shipbuillding

7/31/2019 ShipBuillding

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History:-

In India, 1950 &1960 rapid growth in India commercial shipbuilding industry, Rapid

technological advances in both ship design and construction demand for increasingly large

tankers, increased international competition. Formation of Seven Major shipbuilding

companies through mergers. Shipbuilding markets collapsed in 1973 due to oil crisis.

Large tanker market evaporated, Bulk carrier deliveries dropped by 74% by 1979, Late 1970s

& early 80s restructuring of industry leaving medium sized shipbuilders with half of India

output. Technological development slowed by early 1990s. Product innovation super ceded

by production cost control, so industry movement to maturity favoured cost competitiveness.

Shipbuilding Process:-

Ships are built custom made-to-order. Beginning with inquiries from customer, shipbuilding

then requires the completion of various processes until the vessel is completed. It takes at

least 2 years to complete a fine ship.

1.Bid Proposal

Based on the basic specifications (simplified specifications) provided by their customers, they

lay out a broad design to get a rough overall picture of the ship and subsequently offer a

proposal to the customer. The proposal is a very important step of their business since

customers largely depend on this proposal to decide whether to place an order with them or

not. Therefore, they try our best to show our ability to the full.

2.Discussions on the specifications and Agreement

Once their proposal is accepted, they proceed to discuss the specifications in detail and settle

on the final price of the ship. Once the ship price, shipbuilding process, general layout,

specifications, etc. are determined, an agreement is made.

3.Performance design

Speed is the most significant factor of any ship. By repeatedly adjusting the hull form and

tank testing, they ensure that the ship they are to build can sail at the speed stipulated in the

specifications.

4.Basic Design

There are various factors that influence ship performance, other than speed. Other factors can

include load capacity of cargo, ship stability, fuel cost and so on. The key function of basic

design is to design the ship so that all those factors comply with the specifications.

5. Detailed Design

Based on the information obtained from the basic design, the detailed design plays the role of

clarifying the design of components and parts of the ship to be built. The key point of this

step is to work out drawings that are feasible and accurate enough to facilitate the actual

shipbuilding operation on-site without compromising the ability or performance of the ship.

6. Production Design

The production design organizes the design information in the detailed plans into respective

component information. The production design enables the field staff to meticulously control

a large amount of components on site.


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7.Material Ordering

They place purchase orders for required materials based on the design information. Since a

tremendous volume of materials need to be ordered to build a ship, it is vital to manage and

supervise the delivery dates of those materials so that the procurement is timely and accurate.

8. Production PlanThe production plan has a critical impact on manufacturing efficiency because of the

enormous amount of components, and the large number of workers involved on the job site.

It is vital, therefore, to plan thoroughly so as to control and supervise the flow of materials,

work volume, job assignments and subsequent progress of the shipbuilding process.

9. Cutting & Processing

Steel plates are cut and processed according to the blueprint. The process of heating and

bending a steel plate into curved shapes is of great importance in shipbuilding, and requires

sophisticated skill and technique.

10. AssemblyThe cut and processed components are assembled block by block. In order to maximize

manufacturing efficiency, the assembling of blocks is carried out in a phased manner: small-

scale assembly comes first, mid-scale assembly second and large-scale assembly last.

11. Installation of rigging articles

Assembled blocks are further jointed together to make huge blocks, and at this point, rigging

articles such as pipes, electric wires are installed. In order to enhance manufacturing

efficiency at the dockyard, most rigging articles are installed while the block is still on the

ground.

12.Mounting huge blocks

Following the above step, the huge blocks are mounted on the vessel. In order to maintain the

predefined dimension, even after tens of such blocks have been jointed together; accurate

positioning of each block is critically important. This is where we make full use of our

shipbuilding know-how.

13. Launching

When all the blocks are mounted and jointed, launching is the next stage. While the

launching at a dock simply means filling the dock with water to float the ship, the launching

from a building berth is a very impressive and exciting sight to see since the ship slides its

way majestically into the sea. This is one of the most thrilling moments for all involved withthe shipbuilding process.

14.Operation at the quay

The finishing operation is carried out with the launched hull at the quay. Starting with

finishing work of accommodation and control sections, every equipment and instrument is

checked and re-examined in practice. They are now in the final stretch of shipbuilding.

15. Trial Cruise

The trial cruise includes tests of speed, engine performance and operation of all equipment

and instruments. The test results are kept as the performance record of the vessel.


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16. Delivery

A new ship is born. After the delivery ceremony, the captain, chief engineer and crew embark

for the ships maiden voyage. Their one wish is that the ship always sails smoothly and

safely.

Ship Manufacturing and Production

In an industry where many projects experience tremendous cost overruns and schedule

delays, shipyards are more focused than ever in managing manufacturing costs. Ship

manufacturing involves innumerable elements that must be stringently coordinated and

executed in order to complete a project in time and within budget. Whether a ship is a tanker

or a yacht, interconnected activities must be carefully planned to reach the safest, faster, and

most optimum manufacturing sequence.

