COURSE: SHIPYARD TECHNOLOGY

CODE: MAR 223

CLASS: ND II

PREPARED BY : WILLIAMS E EKWERE

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 COURSE OUTLINE
1. Understand Shipyard practices as a course of study
2. Understand Modern and Ultramodern Shipyards
3. Understand activities of various sections in a ship
4. Understand various materials used for the construction of vessels and their
properties
5. Understand safety practices in shipyard workshops
6. Know Piping systems and method of Installing Machinery
7. Know Inspection, Launching and Trial Procedures for Vessels
8. Understand General Safety Precautions in Shipyards

TYPES OF SHIPYARD
Shipyards are classified into different types based on their size, function and
the types of ship they handle. These include: New build Shipyard, Repair
Shipyard, Breakdown yards, Large Shipyard, Small Shipyards, Military
Shipyard and Commercial.

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TYPES OF SHIPYARD – BASED ON PURPOSE AND
FUNCTIONS
- Ship Construction Yard
- Ship Repair Yards
- Offshore Construction & Repair Yard
- Ship Breaking & Recycle Yard
A Shipyard is an industrial facilities specialized in the design, construction and
repair of ships and vessels.

TYPES OF DOCKING FACILITIES

Dry docking – Is a process design for lifting ships out of the waters to enable
work to be done on the ship hull and areas below the water line that is
portion submerged in the water.
 GRAVING DOCK – Is a large permanent stimulated where water is
pumped out after the ship is floated in, leaving it rested on a dry
platform.
 FLOATING DOCK – Moveable Platforms that can be submerged and
raise to lift a ship.
 SLIP WAYS – Inclined vamps that ships are piled into using winches
rails.
 MARINE RAILWAYS – Similar to Shipways but typically used for larger
vessels.

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 SYNCROLIFT – A vertical lift system that raises a ship from the water
using a platform.
 BOAT LIFTS – Similar to syncrolifts but smaller often used for pleasure
Boats and Yachts.
 WET DOCKS (HARBOR DOCKS) these are used for berthing ships to
load and unload passenger and cargo.
HOW TO DRY DOCK A VESSEL
1. The dry dock is flooded and the ship is floated in
2. The gate is sealed and the water is pumped out allowing the ship to
rest on a dry platform.
3. Maintenance and Repairs are performance
4. The dry dock is reflooded and the Ship is launched

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SHIPYARD WORKSHOP
A Shipyard Workshop is a specialized facility within a shipyard were various
ship related tasks are performed. Examples are Steel Workshop for cutting
and assembling ship plates, pipe workshops for manufacturing and repairing
pipes and mechanical workshops for Engine Maintenance and repair. Others
are specialized in Electrical work, outfitting insulation, or even furniture
making for the ship.

STEEL WORKSHOP
This workshop handles the cutting, bending, welding and assembly of Steel
Plates and sections for the ship hull and structures.
PIPE WORKSHOP: This workshop focus on the fabrication and repair of pipe
lines used for various system onboard such as fuel, water and sanitation.
MECHANICAL WORSHOP: This workshop is responsible for the
maintenance and repairs of the ship’s Engines pumps and other Mechanical
equipment.
ELECTRICAL WORKSHIP: This workshop deals with the installation,
maintenance and repair of Electrical system, wiring and Electronic
Equipment onboard.
OUTFITTING WORKSHOP: This workshop deals with the installation of
various ship accessories including ladders, stair ways, windows, doors and
other interior fittings.
INSULATION WORKSHIPS: This workshop focuses on the Installation
materials for various purposes such as heat protection, fire protection and
noise reduction.
FURNITURE WORKSHOP: This workshop might be involved in the
fabrication and assembly of furniture and interior wood fabrication.
RUDDER, PROPELLLER AND SHAFT WORKSHOP: This workshop focusses
on the maintenance and repair and replacement of the ship’s rudder
propeller and shafting systemic.

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SHIPYARD LAYOUT I

SHIPYARD LAYOUT II

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DESCRIPTION OF THE WORKING AREAS
ADMINISTRATION AREA.
This is the central hub for managing all the administrative tasks related to
the Shipyard.
PLATE AND SECTION STOCKYARD
This area stores raw materials like steel plate and sections that are used to
build the ship.

MARSHALING & PREPARATION

Here materials are organized and prepared for further processing such as
machining.
PLATE AND SECTION MACHINING
This is where materials are cut, shaped and prepared to specific dimensions
for assembly.
UNIT ASSEMBLY: Smaller Units or sections of the ship are assembly in area,
forming larger block.

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PIPE AND ENGINE SHOP: This ship handles the fabrication and installation
of piping system and Engine Components.
BLOCK FABRICATION: Larger blocks of the ship are assembled and welded
together here.
OUTFIT SHIPS: Equipment such as pipes, Cables and other items are
installed on the blocks in these shops.
STORES: These areas house various material needed for repairs overhauls
and new construction.
TOOL CRIBS: Shipyards have central and individual tools cribs for storing
and accessing tools.
OPERATIONS OFFICER: These includes design offices, planning officer and
other specialized areas for project management.
SECURITY: Security Personnel manage access, check ID and direct visitors
WAYS: Standing structures that support the ship under construction, often
constructed of concrete and wooden blocks,
FUNCTIONS OF A SHIP DRAWING OFFICE: The ship drawing office was
traditional responsible for producing detailed working structural general
arrangement and outfit drawings for a new ship. Is the hub for creating
details plans and drawing necessary for ship building, ensuring the structure
and systems of the vessel are built according to specifications and
regulations? Theses drawings serve as a blue print for construction, girding
ship builders and ensure compliance with classification society rules and
international standards.
KEY FUNCTIONS OF A SHIP DRAWING OFFICE
1. PRODUCING WORKING DRAWINGS: Creating detailed structural
general arrangement and outfit drawings, including lines plan, steel
structure details, accommodation spaces, and piping, Electrical
Installations and machines layouts.
2. ENSURING COMPLIANCE: Adhering to classification society rules and
regulations including Lloyd’s and obtaining their approval for structural
drawing.
3. SUPPORTING CONSTRUCTION: Providing the necessary drawings for
ship builders, allowing them to construct the vessel according to
design specifications.
4. DEVELOPING 2D AND 3D CAD DRAWINGS: Utilizing computer-aided
design software to create various ship components and layout.

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UPDATING DRAWING
Maintaining and updating drawings to reflect as- built conditions and
modifications made during construction.
CREATING SAFETY AND FAIR PLANS: Developing plans according to
international Maritime Organization (IMO) requirements, ensuring safety and
emergency response procedures are clearly outlined.

GENERATING CAPACITY PLANS: Creating drawing that details the ship’s

cargo capacity, fuel storage and other operational parameters.
PRODUCING, DOCKING & BERTHING LAYOUTS: Developing plans for
maneuvering and docking the ship in various ports and harbours.
GENERATING STEEL DRAWINGS: Creating details drawings of the ship’s
steel structure, including plastic, framing and connection.
CREATING OUTFITTING DRAWING: Developing drawings for various ship
systems including piping, electrical, HVAC AND OTHER ESSENTIAL
COMPONENTS.
STEEL ORDERING AND STORAGE: Steel ordering and storage require
careful planning to ensure timely delivery, prevent damage and maintained
the materials integrity Ordering involves selecting the correct steel type,
grade of steel, quantity and size, while storage focuses on preventing
corrosion, deformation and theft.
ORDERING
Define Requirements
Before placing an order clearly define the steel’s intended use, considering its
properties (Strength, Corrosion Resistance etc.) and the specific project needs.
CHOOSE THE RIGHT TYPE: Different types of steel (Carbon, Stainless alloy, tool
steel). Offer unique properties suitable for specific applications.
SPECIFIC GRADE: Within each steel type grades vary in chemical composition and
mechanical properties. Select the appropriate grade based on the projects
requirements

DETERMINE SIZE & QUANTITY: Precisely specified the dimensions (Length, width,
thickness) and the require quantity for each steel item,
CONSULT WITH THE SUPPLIER: Engage with requirements, receive quotes and
ensure timely delivery.

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STORAGE
Indoor storage: Storage Steel indoors is preferred especially for mild steel which is
prone to rust in a well – ventilated area to prevent moisture build-up.
OUT DOOR STORAGE
If outdoor storage is necessary, protect Steel from rain and direct sunlight,
potentially using tarps or covers.
SEPARATE BY TYPE
STORE different types of steel separately to avoid contamination and potential
reactions.
PREVENT RUST
Use corrosion distributors (rust preventives) if necessary especially for steel
exposed to moisture.
ENSURE GOOD VENTILATION: Adequate Ventilation helps prevent moisture build
–up and potential rust formation
SECURE STORAGE: Employ Security measure to prevent theft and unauthorized
access to the stored steel.
REGULAR INSPECTION: Periodically inspect the Stored Steel for any sign of
damage coating deterioration or deformation, and address any issues promptly.
PROPER HANDLING: Use appropriate handling equipment (Forklift cranes etc) to
prevent damage during loading and unloading of the steel.
SHIPYARD FACILITIES

Shipyard Facilities are Specialized Infrastructure designed for ship building,

repair and maintenance activities. These facilities include dry docks, wet
berths, fabrication shops and other supporting infrastructure. They provide
the necessary space, equipment and expertise to handle various vessel
types, from commercial ship to military ships.
KEY FACILITIES IN SHIPYARD
1. Dry dock – Structure that allow ships to be lifted out of the water for
repair and maintenance work.
2. Wet Berth/Docks – Areas where ships can be docked for loading and
unloading and other actions.
3. Fabricated shops – Area where ship components are fabricated and
assemble.
4. Cranes and lifting equipment – used for handling heavy ships
components and materials.

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 5. Warehouse and storage facilities – used for storing materials,
equipment and other supplies.
6. Office & Administrative Buildings – Housing the ship yard staff and
administrative functions
7. Welding and Painting Shops – Specialized areas for performing these
essentials ship construction tasks.
8. SLIP WAYS –Structures used to launch and retrieve ships from the
water.
9. Power & Utility System – Providing essential services like electricity,
water and Compressed air.
10. BOLLARD PULL TEST FACILITIES – used to test the bollard pull
strength of ships
11. Training and Certification Facilities – used for training ship yard
staff and certifying their skill.
12. COMPUTERIZED DESIGN & ENGINEERING SYSTEMS – Used for
planning and designing ships
13. Quality Control and Testing Laboratories - Used for ensuring the
quality of materials and workmanship.

