Chapter 4: Shipyard Practice

4.1 Shipyard Layout

An ideal layout for a modern shipyard is based on a production flow basis, with the yard extending back
from the river or shore at which the berths or building dock are located. The furthest area from the berths
is reserved for the material stockyard, and between the two are arranged in sequence the consecutive
work and shop processes. Too often existing shipyards follow the river bank, and are restricted by their
location in a built-up area or the physical river bank slope from extending back from the river, so that
modified production flow lines are required.

Planning a new shipyard, or re-planning an existing one, will involve decisions to be made on the
following:

Size and type of ship to be built.

Material production per year to be achieved.
Material handling equipment to be supplied.
Machining processes to be installed.
Unit size and weight to be fabricated and erected.
Amount of outfit and engine installation to be undertaken
Control services to be supplied.
Administration facilities required.

Shipyards usually have a fitting out basin or berth where the virtually completed ship is tied up after
launching and the finishing off work is completed. This is provided with adequate craneage and the
outfitting and machinery shops are usually adjacent to it.
4.2 Ship Drawing Offices
The ship drawing office is traditionally responsible for producing detailed working structural and general
arrangement drawings for parts of the hull and outfit. Structural drawings prepared by the drawing office
will
be in accordance with Lloyd’s or other classification rules and subject to their approval; also, owner’s
additional requirements and standard shipyard practices are incorporated in the drawings. General
arrangements of all the accommodation and cargo spaces and stores are prepared, which allow for
statutory requirements as well as shipowner’s requirements and standards. Other outfit plans, piping
arrangements, ventilation and air conditioning (which may often be done by an outside contractor), rigging
arrangements, and furniture plans, etc., are also prepared. Manual drawing is replaced by CAD / CAM
/CAE.

4.3 Plate and Section Preparation

Stockyard - On arrival at the shipyard, plates and sections are temporarily stored in the stockyard. As a
rule, the stockyard is an uncovered space having sufficient area to provide storage for enough plates and
sections.

Shotblasting - Plates and sections are in most cases now shot blasted to remove rust and mill scale.

Priming Paint - Following the shot blasting of plates and sections, the material passes immediately
through an airless spray-painting plant. In one pass the material is automatically sprayed with a priming
paint of controlled coat thickness. Following the priming paint stage, a drying process may be provided.

Plate handling in Machine Shops - Throughout the machining shops overhead electric cranes having
capacities from 5 to 15 tonnes may be provided to transport plates and sections to each machine process.
Individual machines may have jig cranes mounted on the frame which can be employed to handle the
plate during the machining process.

4.4 Plate and Section Machining

Plasma Cutting Machine - Plasma cutting is a process that utilizes an optimized nozzle orifice to constrict
a very high-temperature, ionized gas so that it can be used to melt and sever sections of electrically
conductive metals. The plasma arc melts the metal, and the high velocity gas removes the molten
materials.

Hydraulic Press - A hydraulic press is a device used to press out materials, aiding facilities in fabrication,
assembly and maintenance. It employs pressure generated by a pump to push a steel cylinder into a
material at a set force. Hydraulic presses may be extensively used in the shipyard for a variety of
purposes. They are capable of bending, straightening, flanging, dishing, and swaging plates. All of the
work is done with the plate cold, and it is possible to carry out most of the work undertaken by a set of
rolls.

Plate bending Machine - The plate roll machine is hydraulic driven and electro-hydraulic controlled,
capable of accomplishing the processes of rolling steel plate into half-cylinder or conical shape for
shipbuilding. Heavy duty bending rolls used for rolling shell plates, etc., to the correct curvature are
hydraulically operated.
Two lower rolls are provided and are made to revolve in the same direction so that the plate is fed
between them and a slightly larger diameter top roll which runs idly. Either or both ends of the top roll may
be adjusted for height, and the two lower rolls have adjustable centres. With modern bending rolls, plates
up to 45 mm thick may be handled and it is possible to roll plates to a half circle.

4.5 Sub – Assemblies or Panel Fabrication

When plates and sections have been machined, they are ready for assembly into ship units. Panel
assembly is usually highly automated with prepared plates being placed and tack welded prior to
automatic welding of the butts, after which the plates are turned and back welded unless a single sided
weld process has been used. The panel is marked and the stiffeners placed and welded automatically or
with semi-automatic process. Minor sub-assemblies such as deep frames consisting of web and welded
face flat may also be attached at this stage. Curved shell plates are placed on jigs and welded and the
various stiffening members can be aligned and welded in a similar manner to those on a flat panel
assembly.

4.6 Unit Fabrication and Unit Erection (Block Fabrication)

 Joining of two or more subassemblies or panels is called as a Unit Fabrication
 Joining of two or more Units is called as Unit Erection or Block Fabrication

In most instances the 2-dimensional sub-assemblies will be built into 3-dimensional block assemblies. The
size of the block assembly will have been decided at an early stage of the planning process ideally at the
structural design stage. Constraints such as lifting capacities and dimensions that can be handled are
taken into consideration also the provision of breaks at natural features ensuring the blocks are self-
supporting and easily accessed, etc. Panel assemblies used in the block may well have dimensions
restricted by the plate length that can be handled at the machining stage and this can subsequently
influence block length.

