ON BUILDING 3D SUPPORT SYSTEM

IN THE SHIPBUILDING PROCESS

IN VIET NAM Vo Trong Cang1, Nguyen Anh Tuan 2, Vo Anh Dung 3

1 Ho Chi Minh city University of Technology (HCMUT) ,

VNU-HCM.

( vtcang@hcmut.edu.vn)

2 Institute of Computational Science and Technology,

Dept. of Science and Technology HCMC.

(TuanShipLand@gmail.com – TuanShipLand.com)

3 HoanMy Engineering Co.Ltd., HCM city, Viet Nam.

GREENTECH 2012 * CKM-15

* GTSD2012 International Conference on Program

Comprehension

Note: The presentation is prepared based on acepted

paper in Greentech 2012, and is just for academic

purposes.

Source: Dassault Systemes

CATIA for OFFSHORE

FPSO** – External turret design

** Floating Production, Storage and Offloading

2

ABSTRACT:

From concept to deployment, the ship production process requires

innovative solutions that will increase efficiency, lower costs, and

provide support throughout the life cycle of the ship. World

Shipyards experience with new ship construction and production help us to

meet challenging requirements. The ship production service offerings

include: ship design and assembly, materials planning and procurement,

information management, etc.

This paper will explain how to build the 3D support system for shipbuilding

process in the small to medium sized shipyards in Viet Nam.

Keywords:

3D modeling; Support system; Digital shipbuilding; Shipyard;

Product Lifecycle Management (PLM); Virtial Product Management

Research Background 3

The analysis is one of series in project “Research and build digital

simulation-based support system for shipbuilding industry” to assist

marine and offshore builders of Vietnam comprehend the advantages of

SBD and CIM especially in new PLM solution application.

Department of Naval Architecture and Marine Engineering in Ho Chi Minh

city University of Technogy in cooperation with National Key Laboratory of

Digital Control and System Engineering (DCSE-LAB) / Vietnam National

University HoChiMinh city (VNU-HCM) can build and test modules of

simulation and accuracy control for Vietnam’s shipyards [28, 29].

The paper is one of report series of project “Research and build the digital

simulation system in shipbuilding”. The project is funded by Vietnam

National University HCM city under grant number B-2012-20-15 and also

supported by DCSE-LAB.

Summary 1. Progressive Trend of Digiatal Simulation Application

in Shipbuilding

2. 3D Simulation-Based Support Systems in PLM Solution

3. Case Studies

a) Yantai CIMC Raffles Offshore Ltd. China

b) Samsung Heavy Industries South Korea

4. Intelligent PLM applications of CAD/CAM/CAE system

Conclusion

References

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PROGRESSIVE TREND OF DIGITAL

SIMULATION APPLICATION

IN SHIPBUILDING

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3D simulation-based machinery

arrangement in Hyundai SY [5]

In South Korea, Seoul National University,

Samsung Heavy and some national

institutes are funded to carry out the

project “Integrated Digital Shipbuilding

Technology for Development of High

Value-added Ship” since 2001 [2]

Samsung Heavy Industries is an

essential shipbuilder in South Korea has

adopted DEMILIA solution to develop the

next-generation simulation shipbuilding

system since January of 2003 [4]

In May of 2010, Dassault Systemes

cooperated with the government of South

Korea, and Keimyung University in setting

up their Shipbuilding R&D Center at

Keimyung University in Daegu [3]

Hyundai Heavy Industries has

applied advanced 3D simulation-

based solutions as AVEVA

Marine, NAPA, Nastran, and

Teamcenter, Teachnomatix [5]

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600-meter wellhead riser topside

is simulated via AVEVA PDMS

by PTSC M&C [1]

Overview of 3D simulation application in Vietnam

The PTSC Mechanical and Construction

(PTSC M&C) under the Vietnam National

Oil and Gas Group has used AVEVA PDMS

to design and simulate 3D model of 600

meter well head riser topside for the Pearl

field since 2008 [8].

Many 3D CAD/CAM/CAE solutions for

shipbuilding industry are represented in

Vietnam involving Maxsurf, AutoShip, Ship

Constructor, AVEVA PDMS, Smart Marine

3D, Nupas-Cadmatic, Unigraphic NX, and

CATIA [18, 19]

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Hong Ha Shipbuilding Company (or Z173 factory under

Ministry of Defense) implemented successfully Ship

Constructor to design the new naval artillery ship [18,19].