EQUIPMENTS USED IN A SHIPYARDS

Shipyard Utilized a wide array of equipment to build, repair and maintain
vessels. This includes heavy machinery for lifting, cutting and welding as
well as specialized tools for Navigation, Communication and Safety.
Common equipment includes Cranes, Welding Machines, Cutting Tools and
others.
1. LIFTING GEARS – Used for lifting and moving heavy items e.g. hull
sections, machinery and other materials.
2. Welding Machines – Essential for joining metal or steel plates and
other components to build the ship structures.
3. CUTTING MACHINES – Used for cutting Steel and other materials to
the precise shapes and sizes required for ship construction.
4. Hydraulic Metal Cutting Shears – Used for cutting large plates of
metal.
5. Navigation and Communication GPS – Used for precise positioning
and Navigation, especially for large vessels. RADAR – Provide a wide
view of the Ship’s Surroundings including other vessels and obstacles,
aiding in Navigation and collision avoidance. ECHO Sounders – Used
to measure water depth, which is crucial for safe navigation in Coastal
Waters and Rivers.

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6. GYRO COMPASS –Provides a reliable direction indication, independent
of the ship’s movement especially useful in adverse weather
conditions.
7. AUTO PILOT – An Automated steering system that helps the ship
maintain course and avoid collisions.
SAFETY AND MAINTENANCE
LIFE JACKETS – Essential for ensuring the Safety of crew and passengers
during emergency.
IMMERSION SUITS – Provide protection against cold water and
hypothermia in case of a ship sinking
BILGE PUMPS – Used to remove water that has accumulated in the bilge
(the lowest part of the ship)
GENERATORS – Provide Electrical Power for various onboard systems
and appliances.
PERSONAL PROTECTIVE EQUIPMENT (PPE)
Includes Protective clothing, gloves, goggles and welding shields to
protect workers from hazards.
SPEED LOG – An Instrument used to measure the speed of a ship.
TOWING WINCHES – USED IN TOWING Ships and other floating vessel.
FUNCTION OF A PRODUCTION DEPARTMENT
In a Shipyard the Production Department is saddle with the responsibility
of planning, Co-coordinating and executing the construction of ships,
ensuring they are built on time and within budget. This include
overseeing the transformation of raw materials into finished products,
managing resources, and ensuring quality standards are met.

PLANING AND SCHEDULING

The Department develops detailed production plans, including timelines,
resources allocation and production Schedules to ensure timely delivery
of the ship.
PROCUREMENT
They are responsible for procuring the necessary raw materials,
equipment and labour required for the ship construction process.

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MANUFACTURING
The Department oversees the actual construction process, including the
assembly of ship components, welding and fitting out the vessel.
COST MANAGEMENT
The department manages the Costs associated with the production
process aiming to keep costs within budget.
EQUIPMENT MAINTENANCE
They ensure that the production equipment is maintain and keep in a
good working order.

INVENTORY MANAGEMENT
The production department manages inventing levels ensuring that the
necessary materials and components are available when needed.

ENGINE SHOP
In a shipyard the primary function of the Engine shop is to maintain,
repair and overhaul ship engines and related machinery. This include the
main propulsion machinery and Auxiliary engine that power essential ship
systems. They also installed new engines components into ship during
construction. Diagnosing and addressing engine related issues including
electrical, Mechanical and hydraulic problems offering specialized services
such as engine upgrades, reconditioning of engine components.
BOILER SHOP
In the shipyard the boiler shop’s primary function is to manufacture,
assembly and maintain marine boilers which are essential for generating
steam that power the ship’s engine and various other onboard systems.
Boiler are crucial for ship propulsion, heating, cooking, cleaning and
emergency backup power. The shop involved in designing and
construction of marine boilers often using steel or other suitable
materials. This includes fabricating boiler shells, tubes, heating surfaces
and other various components.
FOUNDRY AND BLACKSMITHS SHOP
In a shipyard the foundry produces cast metal components like ship’s
wheel hardware and various fittings, while the blacksmith shop handles
the forging and shaping of metals including repairs, welding and creating
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custom parts. They both play a vital role in ship construction and
maintenance by providing essentials metal parts.
JOINERY SHOP
The joinery shop is responsible for crafting and installing the wooden
components of a ship focusing on both interior and exterior. This includes
creating fixtures, cabinetry, furniture and painting, often using custom
design to fit the ship’s specific contours. Joiners may also work with other
materials like linoleum or fiberglass.
PIPE SHOP
In the shipyard the pipe shop’s primary function, is to fabricate and
assembly piping systems, including pipe spools, for various ships and
vessels. This involves bending pipe, building complex piping system
performing brazing operations and testing piping systems and
components. The pipe shop also plays a crucial role in minimizing pipe
fitting and welding dining subsequent construction stages by
preassembling pipe spools.
LIGHT PLATE SHIP
In the shipyard light plate shop is responsible for preparing and shaping
steel plates for ship construction. These plates are the raw materials for
building the ship’s hull, Internal structures and various components. Is
also involve in cleaning to remove rust scale and other impurities using
automated blasting machines. Marking and cutting plates into sizes
according to the blueprint. It’s also involved in the bending plates using
the bending machine into any shape required.

FUNCTION OF MOLD LOFT SHOP

1. Translating Design Plan – Loft means take dimensions, specification
and other details from ship design plans and translate them into full
size templates and pattern
2. CREATING TEMPLATES – They create various templates, including
batteries, ordinates cutting sketches, profiles and margins to guide
construction. The template ensures that ships structural
components (like frames, bulkheads and decks) conform precisely
to the designed lines and specifications.
MORDENIZATION

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While traditionally using wooden templates modern mold lofts may
utilize advance techniques like 3A modeling and coordination
metrology to achieve the same goal.
FABRICATION SHOP

The fabrication shop is involved in the manufacturing and assembling

of the various metal components needed for ship construction.
METAL WORK – Is responsible for the manipulation and modification
of metals materials, including cutting, bending and shaping metal
sheets and structural components.
COMPONENT FABRICATION – Produce individual parts for the ship
such as hull plates, bulkheads frames and various structural
components.
WELDING – Welding is a crucial parts of a fabrication process, joining
different metals parts together to form larger structures.

THE ROLE OF QUALITY CONTROL IN THE MODERN SHIP

BUILDING PRATICE
In modern ship building, quality control plays a crucial role in ensuring
the Safety, reliability, and performance of vessels as well as meeting
regulatory standards and customer expectations. It involves
inspecting materials and processes: -
I. Ensuring Compliance with Standard. Quality Control ensures
that ships adhere to regulations set by organization like the IMO
and classification Societies.
II. Material Quality – Quality Control verifies that materials used in
construction meet specific quality Standards and Specifications.
III. Construction Standards – Quality Control ensures that
construction processes follow established industry standards and
best practices
IV. Inspection Test Plan (ITPS) – Quality Control utilizes ITPs to
identify critical processes and inspections require throughout the
shipbuilding process, from design to construction.
V. PROCESS CONTROL – Quality Control monitor key processes like
welding painting and Electrical Installations to ensure
consistency and prevents defects.

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 VI. DATA COLLECTION AND ANALYSIS – Quality Control collects data
on various aspects of the shipbuilding process, such as welding
quality material properties and dimension to identify trends and
areas for improvement.
VII. DEFECT DETECTION – Quality Control uses various methods
including visual inspections, nondestructive testing (NDT) and
dimensional check, to identify defects in materials and
construction. When defects are form, Quality Control works with
the builders to implement corrective actions such as rework
replacement or modification. Quality Control identifies the root
causes of defects and implement preventive measure to reduce
the risk of recurrent.
VIII. IMPROVING EFFICIENCY AND REDUCE COST BY MONITORY AND
ANALYSING DATA – Quality Control helps identify areas where
processing can be optimized to improve efficiency and reduce
cost. Quality Control will focus on early detection reduces the
need to rework later after. Completion of the process. Quality
Control fosters a culture of continuous improvement within the
shipyard leading to ongoing advancements in shipbuilding
techniques and quality standards.

STEEL PRODUCTION
Several types of steel are used for ship construction such as carbon steel,
mild steel, high tensile steel, alloy steel and stainless steel.
Specific grades like AH36, BH440, DH36 and EH36 are also utilized. The
choice of steel depends on the specific application and the required
properties such as strength, Corrosion resistance and weld ability.
1. Carbon Steel and mild steel – These are commonly used for hulls,
decks and general structural components due to their high tensile
strength, good workability and relative affordability. Specific grades
like Grade A, Grade ab, and Grade D are often used in ship building.
2. High tensile Steel – These steel offer higher strength and toughness,
making them suitable for areas experiencing high stress like keels etc.
Others are AH36 and DH36, which are commonly used in large ships
and luxury cruise ship.
3. ALLOY STEEL – Alloy steels are manufactured by adding others
materials like copper, nickel and aluminum to carbon steel. The offer

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 enhanced corrosion resistance and can be used for specific ship
components or machinery.
4. STAINLESS STEEL – Stainless Steel is known for its exceptional
corrosion resistance, making it an ideal for applications like hulls,
decks and fittings specific grades like 316lLand 2205 duplex stainless
steel are commonly used in harsh marine environment, also used in
piping tanks and bulkheads.
OTHER TYPES
Nickel alloy use in ship construction and offshore structures for strength
and fire resistance. Low temperature steel, used for vessels operating in
cold environments. High temperature steel used for components that
operate at high temperature. Cast steel used for components that require
high strength and durability.
L-D process of Steel Production
The L-D process, also known as the LINZ DONAWITZ or Basic Oxygen
process, is a steel making method where oxygen is blown into molten pig
to reduce its carbon content and transform it into steel. This process is
efficient and produces large quantities of high quality steel.
PROCESS OF STEEL ORDERING IN SHIP BUILDING
The process of steel ordering in shipbuilding starts with detailed design
drawings, followed by steel ordering based on those drawings. Steel is
then manufactured and delivered, stored and undergoes preparation
steps like cleaning and forming. Finally, it’s used in subassembly and the
final erection of the ships structure.

DETAILS STEP BY STEP OUTLINE IS AS FOLLOWS: -

1. DESIGN DETAILS: The process begins with the design stage
including both basic and the detailed design, Detailed drawing are
crucial for accurate steel cutting and fabrication
2. STEEL ORDERING – Based on the design drawings, the required
quality and specifications of steel are determined and an order is
place with approved steel manufacturing.
3. MANUFACTURING & DELIVERY – The steel is manufacture
according to the specification requirements outlined in the order,
including testing and certification. Its then delivered to shipyard for
storage.
4. STOCKYARD STORAGE – The steel is stored in the stockyard ready
for further processing and fabrication.