Outfit Modules

Units of machinery, pipework and other outfit systems required for a specific zone can be planned and
built up into modules and installed as such into a block fabrication. Modules can range from a small pipe
bank supported by light framing of pipe hangers, or a complete auxiliary machinery unit on its seating
which
has even been test run prior to installation, to a large modular unit which together with several similar units
constitutes the bulk of a complete engine room.
Superstructure blocks are fabricated separately and pre-outfitted with accommodation before erection as a
complete unit.

Outfitting deals with various machineries and ship systems onboard the vessel. The team carries out
necessary machinery installation, piping installation, electrical installation and other miscellaneous ship
equipment's during the construction.

Machinery Installation include propulsion system of the vessel, auxiliary generators, and auxiliary
machinery such as Air Compressors, FW generators, pumps, heat exchangers, steering gear,
Navigational equipment’s, Lifesaving appliances, Firefighting appliances, Galley Installation, Refrigerating
Compressors, Cargo gear, Anchor Windlass, Capstan, bollards, railings, bulwarks, Fair leads.

Piping installation includes SW Cooling system, FW cooling System, Fuel oil system, Air Starting system,
service air system, Lube oil system, FW and hydrophore system, Firefighting system, Ballast system,
Bilge system, Sounding pipes, Tank Air vents, etc.

Electrical installation includes installation of electrical and electronic system such as bridge equipment's
Radar, INMARSAT C, GPS, Anemometer, Navtex, engine and propulsion control systems, tank
monitoring systems etc.

Testing and commissioning of these items are partially done at Block fabrication stage and majority are
done while ship is launched in water

Sequence of erection

4.7 Block Erection

Joining of two blocks is called as block erection.
4.8 Ship Launching, Sea Trials and Commissioning
4.8.1 Launching of ship
Launching of ships is one of the most important procedures of the entire ship construction process. The
ship launching slipway, a structure consisting of a sloping way down to the water from the shipyard, is an
essential aspect of the ship launching procedure and has been extensively used for launching newly made
or repaired ships.

Traditionally, ship launching in the water is done using four main types of methods. These methods are:
1. Gravitational type launching
2. Floating-out type launching
3. Mechanical Type launching
4. Airbag launching

Gravitational type launching: The gravitational type launching system is further divided into three main
types, which are:

Longitudinal Oiled Slideway Launching - The longitudinal oiled slideway launching is one of the oldest
forms of launching systems. Using this system, the ship slides on a slideway and under its own weight
enters the water. Oil or wax is used to assist in the sliding process.

Longitudinal Steel – Roller Slideway Launching - In this type of ship launching method steel rollers are
used instead of oil to reduce friction during sliding. This method uses high-intensity steel rollers, security
devices, and steel board for the launching. The steel plate on the wooden slide helps in the sliding
process and the slide rails help them to protect from steel balls.

Side Oiled Slideway Launching - The side oiled slideway launching system is also one of the most widely
used ship launching systems.

Floating-out type launching: The floating out type launching is carrying out for ships which are built in
dry-docks and are launched by filling the dock with water. (Technically this is not a ship launching
procedure) The floating-out type launching system is a simple, effective, and safe procedure. Though the
initial investment is high, this type of method is most widely used by shipbuilders.

Mechanical Type Launching

This launching method spans a wide range of ships. This method incorporates a mechanical system such
as a crane, winch, or a ship lift to launch a ship into the water. It comes with a variety of restrictions such
as expenditure of setup and maintenance is prohibitive, and the controlling factors are also limited.

The mechanical type ship launching system can be divided into following types:

 Longitudinal mechanized slideway launching

 Two points longitudinal mechanized chute launching
 Wedge-shaped mechanized vehicles launching
 Slope change transverse area mechanized vertical chute launching
 High-low track slide mechanization launching
 Mechanized comb slide
 Lifting ship equipment

All the above-mentioned system requires a mechanical feature to launch a ship. The construction and
maintenance expenditure are high, whereas the mobility and controlling factors of the systems are not up-
to-the-mark. All these methods are mainly used for smaller size vessels and cannot be used for large, high
tonnage ships.

Air bags Launching – Launching ships using air bags is an innovative and safe technique to launch ships
in water. These airbags are usually cylindrical in shape with hemispherical heads at both ends. They are
made of reinforced rubber layers and have high load capacity. This method can easily be used in all types
and sizes of vessels.

4.8.2 Sea Trials

Sea trials are conducted to measure a vessel's performance and general seaworthiness. Testing of a
vessel's speed, manoeuvrability, equipment and safety features are usually conducted. During a sea trial,
you take the boat on the water and operate it under the same conditions you would on a typical boating
trip, including varying speeds, manoeuvring on different water conditions and adding extra weight on
board. There may be one or two sea trials scheduled, each lasting between one and four days, depending
on how much new technology has been included in the ship's design. The first in a new class of ships is
likely to undergo longer and more rigorous sea trials than subsequent ships in the class.
4.8.3 Ship Commissioning
Ship commissioning is the act or ceremony of placing a ship in active service, and may be regarded as a
particular application of the general concepts and practices of project commissioning.