hull new construction - sept 2006
DESCRIPTION
Hull New Construction - Sept 2006TRANSCRIPT
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Hull New Construction Surveys
Some key points to consider during Hull New
Construction at the BUILDING YARD
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Agenda
Review of LR Responsibilities during a New Construction Project Project Management and Survey Team Liaison with Owners Site Team The Basic Essentials Data and Document Control Key Data
Fundamentals of Shipbuilding Quality Procedures and Standards New Building Surveys Construction Monitoring Procedures
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Project Management and Survey Team
Project Manager for each project Ensures contractual requirements are satisfied Acts as main point of contact for owners and shipyard Co-ordinates all survey/inspection activities Ensures all problems/issues are resolved Monitor progress and time spent Arrange deliverable certificates and reports
Team of professionally qualified surveyors Hull construction surveyors Machinery construction/installation surveyors Electrical/control surveyors NDE specialists & metallurgists
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Liaison with Owners site Team
Start-up meeting with owners team Technical briefing for owners supervision team Co-ordinated approach for monitoring and survey activities Outstanding issue list following sea trials Issue full term certificates Close down meeting/follow up actions
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The Basic Essentials
The Request for Services (Form 2500):Contains what LR is contracted to deliver and is our legal contract.
Key Event Dates (Steel Cutting, Keel Laying, Launch, Delivery):Impact on stage payments, Statutory Regulations and preparation of deliverables.
Division of work:Who does what, (London Office, Local P.A., Site Surveyor, Other LR Offices) and Extant Instructions, Checklists, Reports, Flag state authorisations.
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Data and Document Control
Requested plans for approval are submitted on time and any
amendments dealt with - maintain a master lists, up to date checklist.
Design Appraisal Document (DAD)s complied with and any
outstanding items closed.
Correspondence (incoming/outgoing) recorded as necessary dealt
with.
Demonstrate compliance with LRs Quality Procedures (CM 02-04-01)
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Key Data
Special steel locations - High Tensile, through thickness, forgings, castings
Construction Monitoring Locations for Ship Right Notation.
Structural Details- Alignment, Gaps and Edge preparations
Welding Details- Leg-Lengths, Throat, Thickness, Full and Partial Penetration, Spec Techniques
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Shipyard Procedures & Standards
Building Standards
Shipbuilding Quality Standard IACS Shipbuilding and Repair Quality Standard
Weld Procedures Specifications (WPS)
Welders Qualified to recognised standards Approved Welding Procedures different grades & processes Approved Welding Consumable Approved Shop Primers being used
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Shipyard Procedures & Standards
Non Destructive Examination NDE Plan to be approved by surveyor in accordance with the Rule
Requirements for the NDE - based on length of butts and seams and number of intersections
Usually a mixture of RT, UT & MPI To be recorded and evaluated
NDE as part of the quality control procedures
Production NDE (usually UT) Start and end of all submerged arc welding runs
Suitable NDE Qualified operators and procedures
Reviewed NDE Procedures
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Shipyard Procedures & Standards
Tank TestingApproved Tank Testing Plan All Tank Boundaries to be tested to confirm that their design and construction is satisfactory. All pressure gauges to be calibrated.
Air Leak Tests The application of a protective coatings is not allowed prior
to test excluding the shop primer Air pressure be raised to 0.2 bar for 1hour and then lowered
to 0.15 bar Hydrostatic Strength Tests (Structural Testing) Hose Testing: Max distance of 1.5m (not less than 2.0bar) Fillet Weld Air Tests Vacuum Leak Tests IACS UR-S14 Testing Procedures for Watertight Compartments IACS Recommendation No. 72 Confined Space Entry
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Tank Testing - Fillet Weld Air Tests
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Tank Testing Vacuum Leak Tests
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Structural Testing
Rules to be complied with - See Part 3 for details
Correct air pressures/hydrostatic test heads applied - Do Not Over
Pressurise - Danger
Gauges calibrated and working correctly
Vacuum Boxes and fillet air testing
Listen and look for BIG and SMALL leaks
Deformation during and after testing
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The New Building Project - Hull Construction
Materials Forming Block Surveys Pre-erection Surveys Dock Erection joints Surveys Patrols of work in progress Construction Monitoring Procedures Deck house and Accommodation Anchoring and Mooring Equipment Other items
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Materials
From stockyard to production, there needs to be clear identification
of different grade of plates and sections: Visible colour coding and
marking
Spot check material scantling during routine patrols and surveys
Insert plates/partial renewals must be correct grade for the locations
Handling of special steels: avoid contamination and damages
stainless steel and aluminium
Identification and Traceability
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Typical Steel stockyard with plates stored in the as rolled condition.
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Steel plate entering the shotblast and primer treatment line.
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Steel plate immediately after shotblasting and priming.
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Steel plate marking after blasting and priming. Marking is done automatically by machine.
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Transferring identification marks and correct grade manually - just after blasting and priming.
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Forming (Hot & Cold)
Correct procedures need to be applied
Operators need to be properly trained and experienced
Verify that heating is being monitored during the process : Use of Tempel sticks and/or temperature probe
Use guidance notes and work instructions.
Template to be used to verify the shape of curvature to steel plate and structural members
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Plates being Line heated prior to application of water to shape and form the plate to the required curvature .