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 5. PREPARATION AND FABRICATION – Steel undergoes various
preparation steps, such as shot blasting, cleaning and forming to
make it ready for cutting, bending and welding.
6. SUB-ASSEMBLY & ERECTION – The preparation Steel is used to
fabricate Subassemblies which are then assessable and erected on
the berth to form the ship’s structure.
HEAT TREATMENT
Heat Treatment of steel involves a variety of processes that
manipulate the metal’s properties through controlled heating and
cooling cycles.
The four main types are Annealing, Normalizing, Hardening and
Tempering, each affecting the steel’s ductility, hardness and strength.
1. ANNEALING – This process softens the steel, increases its
ductility and relieves internal stress. It involves heating the steel
to a specific temperature, holding it there for a period and then
slowly cooling it down.
2. NORMALIZING – This process refines the steel’s grain structure
and improves the toughness by heating it to a temperature
above its upper critical point and then cooling it in air.
3. HARDENING – This process increases the steel’s hardiness and
strength, but also decreases its ductility. It involves heating the
steel to high temperature, rapidly cooling it (quenching) and then
optionally tempering
4. TEMPERING – This process applied after hardening to reduce
brittleness and improve toughness while maintaining some
hardness. It involves reheating the hardened steel to a lower
temperature and holding it there for a period before cooling.

PROCESS OF ALUMINUM PRODUCTION

Aluminum Production is a complex process that involves the mining or
extraction of bauxite ore, refining it to produce Alumina and then smelting
the alumina to extract our aluminum. The extract alumina can then be used
to manufacture a wide range of products. The alumina is refine using the
Bayer processes. Finally, alumina is converted into aluminum maggots
through an electrolytic process, primarily the Hall-Heroult process.

ALUMINUM ALLOYS

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Aluminum Alloys are classified into two main types, wrought and cast alloys.
Further categorized as heat – treatable and non-heat treatable. Some
common aluminum alloys include 2024, 5083, 6061, 7075, 6060, 5754 and
6082.
Wrought Alloys – These Alloys are mechanically worked into various shapes
like sheet bars and extrusions. 2000 series – feature copper as the primary
alloying element offering high strength but lower corrosion resistance
5000 series – uses magnesium as the main alloying element resulting in a
material with good workability and high tensile strength.
6000 series – Combination of magnesium and silicon, erecting a flexible and
ductile alloy.
7000 Series – Zinc is the main alloying element, offering high performance
under stress and good responsiveness.
CAST ALLOYS
These alloys are produced by pouring molten aluminum into molds e.g.
- SILUMIN - Aluminum – Silicon alloys known for their high thermal
conductivity and Corrosion resistance
- ALNICO – An aluminum – nickel – cobalt alloy with magnetic properties
- DURALUMIN – An aluminum alloy containing copper, magnesium and
manganese, known for its high strength
SHIP LINES PLAN
A lines plan is a two dimensional drawing that represents a ship’s hull form in
a flat perspective. It is essentially a blue print that shows the ships
geometry, including its curves, shapes and dimensions.

KEY ASPECTS OF A LINES PLAN

PROFILE (ELEVATION)
This views shows the side of the ship including the hull’s shape, deck lines
and any super structure.
HALF BREADTH PLAN (PLAN VIEW)
The view looks down onto the ship from above showing the contours of the
hull as it extends along the length.

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BODY PLAN (TRANSVERSE SECTION)
This view shows the cross sections of the hull at various points along the
length revealing the shape of the hull at each station.
WATER LINES
These are lines representing the water lines of different drafts of the ship
showing how the hull changes as the ship floats at various drafts.
STATIONS
These are vertical lines indicating specific points along the length of the ship
often used to referencing dimensions and features.
BUTTOCKS LINER
These are vertical lines parallel to the coveter lines showing the shape of the
hull from the centerline out ward

USES OF LINES PLAN

HULL DESIGNING
The lines plan is essential for designing the shape of the hull ensuring that its
meet the desired performance and stability requirements.
HYDROSTATIC CALCULATION
The lines plan is used to calculate the ships displacement, volume and other
hydrostatic properties.
STABILITY CALCULATION
It’s crucial for determining the ship’s stability and how it will respond to
various conditions

CAPACITY CALCULATION
The lines plan helps to determine the ship’s cargo capacity and other storage
volumes.
CONSTRUCTION
The lines plan is used as a reference for building the ship ensuring that the
hull is constructed according to the design specification.
ANALYSIS

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It is used for various analysis including stress analysis, hydrodynamics and
structural design
PROCESS OF HULL FABRICATION
The process of Constructing a ship or a boat’s hull, involves several key
stages; design, cutting, bending, welding and assembly. The stages
transform raw materials often steel plates, into the watertight structure of a
vessel. The process can be broadly divided into block construction.
HULL BLOCK CONSTRUCTION METHOD (HBCM)
1. Part fabrication: Steel plates are cut, shaped and prepared for
assembly
2. Part assembly: Individual plates are joined to form section.
3. Sub-block or semi-block assembly: Sections are combine to create
larger sub-assemblies.
4. Block assembly: Sub blocks are joined to form hull blocks
5. Grand Block-Joining: Blocks are joined together to form the complete
hull.
6. Hull erection: The assembled hull is placed on the building berth or in
dry dock for final outfitting.
KEY PROCESSES
1. Cutting: Steel plates are cut using various methods including laser
cutting and CNC machining
2. Bending: Plates are bend to form curved surfaces for the hull
3. Welding: Plates and other components are joined using welding
techniques.
4. Assembly: The fabrication parts are assembled, often in a modular
block construction approached.
5. Outfitting: once the hull is complete, it undergoes outfitting,
including installing internal structures, piping, electrical systems
and other components.
TESTING: The completed hull is tested to ensure its watertight integrity and
functionality.

MATERIALS USED
1. Steel: The most common materials for Ship building, requiring cutting,
bending and welding.

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 2. Fiber glass: Used in smaller boat construction involving laying
fiberglass cloth and resin in the mold.
MODERN ADVANCEMENTS IN FABRICATION TECHNIQUES
Laser cutting, CNC machining and robotic welding enhance accuracy and
efficiency.
DIGITAL DESIGN AND MODELING
Computer – aided design (CAD) and 3D modeling are used to optimized hull
design and fabrication process.
SURFACE PREPARATION
Surface preparation is a crucial process that involves treating a materials’
surface before applying anti-corrosive coatings, adhesives, or welding. It
aims to improved adhesion and enhance the material properties by removing
contaminants and creating a suitable surface profile. This can involve
mechanical methods like abrasive blasting or chemical treatments like
etching or solvent cleaning.
Use of abrasive blasting for surface preparation: A abrasive blasting,
also known as sandblasting or grit blasting is a process that uses a stream of
abrasive material propelled at high speed to modify surfaces. It’s used for
tasks like cleaning removing coatings, creating texture, and shaping
surfaces. The process involves using compressed air or water to direct
abrasive media against a surface.
PURPOSES
Abrasive blasting can be used for various purposes including.
- Surface cleaning: Removing rust, old painting or other contaminants.
- Surface preparation: Creating a rough surface for better adhesion of
coatings
- Surface modification: Smoothing rough surfaces or roughening smooth
surfaces.
- Shaping: Removing materials to create desire shape.
PROCESS
1. Abrasive materials (e.g. sand, metal grit or glass beads) is loaded into
a blasting pot
2. Compressed air or water is used to propel the abrasive through a
nozzle.
3. The abrasive stream is directed to the surface to be modify.

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SAFETY
Abrasive blasting can be hazardous due to dust ,noise, and potential
exposure to toxic materials. Safety precautions, such as using personal
protective equipment and proper ventilation, are crucial.
HYDRO BLASTING
Hydro blasting, also known as water blasting is a cleaning method that uses
high pressure water to remove deposits, scale and other materials from
surfaces. It is versatile technique used in various Industries for task like
cleaning pipes, stripping paint, and preparing surfaces for repair and coating
of the surfaces.
MECHANISM
Hydro blasting uses a high pressure pump to force water through a nozzle
creating a powerful jet stream.
APPLICATION
It’s widely used for cleaning pipes, removing scale from heat exchangers,
stripping paint from surfaces preparing concrete for repair and cutting
through certain materials.
ADVANTAGES
Hydro blasting is more efficient and environmental friendly than some other
cleaning methods like sand blasting as it uses only water and does not
generate dust or abrasive waste.
PICKLING PROCESS
Pickling is another method of surface preparation that uses acid solution to
remove impurities like rust scale, and oxide from metal surfaces particularly
steel. It is a chemical process that prepares the metal for further treatments
like coating, painting or cold rolling. This involves immersing metal in an
acidic solution, often hydrochloric or sulphuric acid. This solution dissolves
the unwanted surface layers, leaving behind a clean, reactive surface.
TYPES OF PICKLING
1. Sulphuric acid pickling – commonly used for steel often with inhibitors
to control the reaction.
2. Hydrochloric acid pickling – Another widely used method known for its
speed.
3. Electrolytic pickling - uses an electric current to enhance the pickling
process.

23
 4. Alkaline de rusting - Uses Alkaline solutions for removing rust,
particularly in specific applications.

BENEFITS
- EFFECTIVE REMOVAL OF SURFACE IMPURITIES: Pickling efficiently
removes rust, scale and oxides
- IMPROVED COATING ADHESION – A clean pickle a surface provides a
better foundation for coatings and paints.
- COST EFFECTIVE SURFACE PREPARATION: Pickling can be a relatively
in expensive way to prepare metal surfaces for further processing.

OXY-ACETYLENE FLAME PROCESS

The Oxy-acetylene process often known as gas welding, can be used for
surface preparation, particularly for cleaning, preheating and localized heat
treatment. It involves using a high temptation flame generated by burning
acetylene in oxygen to melt or heat the surface of a material. This can be
useful removing rust, scale or other contaminants from a surface or for
preparing a surface for welding or other processes.
Oxy-Acetylene can be used for other purposes like: -
1. Pre-heating – Oxyacetylene torches can be used to preheat metal
parts before welding or other processes, which can help to prevent
cracking or distortion during the process. Preheating can also improve
the flow of weld metal or the penetration of the heat into the work
pieces.
2. Localized Heat treatment – Oxy-acetylene flame can be used to
selectively heat space fix areas of a metal part, allowing for localized
heat treatment. This can be used for hardening or tempering specific
areas of part or for relieving internal stresses.
Hardening – Oxy-acetylene welding with a suitable filler rod can be
used to build up room surfaces with a hard, wear resistant material.
This process is known as hard facing is commonly used to restore worn
gear teeth, splines and other parts subject to heavy wear.
Cutting – Oxy-acetylene torches can be used for cutting metal by
heating the metal to its kindly temperature and then using stream of
oxygen to burn it away. This method is widely used in metal
fabrication and repair.
SAFETY PRECAUTIONS

24
 Proper Ventilation – Ensure adequate ventilation to remove fumes and
gases produced during the process.

PERSONAL PROTECTIVE EQUIPMENTS

Wear Personal Protective equipment such as glasses, hand gloves,
Safety boot apron, welding shield and coverall.

