Coefficients GoaloftheShipbuilder:Tobecompetitiveinmeetingtheclientsspecificationwithsolutionsthat
are cost effective at an acceptable level of safety. Success in shipbuilding depends on facilities,Shiprepairanddisposal,Supportfacilities. ships/year.
Block Midshipsection Waterplanearea simultaneously meeting following criteria: clients specification, competitiveness, cost Facilities for Hull Production: Steel stockyard, Steel treatment, Plate and section preparation
AM AWP effectiveness,safety.
CB CM CWP CWL
L * B *T B *T L*B Usual owners requirements (Client Spec): Deadweight, Capacity (bulk or liquid, number of
containers, number of cars and passengers), Sea trial speed (engine(s) at maximum rating),
Prismatic Verticprismatic
C C Endurance,Classsociety/Flag.
CP B CVP B KeyfeaturesoftheProduct:Ashipisafloatingstructurethatnotonlysupportsitsownweightin handling (gantry cranes, overhead cranes, roller conveyors, trailers, flat cars) in plate/section
L * AM L * B * T * CM C M AWP * T CWP * L * B * T CWP
water,butcansafelycarryapayloadofcargoandpassengersfromoneporttoanother.Shipsare
ForceDisplacement(or)Buoyancy also used for the exploitation of the ocean resources. Most ships will have some means of Factors Influencing Steel Stockyard: Holding capacity and turnover, Provision of adequate
W F g * * g * w* propulsionsuchasdieselengines,gasturbines,steamenginesorevensails.Crewhavetoliveon offloadingareas,allocatingstoragepilesforhighturnoversteel,Provisionofsortingareas,Areas
board;accommodationandothersupportfacilitiesmustbeprovided.Shipshavevariousrolesto
LightShip Displacement
Lightship Deadweight
performandcanbe:Shipsfortransportation,Shipsforwork,Shipsformiscellaneouspurposes.
LS WST WM WOUT
The Life Cycle of Ships: Bid Preparation, Concept design, Preliminary design, Detailed design,
Procurement,Production,Commissioningandtrail,Operational/Service(includingmaintenance),
Scrapping/Disposal
Characteristics of Shipbuilding: Ship owner has a large influence on the production. Production
stagesthataredependentofeachother.Shipbuildingemploysvaryingmanufacturingprinciplesat
differentstagesofproduction.Shipbuildingrequiresahighdegreeofcraftskill.Differenttypesof
equipmentareneededforthefabricationprocess.Thedesign,planningandmanufacturingalways
overlap.Theworkingenvironmentmaybeharsh(e.g.exposedtoweatherconditions,noise,etc.).
Final(complete)definitionoftheshipisknownafterthecontractissigned.Theshipbuilderhasto
makeimportantdecisionsduringtheproductdefinitionstagebasedonuncertaininformation.It
takesalongtimetocompleteanddelivertheproduct.Shipshaveahighproductvalue(oneoff
products).Shipsarelargeinsizeintermsofbothweightandvolume.Shipshavealongproductlife
of around 20 to 25 years (in passenger ships even longer e.g. 30 years and more after certain
conditionsaremet)
Typical ship systems: Steel hull structure, Power generation system for main propulsion. Power
generation system for auxiliaries. Power transmission system for main propulsion. Power
transmissionforauxiliaryrequirements.Maneuveringandcontrolsystem.Cargohandlingsystem.
Systems to distribute services: sea water and fresh water, steam and condensate, air, fuel and
dieseloil,lubricatingoil,hydraulicoil.Systemsfor:transmissionofinformation,communication,
monitoringandcontrol.
Ship Design and Production: Ship design is a topdown process starting from the requirements
specification and simple parametric relationships and eventually leading to the definition of full
configuration of the ship, her systems and components. Ship production is a bottomup process
where production starts from the fabrication and/or acquisition of the smallest components or
parts,andthroughanorderlyassemblyofthosepartsthefinalshipconfigurationtakesshape.The
ship at the design and production stage is divided first into zones, i.e. parts of the ship having
configurationalandfunctionalsimilarity.Theneachzoneisdividedintoanumberofblocks.The
sizeandnumberofblocksarelargelydeterminedbythephysicalabilitiesoftheshipyard(i.e.space,
size of the enclosed buildings, crane lifting capacities, etc.). From the production point of view,
blocks constitute interim. products or planning units and design information required by
productiondepartmentareforblocks.Thisstageofdesignisknownastransitiondesign.