Shipyards and marine engineering companies rely on Assault Systems Ship

Manufacturing and Production solution and fully integrated PLM environment that supports

design-to-manufacturing approach in order that both design and ship construction processes

can be optimized in ways that would best utilize available resources.

DS PLM virtual construction portfolio offers extensive capabilities unmatched in the

industry. Early and throughout the design process, ship construction planning, scheduling,

and sequencing can be virtually defined and simulated to reduce the occurrence of

construction-delaying problems that typically arise when the systems and machinery are

ready to be placed.

This solution includes scheduling with tools such as Primavera and MS project, equipment

placement, and human simulations including aspects such as vision, display and motion. As

all components and humans are included in the planning, initial requirements, costs, and

construction time can be estimated quite accurately prior to capital orders.

DS PLM environment maintains the relationships between design data and constructiondata. This helps shipyards track late changes, identify parts that may be impacted by design

changes and study the impact of the changes on manufacturing. This integrated PLM

environment gives shipyards the information they need to predict the cost of changes in

dollars and time so that they can decide whether or not to renegotiate the terms of the

contract.

Although interconnected with design, the manufacturing sequence can be arranged

independently of the design structure, providing full flexibility to support the preferred

organization to carry out the manufacturing of the ship.

Raw- material used in ship industry:-

Shipbuilding steel is the most common material. It is to meet rather strict requirements:

strength, flexibility, high manufacturability, weld ability, cost, reparability, etc. Steels used in

the domestic shipbuilding industry differ in high cold-resistance, good welding characteristics

and increased fracture strength. Special cold-resistant welding consumables were worked up

for new steel grades.

Last years, new class of high-strength corrosion-resistant nitrogen-alloyed steel grades were

elaborated. Owing to difference in interaction of atoms of carbon and nitrogen with atoms of

iron, steel acquires unique physicochemical and operating properties (high strength,

flexibility, absolute corrosion resistance, non-magnetic behaviour). Nitrogen steels differ in

good welding characteristics and manufacturability, both in metallurgical production andshipbuilding.


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Structural aluminium alloys with increased corrosion resistance as well as aluminium-based

composite materials became common use in construction of high-speed sea and river vessels,

as well as airfoil boats, hydrofoil ships and aerostatic crafts. Owing to their properties,

titanium alloys became common use in marine facilities. Distinctive characteristic of their

usage is wide spectrum of operational environment with long service life.

In addition to it, the diversity of types of half-finished items used in ship structures

manufacture. Zinc is rather corrosion-resistant material both in air and in water. Rolled zinc is

used in inboard planking of ship rooms. Also, thick plates of rolled zinc are used in

manufacture of protectors. Zinc coating becomes common use in corrosion prevention for

metal surfaces of ship systems.

Environmental safety of new ships is ensured with usage of non-metallic materials with low

emission of chemical compounds into water and air. So, various kinds of fibreglass plastics

are used in construction of hulls of some vessels (trawlers, sweepers, high-speed airfoil and

hydrofoil ships, and yachts).

The main property of the fibreglass plastics is their chemical and biological stability. Strength

and technological properties, improvement of working conditions, and reduction of costs of

workroom air ventilation are their advantages.

New polymeric and metal-polymeric composition materials give possibility to produce non-

composite or partly rigid hull structures of sandwich-constructions with high-tensile steel or

fibreglass outside layer and polymeric or low-tensile composite interlayer. Such hulls become

common use in building of modern high-speed vessels.

Types of Ships:-

1. Bulk Carrier -Bulk Carriers are ships designed for carriage of solid bulk cargoes.

2. Combination Carrier-Combination Carriers include ships intended for separate carriage of

oil and dry cargoes in bulk, ships intended for separate carriage of oil and ore in bulk and

combination of the two above.

3. Container Ship -Container Ships are ships exclusively intended for the carriage of

containers.

4. Gas Carrier-Gas carriers are ships intended for transportation of compressed or liquefied

gas.5. General Cargo Carrier and Ro/Ro -General Cargo Carriers are ships arranged for lift on/lift

off cargo handling and intended for carriage of general dry cargoes.

6. Ore Carrier -Ore Carriers are ships designed for carriage of ore cargoes in centre holds.

7. Passenger Ship-Passenger Ships are primarily ships designed for carriage of passengers

and Car and Train Ferries designed for regular transport of passengers and vehicles.

8. Tanker for Chemicals -Tankers for Chemicals is ships intended for transportation of all

types of liquid chemicals.

9. Tanker for Oil-Oil carriers are ships intended for transport of oil in bulk, whereas oil

product carriers are ships intended for transport of all types of oil products except crude oil.
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