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Intergraph solutions as Smart Marine 3D and Smart

Plant 3D are also effectively applied by

VIETSOVPETRO and PV Shipyard to build complex

offshore structures in 3D visual environment [23,24].

Complex structure of

90- meters Jack-up

Drilling Rig is designed

by PV Shipyard

(Source: Intergraph)

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90 meters jack-up

drilling rig in PV

Shipyard

(Source: PV

Shipyard)

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Saigon Shipbuilding Industry Co. Ltd used Unigraphic NX5 of

Siemens to build 3D simulation-based models of piping and

electric systems [20].

On the other software, Nupas-Cadmatic is used by Saigon

Shipmarine ship yard to move forward 3D simulation-based

design [21].

In offshore market, STX OSV shipyard and PTSC M&C have

adopted AVEVA solution to maintain their competitive

advantages with modern SBD and CIM systems [8, 22].

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3D SIMULATION-BASED SUPPORT

SYSTEMS IN PLM SOLUTION

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Accuracy Control System (ACS)

• Check the block design (block is fabricated by a lot of objects

as steel plate, pipe systems, and etc) and compared with

design model based on 3D CAD systems;

• Review the block assembly process based on 3D simulation,

then analysis and operation;

Erection Forecasting Simulation System (EFSS):

3D simulation-bassed production provides the analysis and

prediction tools of production condition before block erection, and

thus to save erection time and increase shipbuilding capacity.

Erection

simulationapplication

of SAMIN* [30]

* One of popular vendors is SAMIN Information System

Co. (SAMIN) in Korea. According to estimation of

SAMIN, the company covers 25 - 30% share of EFSS

market and 13-14% share of ACS [30]

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Plant simulation is virtual tool for simulating

shipyard activities. The innovative technologies help

production management board can answer many

questions as how can optimize the time, work space,

human power in manufacture processes.

Nowadays, plant simualtion is openly used from

super yacht building project to huge commercial

vessels, and even naval ships as submarine.

Advantages of plant simulation deployment [31]:

• Optimize the shipyard space and enterprise

resources;

• Expend erection schedule, avoide the unforeseen

errors in erection;

• Streamline the accuracy and safety in planning;

• Steamline the complex material management and

coordination;

• Exactly time prediction of ship delivery;

• Manufacture cost estimation capacity

enhancement.

Production based on virtual

simulation in Tecnomatrix ® Plant

Simulation of Siemens [31]

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Shipbuilding Process *

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* Source: AVEVA, AVEVA Integrated Shipbuilding, 2010

15 Project coordination in ship production process [9]

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The shipbuilding process

using block erection technology [10]

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Part Fabrication Part Assembly

Source: TuanShipLand.com

At TRIYARD SSY’s Shipyard (Under EMAS Group, Singapore)

Pre-Processing

Piping Outfitting Block Assembly Onboard Outfitting

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Yantai CIMC Raffles Offshore Ltd.

China

Case study:

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Yantai CIMC Raffles Offshore Ltd has three

shipyards are located in Yantai, Haiyang, and

Longkou in Shandong province, China. It is known

that is the largest rig builder with nearly 4,000

employees and 8,000 sub-contracted workers in

China. The shipyard in Yantai is also called Yantai

Raffles shipyard (YRS) can positively design and

build the Jack-ups with leg’s length over 120 m

besides semi-submersible drilling rigs, and heavy

derrick pipe-lay vessels.

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3D Simulation-based model of

Jack-up of Yantai Raffles

Shipyard [7]

With increasing development and high

competitive pressure, YRS has to

transform the original 2D CAD systems

into the innovative 3D simulation-based

support systems to streamline their

design and production capacity.

Since 2008, DS PLM solutions including

CATIA, SIMULIA, DELMIA, and ENOVIA

VPLM have usefully been implemented

by YRS. [11, 12]

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20 3D simulation-based FEA in CATIA [12]

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Complex systems of

semi-submersible platform

simulated by CATIA [12]

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3D simulation-based

ship structure block

erection process

control [12]

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The new innovative 3D simulation-based

support systems of DS PLM solution enable

YRS to:

• shorten the production process as much as

70% faster

• improve effectively the design capacity as

much as 30%

• optimizes their investment budget

• increases the profitable income

• decreasing over two million man hours in

building the semi-submersible platform.