FLAME CONTROL
Use the correct flame adjustment for the specific application and
maintain proper torch handling techniques.

GASE SAFETY – Follow proper precedes for correcting and

disconnecting gas cylinder and regular check hoses and connections
for leaks.

HAND CLEANING
Hand cleaning also known as hand tool cleaning is a surface
preparation method that uses non-powered or powered hand tools to
removed loose contaminants like rust, mill scale and old paint from a
substance. it’s a common method for localized cleaning or when
powered tools are impractical or uneconomical while effective for
removing loose materials, hand cleaning typically leaves behind tightly
adhered contaminants.

TOOLS USED FOR HAND CLEANING

- Wire brushes: For removing loose rust and scale
- Scrappers – to remove paint and other loose coatings
- Chisel & Chipping Hammers: For removing stubborn or thick
layers of rust or scale
- Abrasive pads – to smooth surfaces and removed minor
contaminants
- Power brush – used for cleaning and removing of mill scale and
rust.
TYPES OF MARINE PAINT
Marine Paints used in a shipyard are formulated to with stand harsh marine
environments and protect various parts of a ship. Commonly types include
epoxy, polyurethane and antifouling paints, along with specialized coatings
like epoxy zinc rich primers, deck paints and bilge paints.
1. EPOXY PAINTS

25
 Properties – Excellent adhesion, durability and resistance to chemicals,
moisture and abrasion.
Application – Commonly used as primers on steel, aluminum and
fiberglass and as protective coatings for under water hulls and ballast
tanks.

Benefits – Provide a robust barrier against corrosion and wear

controverting to the longevity of the ship.
2. POLYURETHANE PAINTS –
Properties – High gloss, ultra-violent resistant and provides a hard,
protective finish with good chemical resistance
APPLICATION
Suitable for both Interior and Exterior application including top side areas
above the water line
BENEFITS
Offers a durable aesthetically pleasing finish while providing protection
against the elements.
3. ANTIFOULING PAINTS
Properties – Specialized Coatings designed to prevent the growth of
marine animals or organisms like barnacles on the hull.
APPLICATIONS
Applied to the hull below the water line where this organism tends to
attach.
BENEFITS
Helps maintain the Ship’s speed and fuel efficiency by minimizing drag
caused by bio fouling.
4. OTHER SPECIALIZED PAINTS
EPOXY ZINC RICH PRIMER – used as a primer for steel components.
Especially those submerged in water offering cathodic protection.

Deck Paints – Design to protect the deck areas of the ship from wear,
moisture and corrosion.
Bilge Paints – Specifically formulated to protect the bilge area of the
ship from corrosion and moisture.

Marine Varnish – Provide a protective and decorative coating for

wooden surfaces as well as other materials like steel polyester or
epoxy.

26
 TOPSIDE PAINTS
Applied to the top sides, or upper hull and deck areas above the
waterline offering protection against ultra violet damage and salt water
exposure.

ANTI – CORROSION COATINGS

Essential for steel – hulled ships, mitigating oxidation and metal
deterioration.

CAUSES OF CORROSION
Corrosion is a process where metals degrade due to reactions with their
environment, is primarily caused by exposure to substances like oxygen,
water, and other chemicals. Other factors like temperature, stress, and the
presence of impurities or pollutants can also accelerates corrosion.
1. METAL REACTION WITH OXYGEN AND WATER: The most common type
of Corrosion, like rust occurs when iron reacts into oxygen and water.
2. EMVIRONMENTAL FACTORS: Exposure to air containing gases like C02,
S02 and S03 as well as moisture (Salt water) can significantly
contribute to Corrosion
3. IMPURITIES AND POLLUTANTS: The presence of impurities like salts or
exposure to pollutants like Sulphur dioxide, can accelerate the
corrosion process.
4. Temperature can increase the rate of corrosion
5. Stress: Excessive stress on metals can lead to cracking and corrosion
6. ELECTRO CHEMICAL REACTIONS: In some cases, corrosion can occur
through electrochemical reactions between two different metals
coming in contact with each other.
7. OTHER FACTORS: Dirt, Bacteria and even Electrical currents can also
contribute to Corrosion.
TYPES OF CORROSION
 Galvanic Corrosion – This occur when two different type of metals
come in contact with each other through electron transfer.
 Pitting Corrosion – Is a localized form of corrosion that create small
cavity like holes or pits on a metal.
 Crevices Corrosion – Is the Corrosion that occur in a narrow confided
spaces where oxygen as limited like under gasket, bottle or in joints.
 General Corrosion – Is the type of Corrosion that occurs uniformly or
evenly across the entire surface of a metal.

27
  Fatigue Corrosion – Is a phenomenon where a metal material
experience cracking due to the combined effect of cyclic stress in a
corrosive environment.
 Cavitation Corrosion – Is a form of localized Corrosion that occurs when
the pressure in a liquid drops below its vapour pressure, causing bribes
to form and collapse on the metal in question.
 Selective leaching Corrosion – Is known as de alloying, where one
element is preferentially removed from, an alloy, leaving behind a
prone and weakened structure.
 Stress Corrosion – Is the acceleration of metal surface damage due to
combined effects of corrosion and tensile stress.
 Fretting Corrosion – Is a form of damage that occurs when two surfaces
in contact experience slight, repetitive relative movements often due
to vibration or pressure fluctuation.
 Erosion Corrosion – When material degradation occurs when a
corrosion fluid, often containing abrasive particles flows over a metal
surface, accelerating the rate of corrosion.

CORROSION PREVENTION
Corrosion can be prevented through various methods, including material
selection, coating or lining, altering the environment, cathodic protection and
using corrosion inhibitors. Protection, and using corrosion inhibitors. These
strategies aim to shield metal from corrosive agents like oxygen, water and
salt water.

APPROACH TO PREVENT CORROSION

1. MATERIAL SELECTION:
Choosing Corrosion – resistant metals like stainless steel or aluminum
can significantly reduce the risk of corrosion. Use of alloying metals
can enhance their resistance to corrosion by modifying their structure
and properties.
2 COATING AND LINING
Applying protective Coating, like paint, varnish, epoxy or polyurethane
serves as a barrier against corrosive agents, lining often made of non-
metallic materials like rubber of plastic offer additional protection in
harsh environments. Methods like galvanizing, tinning, electroplating
and anodizing involve coating the metal with a non-corrosive layer.
3 ALTERING THE ENVIRONMENT

28
 Controlling the Environment around the metal such as reducing
moisture or acidity, can minimize corrosive effects. Using dry agents
can help metal surfaces dry and prevent corrosion.
4 CATHODIC PREVENTION
Sacrificial anodes are used to provide a cathodic protection system,
where the anodes corrode instead of the metal its protecting.
Impressed current systems. Use an external power source to create a
protective current preventing corrosion.
5 CORROSION INHIBITORS
Corrosion inhibitors are substances that reduce the rate of corrosion by
interfering with the electrochemical process. They can be added to the
liquid or gas environment to prevent corrosion or applied as a coating.

6 DESIGN CONSIDERATIONS
Modifying the design of structure or equipment can help prevent
corrosion by minimizing stress points and eliminating areas where
moisture can accumulate. Regular maintenance and inspection can
help identify and address corrosion issues before they become serious
problem.

DOCKING AND UNDOCKING OF VESSELS

Necessary preparation before docking of a vessel. Prior to docking a vessel
comprehensive preparation are crucial for safety and efficiency. These
includes assessing stability, ensuring proper ballast and bunker distribution,
closing overboard discharge valves and thoroughly inspecting the hull,
including shell plating, welding seams and critical components like anchors
and steering gear. Additionally, the engine room, tank top, and bilges need
to be cleaned and bilge lines flushed. For tankers cargo tanks must be
cleaned and gas-freed, and all heavy weights secured, safety measures
including fire safety plans and equipment checks are also essential.

DETAILED BREAKDOWN
1. HULL AND STRUCTURAL INTEGRITY
Inspection - A detailed Inspection of the hull is paramount, focusing on
shell plating, welding and seams and through hull fittings.
Repairs – Any necessary repairs to the hull, rudder or other critical
components should be addressed before docking.

29
 Re-enforcement – Vulnerable area should be re-enforced to with stand
the stress of dry docking.
2. BALLAST AND STABILITY
Distribution – Proper ballast and bunker distribution is essential to
maintain stability during the docking process and to avoid undue hull
stress.
Stability Assessment – The vessel stability should be assessed and
confirmed particularly during the critical period of resting on keel
block.
3 MECHANICAL AND ELECTRICAL SYSTEM
 Engine Room - The engine room, tank top, and bilges should be
thoroughly cleaned
 Bilge Line – Bilge lines need to be flushed
 Overboard Valves – over board discharge valves should be closed
 Emergency Systems – The emergency geometer and lighting should
be tested and ready
 C02 system – The C02 total flooding system should be secured and
locked.
 Navigation and Communication – Navigation and Communication
equipment should be checked and tested.
3. SAFETY AND SECURITY
 Safety Plan – A comprehensive safety plan including fire safety
measure, should be in place and discussed.
 Fire Equipment – On-board fire equipment should be checked
and readily available
 Access – Safe access to the vessel should be arranged and
gangway should be in place.
 Security – Store Rooms, Toilets and other compartments should
be locked and loose gear secured
4. TANKERS
 Cargo tanks – Cargo tanks should be cleaned and gas – freed
 Cofferdams and tanks – Cofferdams and tanks should be sounded
and recorded.