Tasksofdesigndepartment:Determinetheshapeoftheshipwithdefinedfunctionsandacceptable
performance. Examine with what materials, equipment, and methods a ship can be built at a
reasonable cost while at the same time satisfying the desired functions and performance
specifications. Provide the Materials Procurement Department, within a defined time schedule,
informationonspecifications,quantities,anddeliverydatesformaterials.Systematicanalysisof
thedifferencesbetweenestimatesandactualfiguresintermsofcosts,qualityandperformance
bothduringthebuildingprocessandatthecompletionoftheship.
DesignforProduction:Preparingdesignwithfullcognitionofproductionfacilitiesanddifficulties
in fabrication and erection is known as design for production. The main issues of design for
production are: Reduction of variety and use of standard details Use of standard components.
Employment of modularity and cellularity concepts for distributed systems. Full knowledge of
shipyardproductionfacilitiesandcapabilities.
Offshore Construction: The structure is usually stationed at a particular offshore site for a
considerable portion of its working life and therefore cannot be dry docked for periodic
maintenance and repair. the steel plates used in offshore construction are of relatively higher
thickness.thetopsidesofoffshorestructuresareconsiderablyheavythanthesuperstructuresof
shipsandareoftenmanufacturedandinstalledseparatelyfromthemainstructure.thestructure
isdesignedandconstructedtowithstandlongtermenvironmentalloads.considerationsfor(ease
of)decommissioningofthestructureattheendofitsproductivelife.
Production organization: Craft based (or jobshop) Organization: Craft based production
organization uses welltrained and skilled workers to perform a wide variety of tasks in one or
several locations.Semiprocess Organisation: This form of production organisation, like the craft
basedorganisation,alsoutiliseswelltrainedandskilledworkerstocarryoutsimilarprocessesat
specificareasProcess(orBatch)Organisation:Inprocess(orbatch)organisation,specificareasare
usedforspecialisedactivities.Here,theequipmentisfixedwhereastheworkobjectandtheworker
who is trained for a specific task are moved to the production equipment. Product (or Group)
Organisation:Product(orgroup)productionorganisationfocusesontheintermediateproductand
alltheprocessesrequiredtocompleteit.Insuchanorganisationtheworkerandhisequipmentis
fixed and the working object moves from one workstation to another. Mass Production
OrganisationMassproductionorganizationmaximisestheuseofmechanisation,continuousflow
lines,andspecialisationofactivitiesatsequentialworkstations.Materialhandlingisdecidedatthe
timeoffacilitydesign.
Shipyard Facilities: Hull production, Outfitting, Pipe work, Painting, Erection and launching Tutorial2:Ashipyardwishestoinvestonapanellinetohelpintheproductionof3
SHIPDATA;No.ofpanels/ship=200,No.ofplates/panel=4,No.ofsections/panel=
areas, Fabrication workshops, subassembly, assembly and unit assembly, Block assembly, 15,Boughtinplatesize=12m*3m,Boughtinsectionsize=12m.SHIPYARDDATA;No.
outfitting,paintingworkshops. ofworkingweeks/year==47,No.ofworkinghours/week=40,Overallutilizationfactor
SteelStockyardBackground:Accessfromroadorsea,Plate/sectionstockyardisarrangedfora =70%.EQUIPMENTDATA;No.ofE.O.T.cranes=1,Timetoliftandalignaplate==6
direct feed of material into the preparation shops, Stacking plates, flat or vertical, Material mins,Timetoturnoverapanel=30mins,Timetotransportfinishedpanel=20mins.