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Samsung Heavy Industries

South Korea

Case study:

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In 2001, Samsung Heavy Industries (SHI) was a

member of the key national project in building a

simulation-based digital shipyard. The essential

goal of this project is to improve national

shipbuilders’ competitive advantages. Since 2003

Samsung’s shipyard has effectively launched

DELMIA digital manufacturing technology of

Dassault Systemes to build their simulation-based

digital shipyard.

SHI with around 13,000 employees can deliver

more than 70 vessels every year.

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Recently, SHI has carried out the new

projects of field development ship

(FDS) design. The structure of FDS is

such a complicated design that SHI

has coped with difficult situations in

design stage. Smart Marine 3D

provides state of the art digital solution

to support marine engineers design the

complex structures as bulbous bow

design and systems as HVAC, piping,

and electrical. SHI owns advanced

method of mega-block erection process

to minimize the fabricated blocks and

thus to shorten delivery time. SHI has

to fabricate such complex mega-blocks

and install marine equipment in pre-

assembly stage. Material procurement

planning plays a very essential role to

secure the project schedule.

Drilling platform is built

by Geoje shipyard [13]

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As positive results, Geoje shipyard of SHI

applied usefully DELMIA to optimize block

erection procedures and also enhance the

maintenance processes. The new technology is

expected to save US$7.3 million a year by

simulating all aspects of ship production

processes in visual environment.

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Intelligent PLM applications of

CAD/CAM/CAE systems

Next generation

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Up to now, many vendors consult and provide the PLM

solutions from open source as Aras Innovator of Aras

Corp. to commercial software as Enovia SmarTeam of

Dassault Systemes [32]. In marine and offshore

industry, there are four famous companies in total

solution development for ship lifecycle management

including Dassault Systemes (France), Siemens (USA),

AVEVA (UK) and Intergraph (USA). In the limited paper,

the authors briefly represent SBD and CIM integrated

into PLM solution of Dassault Systemes and Intergraph.

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3D Experience platform of Dassault

Systemes for ship lifecycle

management [27]

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3D-based

simulation of

piping system in

CATIA [9]

3D-based

simulation of engine

room [9]

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Catamaran Yacht Structure Optimization via CATIA (Source: Linea Concept)

Production Simulation of Composite Resin of Sailing Yacht Via CATIA

(Source: AITAC)

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31 PLM platform of SmartMarine Enterprise of Intergraph [17]

The whole offshore lifecycle data is built, shared and managed based on 3D

simulation in real time. All concerns from engineering, design through

production to warehouse operation, cost control, and production planning will

be integrated into one platform of SmartMarine Enterprise.

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3D simulation-based

bulbous bow structure in

Smart Marine 3D [17]

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Piping routing based

on 3D simulation in

Smart Marine 3D [17]

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Conclusion 33

The advantages of the digital shipbuilding database management and 3D

simulation-based technologies,

(1) save man hours, and manufacturing cost,

(2) optimize ROI rate,

(3) decision making assistant,

(4) improve design, production, operation and maintenance capability.

Up to now, Vietnam has lack of research and analysis of intelligent PLM

platform although 3D simulation-based design (SBD) and computer

integrated manufacturing (CIM) has recently appeared in foreign-invested

shipyards and government-owned groups.

Marine and offshore builders in Vietnam should consider clearly new PLM

solutions based on project budget, shipyard’s size, and employee ability.

Hence, shipyard can choose the suitable PLM package to optimize ROI and

advance the competitiveness.

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Conclusion 34

These will encourage universities catch the new technology trends in

joint-venture shipyards in Vietnam, and also provide high quality

engineers for labour market in marine and offshore field. As result, the

shipyards will not waste time and money to train the junior engineers,

and vendors can also diffuse the new intelligent simulation solutions. To

obtain the objects, universities need to strong supports and education

cooperation policies from 3D simulation solution vendors.

In order to do so, Intergraph and HCMUT will cooperate to build up a

cooperation model to study Intergraph software solutions applied in

engineering, operation, maintenance, marine and offshore. So, HCMUT

may exploit the Intergraph’s Educational Grant Program for that initative.

This cooperation could be potential to train students because the gap

between academic training and industrial design and production

problems can be reduced significantly.

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Next Steps 35

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SBD – CIM Systems

3D Models

3D CAD Solutions

Popular Interactive

Programming

Languages

Simulation – Analysis – Prediction – Statistics – Bill of Materials (BOM)

Project Management

Ship Lifecycle Management

Production Process Control and Evaluation

Production

Planning

Production

Environment

36

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