Hot Forming Line Heating
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Wooden template being used to check the shape of a side shell plate during Line heating .
Hot Forming Line Heating
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Cold Forming Mechanical forming
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Cold Forming Mechanical forming
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Block Surveys
Verify structural details against approved plans to ensure:
the working drawings comply with approved Plans
welding details and quality visual, leg-length & throat
plate and section edge preparations for fit to next unit
W.T. /O.T. Boundaries for penetrations missing members collars, bkt, etc.
Positions of air and drain holes should not in high stress areas and placed in correct places for drainage and pressure relief
alignment, deformation, unsupported structure
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Numerical Control steel cutting. This is the first stage of the block where the piece parts are cut from the parent plates.
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Piece parts from parent plate now arranged ready for sub assembly of block sections.
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Automatic fillet welding of stiffeners for sub assembly.
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Submerged Arc Welding for plate joints. Note run off plate at the end of the weld.
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Transportation of sub-assembly to the block construction shop
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Typical double bottom block
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Pre-erection Survey
Alignment, deformation, any unsupported structure and welding
Lifting lug positions and removal - MPI testing of areas effected to
verify possible cracks due to stress and notches.
Structural testing in way of outfitting is completed or noted for later
- before insulation, pipe, cable, machinery equipment and etc are
fitted and access to weld is not possible
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Pre-erection of fore body section
Four individual units brought together to form one single block
Lifting lugs will also be removed after erection
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Typical Pre-erection for Aft body / Machinery space
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Typical pre-erection for side shell
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Pre - erection of a very large section of main hull and LPG tank
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Erection joints Survey
Alignment, deformation, unsupported structure welding and missing
members
Fairing aid positions Not on stress areas
Bad workmanship/practices - wide gaps, excessive force, Backing plates
Adverse environmental conditions
Welding in rain Wind blowing away shielding gas Steel temperature too low in winter
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Typical erection of double bottom blocks being placed in the building dock (Oil Tanker) .
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Typical erection of double bottom blocks (Oil tanker) laid out in the dock bottom ready for fairing .
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Typical lower hopper joint to double bottom(Oil Tanker). This is a Critical location
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Typical erection joint of double bottom to longitudinal and transverse bulkheads (Oil Tanker).
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Typical erection joints forward - Longitudinal bulkhead and lower hoppers to double bottom (Oil Tanker) .
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Typical erection joint of forward side shell to double bottom (Container Ship)
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Patrols of work in progress
Carry out regularly, daily if possible
Tell the yard and owners that you do patrols
Vary your routine, time and places
Mark up with chalk or paint any problems you find and report
them to QC
Follow up any problems identified
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Ceramic baking strip fitted at the root of a full penetration weld
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Ceramic backing strip viewed from the root side of the weld .
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Poor root weld after removal of the ceramic backing strip .
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Arc air gouging of a shell butt prior the root sealing run
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Shell butt weld after arc air gouging
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After repairing of shell butt weld
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Construction Monitoring Procedures
LR ShipRight Procedure ShipRight (CM) assigned as a class notation Mandatory Part of ShipRight procedures involving
Materials Alignment Welding Construction procedures
Objective To ensure that special attention is given to critical joints
to avoid stress concentrations
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Construction Monitoring Procedures
Construction Monitoring Plan Approved - by PAS Critical locations identified at design approval stage tolerances
for fit up, gap, etc
Enhanced alignment tolerances specified by LR Shipyard develops working procedures to control fit-up at these
locations
Shipyard controls checked by the surveyor at the critical locations by monitoring & direct inspection
This procedure is unique to LR
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Construction Monitoring Procedures
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Construction Monitoring Procedures
MidshipSection Plan showing location of Critical Areas
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Construction Monitoring ProceduresMidship Section Critical Areas
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Surveyor confirming that the 100mm reference mark (to indicate position of girder under)
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Close up of same location as previous slide
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Same reference mark (100mm) for hopper joints alignment to double bottom girder
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Another typical example of a Critical joint at the connection of the tank top with the longitudinal bulkhead transverse web brackets
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Typical transverse end bracket toe or side shell frame lower bracket toe at the connection to the double bottom tank top or lower hopper plating
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Deckhouse and Accommodation
Fire protection and detection as per approved plans
Crew Accommodation (as per Flag State)
Routing of cables and pipes
Structural compensation
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Typical complete Deckhouse being erected as single unit.
Theses units are often constructed outside the shipyard at a specialist contractor.
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Anchoring and Mooring Equipment
Verify supplied anchors and cables against approved equipment plan
Anchors and cables from approved works with LR Certificates
Certificates verified with the marking on the equipment
Check Rule requirements for Mooring lines
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Anchoring and Mooring Equipment
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Anchoring and Mooring Equipment
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Other Items
Keel Sights (Especially on slipways )
Principal Dimensions (L.B.D.) , Draft Marks (FWD and AFT for Tonnage, Midships not required)
Non-LR certified materials (other IACS members) Should not exceed 10% of lightship
Outfitting (pipe supports in tanks and on deck)
Bilge Keels and their attachments
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If all goes well with the Project then LR is the winner and the Client comes back
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Building better business
Working together to improve business performance