EQUIPMENT DATA; Welding speed of submergedarc machines = 0.4 m/min, Setup
storageareas,Structureofground,cementortimber,Accessbetweenpiles time/seam = 5 mins, Speed of filletweld (gravity) machines = 0.7 m/min, Setup
time/stiffener=5mins/side,
a)No.ofE.O.T.(ElectricOverheadTravelling)cranes
for return of outgoing or rejected materials Additionally: No. of piles required for standard Timetoliftandalignplates=3x200x4x6/60=240hrs
plates/sections,No.ofpilesrequiredforpreparationmachines,No.ofpilesrequiredforweekly Timetoturnoverpanel=3x200x30/60=300hrs
loads,howtodealwithprioritymaterial,howtodealwithQ.C.inspections. Timetotransportfinishedpanel=3x200x20/60=200hrs
SteelStockyardSurfaceLoadingandCraneUtilization: Totalrequiredcranetime=240+300+200=740hrs
Surface loading = Weight per pile (tones) / Area (m^2). Stockyard efficiency can greatly be Craneutilisation=740/1,316x100=56.23%
affected by the handling facilities, i.e.: The number of stockyard cranes available, The (1,316hrs=47x40x0.7),concluding1craneisadequate
transverse/longitudinaltravelspeedofcrane,Capabilityofcranetoliftsingleormultipleplate b)Portablesubmergedarcweldingmachines
lifts using magnets, Crane Utilization = Actual hours worked / Total hours available Crane No.ofseamstobewelded=3x200x3=1800
Utilizationshouldbelessthan1. Setuptime=1,800x5/60=150hrs
Steel Treatment: Plates are generally blasted and primed at the shipyard before fabrication. Totalweldedlength=1,800x12=21,600m
Blastingremovesmillscale andcleanstheplate.Millscaleis formedontheoutersurfacesof Weldingtime=21,600/(0.4x60)=900hrs
plates,sheetsorprofileswhentheyarebeingproducedbyrollingredhotironorsteelbilletsin Totaltime=900+150=1,050hrs
rollingmills;initiallyprotecttheplate,butifthereisanybreakonthescale,wehaveaccelerated Submergedarcweldingmachineutilisation=1,050/1,316x100=79.8%
corrosion.Primerprotectsthesteelduringfabricationandprovidesasurfaceonwhichfinalcoats (1,316hrs=47x40x0.7),concluding1machineisadequate
of paint can be applied without a major cleaning operation. Plates are lifted from stockyard, c)Filletweldingmachines
processedandthendeliveredtoplatepreparationareaforsubsequentoperations. No.ofsections=15x200x3=9000
PlatePreparationAreaandItsProcesses:Thefunctionoftheplatepreparationareaistoprepare Setuptime(bothsides)=9000x5x2/60=1500hrs
plate edges and form the plates into required shapes for subsequent welding and assembly Totalfilletlength(bothsides)=9000x2x12=216000m
activities.Platepreparationitselfmayrequiremarking,cuttingand/orshaping.Marking.Cutting: Weldingtime=216,000/(0.7x60)=5,143hrs
Mechanical(forthinplates)Shearing,Planning,Milling.Oxicutting,plasmacutting(820mm), Totaltime=5,143+1,500=6,643hrs,
lasercutting.Shaping(eithercoldformingorlineheating):Rolling,Flanging,Pressing,Lineheat Filletweldingmachineutilisation=6,643/1,316x100=505%
shaping(applyheat,expansion,contraction,bend). Layout Performance: CRITERIA Cost minimization, Transport distance minimization,
Plate Preparation Area Requirements: Treatment, Preparation, then Marshalling. For Maximizationofthevolumeoftransportedunits,Maximizationofcommunicationand
maximizationofareautilization:Workingareasneedtoincludemachiningitself,workingarea control CRITERIA SELECTION Physical attributes of the product, Volume of units
aroundmachineryandstowageareaetc.Platestowageareastowageplatesintomachinepiles. travellingamongstprocesses,Frequencyoftransportationamongstprocesses,Material
Bridging area. Repair of burned plates. Wooden pallets. Containers for scrap materials. handlingcost(costpermovementxnumberofmovements).
Marshallingarea.Walkwaysandroadways ShipyardLayoutFactorseffectingthedevelopmentoffacilities:Weldedships,Block
SectionPreparationArea:Thefunctionofthisareaistomark,burn,punch,formandmarshal assembly, Cranes, Ship types, Ship dimensions, Dry docks, Gantry cranes, Cutting
sectionsreadyforthenextoperationoffabrication.Sequenceofflowisasfollows:Sections systems, Panel & Web lines, Automated welding systems, Preoutfitting, Type and
fromthestockyard,Sectiontreatment. numberofshipstobebuilt,Arearequirement,Existingarea,Degreeofmechanization,
SectionPreparationAreaTypicalMachinery:Beambender:tobendvarioustypesofsections, Material handling and transfer systems, Productionmethods adopted, NC processes,
i.e. camber deck beams, also used to straighten sections which might have been distorted PanelLines,Blockandsubassemblies,Shotblastandpainting,Coveredspace
(shipyard preference for straightening sections), typical production rate is 20 sections/hour. Differentshipyardtypesandlayoutsdependingon:Sizeofshipsbeingbuilt/repaired.