DRY DOCKING
Dry- Docking is a procedure that is commonly used for the inspection,
repairing and maintenance of ships. The main objective of dry – docking is
to expose those parts of the ship that has been submerged in water for a
very long time. A ships travel for comparatively long time; the submerged

30
part of the ship need to be checked regularly. Dry-docking is also significant
when ship sale and purchase are considered to determine whether the ship
is in a perfect condition and to determine its seaworthiness.
PREPARING THE SHIP FOR DRY-DOCKING
 Create a repair and maintenance list and obtained a dry-dock hand book if
required. Assign respective staff to their specific duties on the list. Divide
your staff into a small group for supervision of the work carried out by the
yard staff.
 Each and every spare part must be make ready and handy to avoid delay at
the dock.
DRY-DOCKING A VESSEL WITH DAMAGED BOTTON
Dry-docking a vessel with damaged bottom requires careful planning and execution
to minimized stress on the hull and ensure safe repairs. Instead of attempting a full
dry docking of the vessel, it is often better to partially lower the water level to
expose the damaged area, allowing for diver to assess and plan repairs. The vessel
may be removed for more extensive repairs of repositioned with specially designed
blocks.

DETAILED BREAK DOWN

1. INITIAL ASSESEMENT AND PLANNING
Diver Inspection – Divers assess the damaged underwater, taking
measurements and photos to inform the repair plan.
Dry Dock Selection – The dry dock must be of adequate size and have the
necessary equipment for the specific repair.
Block Arrangement – A detailed block arrangement plan is crucial. The block
must be positioned to support the hull correctly especially given the
damaged.
Yard Specification – Agree on the scope of work in the ship yard and ensure
access for any necessary subcontractors.
Safety Measures – Implement necessary Safety measure for divers, yard
personnel and the vessel.
2. DRY DOCKING PROCEDURE
 Partial Flooding – The dry dock is flooded to a level that allows the
vessel to be floated in and positioned over the pre-arranged blocks.
 Water level adjustment – The water level is lowered to exposed
the damaged area. Divers can now work on the exposed hull
while the vessel is partially water borne.
 Block support – Ensure the vessel is adequately supported by the
blocks especially in the damaged area.

31
  Water removal – The remaining water is pumped out and the
vessel is fully supported on the blocks.
 Repairs – Conduct the necessary repairs, such as plating, welding
or replacing damaged sections.
3. CONSIDERATION FOR DAMAGED BOTTOM
Hogging and Sagging – Be mindful of potential hogging (upward
bending) and Sagging (down ward bending) of the hull, especially
during partial support of the vessel
4 FINAL STEPS
Inspection – Thoroughly inspect the damaged repaired area to ensure
it meets required standard.
Float-Out - The dry deck is flooded and the vessel is floated off the
blocks and removed.
Precaution when dry docking a vessel –
When dry docking a vessel, several key precautions must be taken to
ensure safety and prevention of vessel damaged.
KEY ASPECTS ARE: -
 Stability – Before entering the dry deck the vessel stability must be
positive
 All loose gear including moving lines, gangway and movable weight,
must be properly secured or stowed away
 Cargo tanks must be gas – freed, some with pump room
 Clear and Continuous Communication between the crew and shipyard
staff must be maintain.
 The vessel should be carefully aligned with the keel blocks in the dry
dock.
 After docking Inspections of the hull sea chests, and other critical areas
should be carried out.
 Regular monitoring of the vessels condition including stability and
structural integrity should be conducted throughout the dry deck
process.

PRECAUTION WHEN UNDOCKING A SHIP BEFORE UNDOCKING OF

VESSEL
1. STABILITY ASSESSMENT – A thorough stability check is paramount.
This involves verifying the vessels displacement, centre of gravity(G)
and metacentric height(GM). Compare this values with the pre-dry
docking calculations to ensure the vessel is stable

32
 2. Watertight Integrity – All hatch covers should be closed and secured
and the watertight integrity of the upper most deck confirmed. Ensure
all bilges and bilge tanks are dry.
3. All pipelines, power lines and other connections to the shore must be
disconnected and secured anchors and chains should be properly
stowed.
4. Adequate man power should be available both on board and ashore to
assist with the undocking process. Tugs if needed should be on
standby, and linesmen should be ready to released mooring.
5. Established clear Communication between the bondage, Engine room
and shore personnel should be done. Ensure all parties are aware of
the undocking plan and potentials hazards.
6. Safety checks – verify that all safety equipment such as fire doors
and watertight doors are functioning correctly.
DURING UNDOCKING
a. Undocking should be done slow and steady
b. If using springs lines, ensure they are released at the appropriate
time and in a controlled manner.
c. The vessel should be control and propelled away from the dock
safely
d. Continue to monitor the vessel’s stability watertight integrity, and
other critical systems.

FRAMING SYSTEM ON BOARD

The Primary types of framing systems used in ship building are transverse,
longitudinal and combined (hybrid) system.

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TRANSVERSE FRAMING
This system is characterized by closely spaced frames running perpendicular
to the ships length. These frames provide strength in the transverse
direction. Historically it was common in older ships and those with less –
emphasis on longitudinal strength and is often preferred for longer ships and
those carrying significant cargo.
LONGITUDINAL FRAMING
This system features closely spaced longitudinal stiffeners running along the
length of the ship and fewer, more widely spaced transverse farms. It offers
greater longitudinal strength and is often preferred for longer ships and
those carrying significant cargo.

COMBINED FRAMING
This system utilizes both transverse and longitudinal framing to optimize the
ships structural performance. The specific arrangement and spacing of
framers vary depending on the ships design and intended use.

34
 DECK MACHINERY
Deck Machinery is generally arranged on the ship deck to facilitate various
operations like anchoring, mooring, cargo handling and ship maneuvering.
Common equipment includes windlasses, mooring wincher, cranes and
steering gear with power systems being primarily hydraulic or electric. The
arrangement varies depending on the ship type and its intending operation.
1. Windlasses - Used for raising and lowering the anchor and chain.
2. Mooring winches – Used to secure the ship to the dock using mooring
lines.
3. Captains – Vertical axle winches used for warping (moving) the ship
short distances and handling mooring lines.
4. Fair leads and Bollards – Used to guide mooring lines and provide
strong points for securing them.
5. Deck Cranes – Used to lift and move cargo, containers, and other
heavy items
6. Hatch covers used to seal and protect cargo holds.
7. Steering gears – System that controls the ships rudder, allowing it to
change direction.
8. Davits – Used to lower life boats and rescue equipment
9. Fenders – Protect the ship’s hull from damaged when alongside the
dock.
10. Ladder and Gangways – Used for access to and from the ship.
ARRANGEMENT CONSIDERATION
SAFETY – Deck machinery is strategically placed to minimized hazards to
crew and passengers.
EFFICIENCY – They layout is designed to facilitate smooth and efficient
cargo handling and mooring operations.
ACCESSIBILITY – Equipment is positioned for easy maintenance and repair.
CRITERIA FOR THE LOCATION OF DECK MACHINERY
The placement of the deck machinery on a vessel is determined by a
combination of factors including structural integrity, operational
requirements, Safety considerations and ease of maintenance. Specific
criteria include load capacity, power source, vessel type and the need for
accessibility.

KEY CRITERIA

35
 1. Structural Integrity – Heavy equipment should be positioned near
structural support to distribute weight effectively and minimize stress
on the deck.
2. Operational Requirements – Deck machinery must be placed to
facilitate specific tasks like mooring, anchoring, cargo handling and
towing.
3. Safety – adequate clearances for personnel and equipment during
operation and maintenance are essential. Consideration for lifting and
access points for maintenance is crucial.
4. The location must be compatible with the power source.

PROPULSION UNIT
The primary function of a ships main propulsion unit is to generate the thrust
needed to move the vessel through the water. This is achieved by
converting energy from fuel combustion or electricity, into mechanical
energy that turns the propeller, pushing the ship forward.
CONSIDERATION WHEN CHOOSING PROPULSION SYSTEM
When choosing the main Propulsion System for your vessel, there are several
factors required in order to get the system that will fit your need, in the
operating environment.
1. TYPE OF VESSEL AND AREA OF OPERATION
The size of vessel will determine the output power required for the
propulsion system to deliver optimally. The area will be if the vessel is
leisure boat, work boat, ferry, fishing boat or ship. Work boat will
require a reboots system.
2. EFFICIENCY AND OPERATING COST
The Propulsion System are design to be more energy efficient, which
can reduce both fuel consumption and emission, easier to maintain
and have a longer lifespan, which can reduce overall operating cost
overtime.

36
GENERAL CRITERIA FOR SELECTING SHIP AUXILIARY MACHINE
Selecting Ship Auxiliary Machinery involves considering factors like power
needs, operational reliability, maintenance requirements, space constraints
and cost effectiveness. The choice also depends on the type of ship, its
intended trade and relevant regulations.
KEY DETAILED BREAKSOWN
1. POWER REQUIREMENTS
CAPACITY – The machinery must be also to provide sufficient power for
all auxiliary systems (e g. Electrical Power Generator, Pumping and
Ventilation etc.)
LOAD – Consider the expected load venations and ensure the
machinery can handle peak demands and fluctuating Loads.
REDUNDANCY – Having back up or redundant systems is crucial for
critical functions to ensure continued operation in case of failure.
2. RELIABILITY AND AVAILABILITY
OPERATIONAL RELIABILITY – The machinery should be designed for
reliable operation under various conditions including harsh marine
environments.
MAINTAINABILITY – Chose equipment that is easy to maintain, with
readily available spare parts and accessibility components.
DURABILITY – Consider the life span and durability of the equipment,
especially for the criterial components.
3. SPACE AND WEIGHT

37
 ENGINE ROOM LAYOUT – The arrangement of the machinery should
optimize space utilization and ensure efficient workforce for
maintenance.
WEIGHT DISTRIBUTION – Distribute weight of machinery evenly to
maintain ship stability.
ACCESSIBILITY – Provide sufficient space for maintenance access and
personnel movement within the Engine Room.
4. OPERATIONAL EFFICIENCY
FUEL CONSUMPTION – Evaluate the fuel consumption of different
machinery options and consider their impact on operating costs.
ENERGY EFFICIENCY – Prioritize energy efficient machinery to minimize
environmental impact and reduce fuel costs.
AUTOMATION – Consider automation systems for improved efficiency
and reduced manpower requirements.
5. SAFETY AND REGULATORY COMPLIANCE
SAFETY FEATURES – Ensure the machinery has appropriate safety
features and complies with relevant safety regulations.
ENVIRONMENTAL REGULATION – Consider the environmental
impact of the machinery and ensure it complies with the emission
standards vibration and noise.
CLASSIFICATION SOCIETY RULES – Ensure the machinery comply with
the rules and regulations of classification societies (e.g. Lloyd’s
Register)
6. COST CONSIDERATION
INITIAL Cost – Consider the initial purchase price of the machinery.
OPERATING COSTS – Factor in the cost of fuel, maintenance and other
operating expenses.
LIFE CYCLE COSTS – Consider the total cost of ownership over the
lifespan of the machinery
7. SPECIFIC APPLICATIONS
PROPULSION SYSTEMS – The main propulsion System needs to be
reliable and powerful enough for the ship’s intended speed and
voyage.
PUMPING SYSTEMS – Pump for various purposes (e.g. ballast bilge,
firefighting) need to be selected based on their capacity, pressure and
reliability?
ELECTRICAL POWER GENERATION – Auxiliary engine and generators
must provide a reliable power supply for all electrical systems onboard.
REFRIGERATION AND AIR CONDITION – These systems require specific
equipment to maintain comfortable living and working conditions
onboard.

