COMPLETION AND SLIPWAY LAUNCH Draught and Load Line marks Launching and structural reinforcement Drag chains required?

PowerPoint Presentation: 

Questions

PowerPoint Presentation: 

For more information please contact: Marine Training Services 71 Fenchurch Street London EC3M 4BS, UK T +44 (0)20 7709 9166 F +44 (0)20 7423 1573 E mts@lr.org