Framebender:tobendshellframesbyprogressivemethod:theframesareclamped,bent,fed Specificsiteselectedforshipyardlayout(e.g.portarea,remotelocation,waterdepth,
throughcontinuouslyandprogressivelyafootatatime,typicalproductionrateis3pairs/dayfor nearbyresidentialarea,workersaccommodationetc.).Proximity to sources of raw
S shaped frames and 22 pairs/day for simple parabolic shaped frames. Portable bending material etc. Proximity to ship operations (e.g. North Sea, Far East, Middle
machines:sectionsaremoreirregularthanplatesand,onaverage,eachsectioniscutinto21/2 East, Mediterranean Sea), Environmental conditions, Governmental
facilitation, Financial resources available
parts/section.Eachpartcanhaveanendpreparation.
SectionPreparationAreaLayoutConsiderations:Machinesandbufferareasshouldbearranged
to provide an orderly flow of material without the needto backtrack. The section bay can be
consideredtohave4majorflowlines(acombinationofaseries/parallelarrangement).Buffer
areas should be allocated and adjacent to work sites. Finally, sufficient space must also be
providedforwalkways,clearwaysforforklifttrucks,containersforscrap.
SteelworkFabrication:Thetopicscovereduptonowlookedathowplatesandsections(profiles)
aretobestockedinitially,treated,cut,edgepreparedandshapedintocomponentparts.Steel
Fabricationdealswiththemannerinwhichthecomponentpartsarefabricated,undercoverin
shops, into an assemblage for subsequent joining on an erection berth or building dock. The
sequenceofworkinthiscategoryisbroadlydivided,dependingonsizeandtypeofshiptobe
built,intosubassemblyandassembly.Subassemblies:aregenerallyregardedasbeingminor
fabrications,assembledfrompreparedplatesandsections.Suchfabricationsareofarepetitive
naturewithsimilargeometryandscantlingsoveralargeproportionoftheshipslength.
Steelwork Fabrication Types of Assemblies: Subassemblies. Main unit assemblies: Flat unit
assemblies, Curved unit assemblies, Threedimensional unit assemblies, Block assemblies.
Orthogonalassembliesornonorthogonalassemblies.
Tutorial1:Ashipyardistenderingforten60,000DWTtankersalltobedeliveredwithinoneyear.
Information available is as follows: SHIP DATA: No. of plates/ship = 5000. Weight of steel
plates/ship==9,000tones.Averageplatedimensions==9m*3m.SHIPYARDDATA:Stockyard
handlingfacilities=1Goliathcrane.Areaavailableforplatepiles=5,000m2.Surfaceloading==
3tones/m2.Averagestockturnover=8weeks,Companyholidays=3weeks(summer),2weeks
(winter),Productionweek==Two8hourshifts,5days/week.Assumethataveragenumberof
movesperplateis4(unload,sort,2ndsortandpile),andthattheaveragetimepermoveis3
minutes.
a)Calculatetheaveragenumberofplates/pile.
Numberofplatesinstockyard=8/47x10x5,000=8510
Numberofavailablepiles==5,000/(9x3)=185
Numberofplatesperpile==8510/185=46
b)Whatisthesurfaceloadingofthisallocation?
Weightofplatesinstockyard==8/47x10x9,000=15,319tones
Weightofplatesperpile=15,319/185=82.8tones
Surfaceloading=82.8/(9x3)=3.07tones/m2
c)Whatisthecraneutilization?
Numberofplatesperannum=50,000(10x5,000)
Numberofmovesperannum=4x50,000=200,000
Actualhoursrequiredperannum=4x50,000x3/60=10,000
Availablehoursperannum=(2x8)x5x47=3760hours
Craneutilization=actual/available=10,000/3,760=2.661craneunabletomeetdemand
d)Commentupontheresults.Recommendeither:purchaseoftwomorecranes;ortenderingfor
partofordertomatchexistingcranefacilities;orcreatingadditionalstockyardfacility;or
reducenumberofplatemovementsinstockyardthroughplanning.