38
MACHINERY OPENING FOR CLASSIFICATION SOCIETIES FOR
INSPECTION.
Opening Machinery for Inspection by classification Societies generally
involves a structured process that includes notification, preparation,
Inspection and reporting. The process ensures machinery is maintained and
operating safely, adhering to established class rules and standards.

DETAILED PROCEDURE
1. NOTIFICATION AND PLANNING
 The Ship owner or operator notifies the relevant classification
Society (e.g. DNV, Lloyd’s Register, and Bureau Veritas) in
advance of the planned machinery opening for inspection.
 A Specific Schedule for the survey is agreed upon considering
the type of machinery, its operational history, and any relevant
maintenance records.
 The classification surveyor will review the planned schedule and
may request additional information or adjustments to ensure
comprehensives coverage of critical components.
 The continuous machinery survey (CMS) schedule if applicable
should be prepared and kept onboard for reference.
2. PREPARATION FOR INSPECTION
The machinery is prepared for Inspection according to the agreed
schedule and any specific requirements of the classification societies.
 This May involve cleaning, draining or removing protective
covers to allow for proper visual and physical examination of the
machinery components.
 Any necessary safety precautions are implemented, such as
ensuring proper ventilation and isolating power supplies.
 If required specialized tools, equipment or access arrangements
may be prepared
3. INSPECTION PROCESS
 The classification Society Surveyor(s) will attend the machinery
space to conduct the Inspection.
 The surveyor will visually examine the machinery, checking for
signs of wear, corrosion damage or other abnormalities.
 They may also conduct nondestructive testing (NDT) techniques,
such as ultrasonic testing or magnetic particle inspection, to
assess the integrity of critical components.

39
  Operational tests may be performed such as load tests on
engines or pressure tests on piping system, to verify
performance and safety margins
 Maintenance records, including any previous survey reports and
repair histories will be reviewed.
4. REPORTING AND FOLLOW-UP
 The Classification Society surveyor will prepare a detailed report
outlining the findings of the inspection.
 This report will include any recommendations for corrective
actions or further maintenance.
 If any critical issues are identified the surveyor may require
immediate action or further investigation.
 The ship owner or operator is responsible for addressing any
identified deficiencies and ensuring compliance with the
classification Society’s recommendations.
 Upon satisfactory Completion of the Inspection and any required
corrective actions, the classification Society may issue or renew
the relevant certificate of class.
SERVICES CARRIED OUT OF A SHIP DURING DRY DOCKING
Dry Docking involves a range of Services focused on Inspecting, Maintaining,
and repairing a ship’s underwater components, as well as performing
necessary hull maintenance and other repairs. These services are crucial for
the ship to remain it is class by operating in a safe and efficient condition.
DETAILED SERVICES
1. HULL MAINTENANCE
Cleaning and Painting – Removal of marine growth, rust and old paint,
followed by the application of new coatings, including anti-fouling paint to
protect the hull from corrosion and biofouling.
INSPECTION AND REPAIR – Examination of the hull for damage like
cracks, dents, or structural issues with necessary repairs or
replacements.
CATHODIC PROTECTION – Maintenance or replacement of sacrificial
anodes to prevent corrosion, particularly in areas prone to
electrochemical reactions.
2. UNDERWATER COMPONENT MAINTENANCE PROPLELLER AND
RUBBER
Inspection, repair or replacement of propeller blades, rudders and
associated shafts and seals.

40
 SEA CHESTS AND VALVES – Cleaning, Inspection and overhaul of sea
chests (openings in the hull for sea water intake) and associated
overboard valves.
SHAFT AND SEAL INSPECTION – Measurement and replacement of tail
shaft seals and inspection of other underwater components.
3. ENGINE ROOM AND MACHINERY
ENGINE MAINTENANCE – Routine checks, Servicing and repairs on main
engines, Auxiliary engines pumps and other machinery.
TANK MAINTENANCE – Cleaning and inspection of fuel, ballast and
other tanks for corrosion, leaks, or other issues.
PIPING AND VALVES – Inspection and maintenance of piping systems,
including sea water piping, ballast systems and other essential piping.
4. DECK AND SUPERSTRUCTURE
DECK REPAIRE –Inspection and repairs of deck plating, hatch covers,
and other deck structure.
ACCOMMODATION REPAIRS – Maintenance and repair of living spaces
galleys, and other onboard facilities
Electricity Systems – Inspection and maintenance of electrical wiring
switch boards and other electrical components.
5. OTHER SERVICES
ANCHOR AND CHAIN INSPECTION – Inspection and maintenance of
anchors, anchor chains and related equipment.
Safety equipment Inspection – Checking and Inspecting and Servicing
of firefighting equipment, life –saving appliances and other safety
systems
STEEL AND PIPING REPAIRS
Cutting, Welding and fabrication of steel plates and piping as needed.
Surveys and Inspections – Conducting class and statutory surveys to
ensure compliance with maritime regulations.
Waste Disposal – Proper management and disposal of waste materials
generating during the dry docking process,

SHIP SEA TRIAL

A Sea trial is a controlled test of a vessel, conducted at sea to evaluate its
performance safety systems, and overall sea worthiness. This trial helps
ensure this vessel meets required standards and functions as expected
before it put into service.

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 KEY ASPECTS OF A SEA TRIAL
EVALUATION
Sea trial assess various aspects of the vessel including speed, maneuver
ability, fuel consumption, Navigation Systems and Safety features.
CONDITIONS
Trial are conducted on open router, using real sea conditions, not just calm
harbor test.
PURPOSE
It helps identify any potential issues of defects that need to be addressed
before the vessel is used commercially or by its owner.

PARTICIPANTS
Sea trial can involve prospective buyers, marine surveyor, and sometimes
even marine engineering.
TIMING
They typically take place after construction or major repairs/refits
IMPORTANCE
Sea trials are crucial for ensuring the Safety of the vessel, crew and
passengers, as well as confirming that the vessel meets contractual
specification.
STAGES
Sea trial often involve different stages each designed to test specific aspects
of the vessel performance.
TROUBLE SHOOTING
They provide an opportunity to trouble shooting any issues that may arise
during operation.

HOW TO A CERTAIN RUDDER EFFICIENCY DURING SEA TRIAL

To assess a rudder’s efficiency during sea trial, you need to measure its
turning performance, thrust contribution and the resulting impact on the
ship’s overall propulsion efficiency. This involves analyzing data from
various maneuvers, using sensors to track forces and moments and

42
comparing the results with predicted performance based on model tests or
simulations.

KEY DETAILED
1. MEASURING TURNING PERFORMANCE
Maneuvering Trials – Conduct standardized Turning Circles, Zig –Zag
tests and others maneuvers to assess the rudder’s ability to change
the ship’s heading.
Instrumentation – utilize sensors like rate of turn indicators, rudder
angle indicators and GPS for accurate measurements of the ship’s
trajectory and heading changes.
ANALYSIS – Calculate metrics like advance transfer tactical diameter
(for turning circles) and over shoot angle (for Zig – Zag tests) to
evaluate the rudder’s effectiveness in achieving desired turning
characteristics.

2. ANALYZING THRUST CONTRIBUTIONS

Propeller – Rudder Interaction – Analyze how the rudder, especially
when located behind the propeller, affects the propeller thrust and the
overall propulsion efficiency.
CFD SIMULATIONS – Use computational fluid dynamics (CFD) to
simulate the flow around the rudder and propeller, helping to
understand the forces and moments acting on the rudder and their
impact on thrust and resistance.
SELF – PROPULSION TESTS- Compare the ships performance with
and without the rudder to quantify the rudder’s contribution to the
ship’s resistance and thrust requirements.
3. ASSESSING OVERALL PROPULSION
PROPELLER EFFICIENCY – Determine the propeller’s open water
performance with and without the rudder in place. This involve
analyzing propeller thrust and torque at various speeds.
HULL RESISTANCE – Measure the ships resistance with and without
the rudder to assess the rudder’s influence on the overall hull
resistance.
FUEL CONSUMPTION – Monitor fuel consumption during different
maneuvers to assess the impact of the rudder on the ships overall
propulsive efficiency.
4. ANALYZING DATA AND COMPARING WITH PREDICTIONS

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 Data Acquisition – Gather data from various sensor and Instruments
during sea trial, including rudder angle, heading speed thrust, torque,
and fuel consumption.
Data Analysis – Analyze the collected data to assess the rudders
performance against pre-define criteria or prediction from model tests
or simulations.
COMPARISON AND VALIDATION – Compare the results from sea
trials with prediction from model tests or CFD simulations to validate
the accuracy of the models and access the rudder effectiveness.
HOW TO A CERTAIN ENGINE PERFORMANCE DURING SEA TRIAL
To ensure a certain engine efficiency during a sea trial, focus on monitoring
key Parameters conducting specific tests and analyzing data. Key aspect
including observing engine temperatures, oil pressure and exhaust smoke,
as well as performing load tests at various percentage of maximum
continuous rating (MCR) and conducting steering and reverse tests.
Analyzing specific fuel consumption (SFC) and comparing it to performance
curves can help pin point areas for improvement.
1 MONITOR ENGINEN PARAMETERS
TEMPERATURE – Keep a close watch on engine room temperature and
temperature of air entering the engine. It’s crucial to ensure these
temperatures stay within acceptable ranges usually not differing
significantly from the outside air temperature e.g. (16-17 0c)
OIL PRESSURE – Maintain stable oil pressure throughout the engine’s
RPM range.
EXHAUST SMOKE – Observe the exhaust for any smoke especially after
the engine warms up, as excessive smoke can indicate combustion
issues.
ENGINE SPEED AND LOAD – Monitor Engine speed (RPM) and load
during various tests inducing running at 1500 RPM 80% MCR and 100%
MCR.
1. CONDUCT PERFORMANCE TESTS
COLD START AND WARM –UP – Document the engines behaviour
during cold starting and warm-up, including exhaust color and
operating temperatures.
LOAD TESTS – Perform tests at different load percentages (erg 25, 50,
75, 100% MCR) to assess the engine performance under various
conditions.
STEERING AND REVERSE TESTS – Execute steering tests to check
steering gear functionality and reverse tests to evaluate the engine’s
ability to reverse direction.

