NSWLC Shipyard Modernization Project

Bob Hillstrom, SMP Project Manager

October 16, 2014

Shipbuilding Stages of Construction • Fabrication

– Cutting of parts from raw material – Forming of parts

• Subassembly – Joining of parts by welding to create interim

products up to ~20 tonnes

• Block Assembly – Assembly of 12m x 12m standard hull blocks

• Pre-Outfitting – Installation of outfit on hull blocks

• Blast and Paint – Abrasive blasting for surface preparation – Coating of hull structure and outfit items

• Pre-Erection – Joining of blocks to create grand blocks

• Erection – Erecting and joining of grand blocks to create

the vessel

2

Panel Shop

Forming Shop

Block Assembly

Pre-Outfitting

N/C

B&P

Erection

Pre-Erection

Repair B&P

Careen Drydock

Building and Area Identification

Loadout

Pier

Facility Process Flow

Shop and Area Capabilities Subassembly Shop (24m x 168m)

• Cranes – (1) 20-tonne with permanent magnet lifting

beam for plates

– (1) 5-tonne for handling profiles

– (3) 10-tonne to support subassembly operations

• Robotic profile line – Automatically cuts, bevels, marks and provides

layout information from N/C files

5

Subassembly Shop Cranes

Plasma Cutting Machine

Robotic Profile Line

• Plasma cutting machine – Cuts plates up to 3m x 10m from N/C

files

• Oxy-Fuel cutting machine – Used for fitting aids and small parts

• New 1000T plate press

– Forms compound shape

in hull plating

– Capacity up to 60 mm

thick plate

• Existing forming equipment

– 1000T press brake

– 300T press brake

– 400T stiffener forming

– 500T C-frame press

– 8 ft plate rolls

6

Shop and Area Capabilities Forming Shop (14m x 130m)

1000T Plate Press

• Panel Line

– Automated conveyor line to produce

12m x 12m flat stiffened panels

• Single-side plate welding

• Panel cutting, layout & marking

• Stiffener fitting

• Stiffener welding

– Three manual stations at end of line for

installation of web frames, bulkheads,

etc.

7

Shop and Area Capabilities Panel Shop (28m x 170m)

Stiffener Fitting Gantry Panel Cutting

Single-Side Plate Welding

• Cranes

– (2) 40T bridge cranes each with two 40T trolleys for block turnover

– (2) 15T cranes for setting of web frames, bulkheads, etc.

8

Shop and Area Capabilities Block Assembly Shop (30m x 130m)

• Pin Jigs

– Telescoping pipes adjusted to height to match hull form configuration

– Supports accurate assembly of complex curved hull blocks

Chip Barge Construction in Block Assembly Pin Jig Upright and Base Pipes

9

Shop and Area Capabilities Blast and Paint Shops (New Const. 30m x 60m & Repair 28m x 76m)

• New Construction

– Two blast positions

• Steel grit vacuum and

elevator recovery system

• Dedicated dust collection

system

– Four paint positions

• Repair

– Building shell relocated to new foundation

– New cladding, ventilation and blasting equipment installed

– Accommodates vessels up to 75m in length and 22m in height

Exhaust Ventilation System New Construction Paint

Repair B&P Building Relocation Dust Collection System

10

Shop and Area Capabilities Pre-Outfitting Shop (New Const. 30m x 180m)

• Block outfitting

– Installation of outfit components on structural hull blocks

– 5 bays each 16m x 28m

– 10 block outfitting positions

• Module construction

– Installation of outfit components on a structural framework

– Two bays each 16m X 28m

Block Outfitting

Module Construction

Pre-Outfitting Shop

• 300T Goliath Crane

– Schedule • Order Feb 28, 2013

• Design Mar-June

• Manufacture June-Dec

• Erection Mar-Apr, 2014

• Test Aug

– Capabilities • 300T block lift

• 200T block turnovers

– Crane specifications • Two trolleys

– 2 x 100 T

– 1 x 150 T

• Hook height 70 m

• Bridge span 76 m

• Travel speed 30 m/min

• Hoist speed 12 m/min

11

Shop and Area Capabilities Pre-Erection and Erection (76m x 230m)

12

Shop and Area Capabilities Pre-Erection and Erection cont. (76m x 230m)

• Careen Drydock

– Capable of launching Panamax vessels up to ~200m

• SPMTs – 32 axles & 2 power units

– Grandblock and vessel moves to 960T

• Loadout Pier – Provides level vessel transfer to floating drydock

• Rolling Mobile Shelters

– (3) 30.5 m x 29m x 20m