44
 GET HOME SYSTEM TEST – If applicable test the get home system at
80% load for a minimum of 15 minutes.
1 ANALYZE DATA
Specific fuel consumption (SFC) – calculate SFC by measuring fuel flow
rates and engine power output. Compare the measured SFC, with the
engine’s performance curves to identify any deviation or inefficiency.
PERFORMANCE CURVES – Compare the sea trial data with the engine’s
performance curves to assess if the engine is performing as expected
and to identify areas for optimization.
2. OPTIMIZE ENGINE PERFORMANCE
Waste heat Recovery – Consider implementing waste heat recovery
system to capture and reuse waste heat from the engine’s exhaust.
PROPELLER OPTIMIZATION – Evaluate the efficiency of the propeller
and consider upgrading to a more efficient model if necessary.
DESIGN OPTIMIZATION – Explore design optimization techniques for
engine components to improve overall efficiency.
HOW TO A CERTAIN HULL EFFICIENCY DURING SEA TRIAL
To assess a certain hull efficiency during sea trials, focus on measuring key
parameters like resistance, thrust, and power and then calculate the hull
efficiency using established formulas. This involves ensuring the ship is in a
clean and well maintained condition running the vessel at specifies speed,
and accurately measuring relevant data.
KEY DETAILED
1. PREPARATION AND CONDITIONS
CLEAN HULL AND PROPELLER – The hull and propeller must be clean
and free of marine growth or debris, as these can significantly impact
resistance and affect the accuracy of measurements.
EVEN KEEL AND SUBMERGE RUDDER – The ship should be at an even
keel draft with the rudder fully submerged during testing.
CALM WEATHER CONDITIONS – Sea trial should ideally be conducted in
calm weather to minimize the impact of waves and wind resistance on
the result.
2. MEASUREMENT AND DATA ACQUISITION
SPEED AND POWER – Measure the ships speed at different engine
settings (RPM) and note the corresponding shaft power (or Engine
power)
RESISTANCE – Determine the total resistance the ship encounters by
measuring the force required to it at various speed.
THRUST – Measure the thrust generated by the propeller at different
speeds and pitch settings.

45
 WAKE AND THRUST DEDUCTION – Determine the wake fraction (how
much the propeller stream is slowed down by the hull) and thrust
deduction factor (how much the propeller thrust is reduced by the hull)
3. Calculation of hull efficiency
Hull efficiency elements – Calculate the hull efficiency elements which
includes augment (the increase in resistance due to the propeller)
wake fraction and relative efficiency.
FORMULA – Use the following formula to calculate hull efficiency.
Hull efficiency = (Thrust deduction factor)
(1- Mean wake fraction)

PROPELLER EFFICIENCY – Propulsive efficiency is calculated as the ratio

of effective horse power = Thrust Power
Power delivered to the propeller

4. ANALYSIS AND OPTIMIZATION

Compare with model tests – Compare the results from the sea trial with
the model test to validate the ships performance and identify any
discrepancies.
HULL FORM OPTIMIZATION – Based on the analysis consider hull form
optimization techniques (e.g. bulbous bow) to reduce resistance and
improve fuel efficiency.
MAINTENANCE – Regular hull cleaning and maintenance can have
minimized resistance and improve long term efficiency.

LAUNCHING OF A NEW SHIP

Preparing for a ship launch involves meticulous planning and execution
a cross several key areas. These includes site preparation, ensuring
that the ship is properly secured for launch, and having all necessary
equipment ready. Additional safety protocols and contingency plans
must be in place to handle any unexpected issued.

MORE DETAILED
1. SITE PREPARATION
LAUNCHING AREA- The launch area whether a ship way or a ship lift,
needs to be carefully prepared. This includes ensuring a stable and
adequately graded surface, particularly if using air bag launching
system.

46
 GROUND STABILITY – A hard ground is crucial for a safe launch.
Soft ground can lead to instability and potential problems.
RAMP Length and Grade – The ramp length and grade must be
appropriate to the size and weight of the ship.
OBSTACLE REMOVAL – All debris and potential hazards like sharp
objects, should be cleared from the launching area to prevent
damaged to the ship or airbags.
2. SHIP PREPARATION
SECURING THE SHIP – The ship needs to be securely fastened to the
launching platform or shipway using appropriate supports like
wooden blocks or mechanical supports.
LUBRICATION – If using a slipway, the sliding surface needs to be
properly lubricated to ensure a smooth launch.
EQUIPMENT CHECK – All necessary equipment including winches,
wire ropes, pulleys and shackles, should be inspected and prepared
for used.
WEIGHT DISTRIBUTION – The ships weight needs to be evenly
distributed to maintain stability during the launch process.
DRAIN PLUG – The drain plug should be securely installed to prevent
water increase during the launch.
SPARK TESTING – For new vessels, spark testing is recommended as
a quality control measure to ensure the integrity of the hull.
2 AUXILIARY EQUIPMENT
AIR COMPRESSORS – If using airbags ensure adequate air
compressors are available to inflate them.
WINCHING SYSTEM – The winching system needs to be properly
maintained and ready to handle the ships weight during the launch.
SAFETY EQUIPMENT – Personnel flotation devices (PRDs), ropes
and other safety equipment should be readily available for
personnel involved in the launch.
DOCKING AND MOORING – Have deck lines and fenders ready for
securing the ship once it enters the water.
3 SAFELY AND CONTINGENCY
WEATHER CONDITIONS – Monitor weather forecast and water
conditions to ensure a safe lunch.
EMERGENCY PROCEDURES – Established a clear emergency
procedures and communication protocols for handling unexpected
situation.
PERSONNEL TRAINING – Ensure all personnel involved in the launch
are properly trained and understand their roles.
COMMUNICATION – Established a reliable communication system
between all teams involved in the launch.

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 4 LAUNCH CEREMONY
CEREMONIAL ASPECTS – Consider any ceremonial aspects of the
launch, such as a naming ceremony or blessing
PUBLIC RELATIONS – If the launch is a Public event, prepare
appropriate communication and logistics for spectators.

SAFETY IN THE SHIPYARDS

FIRE FIGHTING APPLICATION IN THE SHIPYARD- Firefighting in the shipyard
include fire detector and alarm system, various suppression systems ( water,
foam and CO2), personnel protective equipment and fire resistant
construction materials. These systems are strategically deployed across
different areas, including engine rooms, cargo holds and living quarters, to
mitigate fire risks and enable effective response.
DETECTION AND ALARM SYSTEMS
Smoke detectors – These can be photo electric or ionization based
providing accurate fire detection
HEAT DETECTORS – These can be fixed temperature or rate-of-rise models,
depending on the specific area.
IR/UV FLAME DETECTORS – These often rapid detection with algorithms to
prevent false alarm.(INFRA RED)
ALARM PANELS – These are modular systems that integrate various
detectors and provide a centralized interface for monitoring and control.
SUPPRESSION SYSTEMS
Water – Base Systems – These include fire hoses, nozzles, hydrants, fire
pumps and sprinkler systems
FOAM SYSTEMS – These are used for flammable liquid fires.
C02 Systems – These are used for enclosed spaces like engine rooms, and
machinery space.
Water Mist Systems – These offer an effective and environmentally
friendly fire suppression method.
PERSONNEL PROTECTIVE EQUIPMENT (PPE)
Emergency Breathing Apparatus – This includes EEBDs for evacuation and
SCBAs for interior fire fighting

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Fireman’s Outfits – These includes heat resistant suits, gloves, boots and
helmets and safety lamps.
FIRE RESISTANT CONSTRUCTION
Fire retarded bulkheads – These are used to contain fire spread
Fire Doors – These are self closing doors that are fitted in fire retarded
bulkheads
Fire Dampers – These are provided in ventilation systems to block oxygen
supply to the fire.
ADDITIONAL APPLICATIONS
Fire Pumps – These deliver water to hydrants and sprinkler systems at the
required pressure.
Fire main piping and valves – These distribute water throughout the ship
EXTERNAL FIRE FIGHTING SYSTEMS – These are used on firefighting
vessel’s and can include water spray systems for cooling
Pre-fire Planning – This includes identifying hazards establishing procedures,
and creating evacuation plans.
Fire Fighting Training – This is essential for all personnel involves in fire
Safety including structural, wildland, and ship board firefighting.
PRECAUTIONS NECESSARY TO AVOID ELETRICAL FIRE IN WELDING
WORKSHOP
To prevent electrical fire in a welding work ship, welders should prioritize
equipment for damage, ensuring proper grounding, avoiding damps areas
and using appropriately rated extensions cords. Additionally, a clean and
organized workplace, proper ventilation and readily available fire
suppression equipment are crucial.
SPECIFIC PRECAUTIONS
Equipment Inspection and Maintenance
1. Regularly Inspect Welding Machines, cables and electrode holders for
any signs of damage such as frayed insulation or exposed wires.
2. Replace damage cable promptly.
3. Ensure electrode holders are in good condition with proper insulation.
GROUNDING
1. Properly ground the welding machine to prevent electrical shock.

49
 2. Ground the work piece to the same electrical ground as the welding
machine.
ELECTRICAL SAFETY PRACTICES
1. Avoid working in damp or wet areas as this can create electrical
hazards
2. Use dry insulated gloves and other appropriate PPE.
3. Ensure extension cords are properly rated for the amperage and
length.
4. Do not strike an area without proper eye protection.
FIRE PREVENTION
1. Remove all flammable materials from the welding area
2. Keep the flammable materials as far as possible.
3. Have a fire Extinguisher readily available and know how to use it.
4. Consider a fire watch especially after welding is complete, to monitor
for any smoothening or ignition.
5. Ensure adequate ventilation to remove welding fume and gases.
WORK PLACE SAFETY
 Clearly mark hazardous areas and establish restricted zones.
 Avoid overcrowding the welding area
 Ensure good lighting to improve visibility and reduce tripping hazards.
 Secure the work piece to prevent it from shifting, during welding
 Consider using fire resistant curtain or shields to protect nearby
workers and equipment
TRAINING AND SUPERVISION
 Ensure all workers are properly trained and qualified to operate
welding equipment
 Provide appropriate supervision to ensure safe work practices are
followed.
PRECAUTIONS NECESSARY DURING WELDING
When welding, its critical to prioritizes Safety to prevent injuries and hazards.
Personnel Prospective Equipment (PPE), proper ventilation fire safety
measures, and equipment inspection are all essential precautions.
PERSONAL PROTECTIVE EQUIPMENT
1. Welding helmet – Protects eyes and face from sparks, intense light and
ultra-violet radiation (UV ray).
2. Welding gloves – protects hands from heat, sparks, and hot metal

50
 3. Flame resistant clothing – jackets, apron, and boots protect the body
from burns and spatter.
4. Ear Protection – Ear muffs or earplugs protect against loud noises.
5. Respirator – Fitters harmful fumes and gases, especially in poorly
ventilated areas.
VENTILATION
1. Adequate ventilation – prevents the buildup of harmful fumes or gases
produced chip welding
2. Avoid welding ON COATED METALS – Ensure coating are removed from
the welding area and ventilation is adequate.
FIRE SAFETY
1. Clear flammable materials away from the welding area.
2. Use curtains or shields to protect nearby workers and areas.
3. Keep a fire extinguisher nearby and know how to use it.
EQUIPMENT AND WORK PLACE
1. Regularly check welding machines, cables and other equipment for
damage
2. Ensure proper grounding of welding machines to prevent electric shock
3. Remove clutter and debris to prevent tripping hazards and potential
fires.
ADDITIONAL PRECAUTIONS
Read Manuals – Familiarize yourself with the welding machine operating
manuals.
AVOID TOUCHING ELECTRODES – Do not touch the electrode while in
contact with the work or ground.
Take Breaks – Avoid fatigue and potential injuries by taking regular
breaks
Inform Others – Warn others about the welding area and potential
hazards.
COMMON HAZARDS IN WOOD WORKSHOP
The common hazards in wood working shop includes dust, avoid air burn
particles, noise induced, hearing loss, sharp tools and blades electrical
hazards, fire risks, and harmful chemicals. Additionally, injuries from flying
objects, improper lifting and machine hazards are also prevalent.
DETAILED BREAKDOWN

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 1. Dust and air borne particles – Wood working generates a significant
amount of dust, which can cause respiratory problems skin irritation
and allergic reactions.
2. Noise induced Hearing Loss – Many wood working tools, like saws and
sanders produce high noise levels potential level leading to hearing
damage.
3. Sharp Tools and Blade – Wood working involves using sharp blades,
cutting edges, and tools that can cause lace rations and amputation
and other hand and finger injuries.
4. Electrical hazards – Faulty wiring damaged cords and improper
grounding of equipment can lead to electrical shocks or fires.
5. Fire Risks – Wood dust, flammable finishes and any other materials can
easily ignite posing a fire hazards, improper storage of flammable
materials and inadequate fire safety precautions can exacerbate the
risk.
6. Harmful chemicals – Finishes, adhesive solvents and cleaning agents
used in wood working can contain hazardous chemicals that can cause
skin and respiratory problems.
7. Machine Hazards – Wood working machines can pose several hazards
including point of – operation hazards, nip points, kickbacks and flying
chips.
8. Improper Lifting – Lifting heavy pieces of wood or equipment can lead
to strains, sprains and other musculoskeletal injuries.
MEASURES TO BE TAKEN TO AVOID ACCIDENT IN THE WOOD
WORKING SHOP
To prevent accidents in a wood working shop, prioritize safety by using
proper personal protective equipment, maintaining tools and ensuring a
clean, organized work place. Always disconnect power before changing
blades or bits and never work under the influence of drugs or alcohol. Be
mindful of the surroundings, avoid distractions and use push sticks or jigs
when necessary.
DETAILED MEASURES
1. Personal Protective equipment (PPE)
Eye Protection – Always wear Safety glasses or goggles to shield
eyes from flying debris dust and particles.
Hearing Protection – Use earplugs or earmuffs to protect your ears
from the loud noise of power tools.
RESPIRATORY PROTECTION – Wear a dust mask or respiratory to
avoid inhaling sawdust or fumes especially when sanding or using
finishes.

52
 PROPER CLOTHING – Avoid loose fitting clothing, Jewelry and
dangling items that could get caught in machinery.
FOOT PROTECTION – Wear stirdy closed toe shoes to protect your
feet from falling objects or sharps tools.
2. TOOL SAFETY
Sharp blades and Bits – Use sharp blades and bits to ensure smooth
cuts and reduce the risks of kick back.
 Proper blade selection – Ensure the blade is appropriate for the
materials and the tool.
 Blade guards – Always use blade guards and ensure they are
properly adjusted.
 Tool maintenance – Regularly inspect and maintain tools
keeping them clean and in good working condition.
 Disconnect power – Always disconnect the power supply before
change blades, bit, or making adjustments.
 Use push sticks/Jigs – Use push sticks feather board and Jigs to
keep your hands away from the blade when working with table
saws and other machinery
3. WORK SPACE SAFETY
 Cleanliness – Maintain a clean and organized work space
removing saw dust and debris to prevent slips and trips
 Clean access – Ensure clear access to tools and machinery and
keep aisles free of obstacles
 Proper lighting – Ensure adequate lighting to see clearly and
avoids accident
 Secure work space – Secure tools and materials to prevent them
from falling or shifting.
4. WORK SHOP TEST PRACTICES
 Avoid distractions and concentrate on the tasks at hand.
 Take regular breaks to avoid fatigue, which can lead to error
 Use proper lifting gear or techniques when handling heavy
object.
 Familiarize yourself with your working tools
 When working with heavy materials or complex tasks consider
working with another person’s.
EMERGENCY PROCEDURES
 Have a basic emergency plan in place including how to response
to injuries or accidents
 FIRST AID KIT – Keep a well-stocked first aid kit readily available.
 Know location of emergency shut off
 Be familiar with the location of emergency shut-off switches for
all machineries.

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SAFETY RULE RELATED TO CLOTHING
In a workshop environment clothing safety rules are crucial for
preventing accidents appropriate clothing choices can minimize risk
association with machinery and materials. Key considerations include
wearing protective clothing, securing loose items and selecting
suitable foot wear.

PROTECTIVE CLOTHING
 Aprons or overalls – wear an apron or overall to protect your
regular cloths from dust, dirt, oil and sparks from welding
 Lab coat or coveralls – Consider a Lab Coat or coveralls for
added protection, especially when working with chemicals or
spills.
 Securing Loose items – Long sleeves – Roll up long sleeves when
operating machinery to prevent them from getting caught in
moring pants
 Long hair – Secure long hair with a cap or bonnet, or hair tie to
keep it away from machinery
 Loose Clothing – Avoid wearing loose clothing that could get
caught in machinery.
 Jewelry – Remove all jewelry including watches, rings, necklaces
and bracelets before starting work.
FOOT WEAR
Closed Toe Wear sturdy closed toe shoes or boots, preferable with
steel or composite toes, to protect your feet from falling objects
and sharp materials.
No Sandals or Open toe shoes – Sandals and open toe shoes are
not permitted in the workshop due to risk of injury.
Materials – Opt for natural materials for hot work such as welding
as synthetic materials can melt or burn.
HIGH Visibility – In busy or low – light areas, consider wearing
high visibility clothing to enhance visibility
Cleanliness – Keep your work area and clothing clean to minimize
the risks of accidents.
FIRST AID – Have a first aid kit readily available for treating minor
injuries.

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 GENERAL SAFETY
 Be alert – Pay attention to your surrounding and potential
hazard
 Follow instructions – Always adhere to the instructions
provided for each task and machine.
 Ask for help – If you are unsure about any procedure ask for
help from a supervisor or experience worker.

SAFETY RULES RELATING TO HYGIENE

In work-ship, maintain good hygiene is crucial for safety and health. This
includes personal hygiene.
1. Hand Washing – Wash hands frequently with soap and water,
particularly after using tools handling materials and before eating or
drink.
2. Personal Protective Equipment (PPE) – Wear gloves, hand gloves,
aprons and other appropriate PPE to protect skin and clothing from
chemicals, dust and other hazards
3. Grooming – Keep hair tie back to prevent it from getting caught in
machinery of contaminating work.
4. Avoid eating or drinking in the work shop – This help prevents ingestion
of harmful substances.
5. Cleaning – Regularly clean surfaces tools, and equipment to remove
dust, debris, and potential contaminants.
6. Waste disposal – Dispose of waste materials properly in designated
containers
7. Ventilation – Ensure adequate ventilation to removes fumes, gases,
dust and other air borne hazards.
8. Food storage – If food is allowing in certain areas, ensure it is stored
properly to prevent contamination.
9. First Aid – Be aware of the location of First Aid supplies and know how
to use them in case of minor injuries.
EMERGENCY PROCEDURE – Familiarize yourself with the emergency
procedures including the fire exits and evacuation plans.
Safety rules relating to tools handling storage in a work ship, safe tool
handling and storage are crucial for preventing accidents. Such as using the

55
right tool for the job, keeping tools clean and sharp, storing them securely
and wearing appropriate PPE.
GENERAL TOOLS SAFETY
1. Use the right tools – Using the wrong tool for a job can lead to accident
and damage of tools.
2. Keep tools clean and sharp – Clean tools after each use and sharpen
them regularly to ensure safety and efficient operation.
3. Store tools securely – store tools in a designated rack, holders or tool
boxes to prevent them from falling or being misplace.
4. Carry tools safely – Never carry sharp or pointed tools in pockets. Use
tool box or tool belt when working at height, use a belt or hoist to
transport tools.
5. Be aware of your surrounding – Pay attention to your work area and
other people to avoid accident.
6. Power tools – Store power tools in a dry place and unplug after use.
7. Heavy tools – Store heavy tools in low stable locations to prevent them
from falling
8. Organized Storage – Keep tools organized and easily accessible on a
tool box, on a tool wall or in a tool rack.
9. Keep exits clear – Ensure that doorways and exits are free from
obstructions.
10. Avoid distractions – Focus on the tasks at hand and avoid
distractions that can lead to accidents.
SAFETY RULES RELATING TO MACHINE OPERATION
Operating machinery safely requires adherence to specific rules to
prevent accidents and injuries. This includes: -
 Machines Guards – Never operate machinery without safety guards
– in place and ensure they are functioning properly.
 Pre operation Inspection – Before each use, thoroughly Inspect the
machine for any damage or potentials hazards. Report any issues
to a supervisor immediately.
 LOCK OUT/TAG OUT – When performing maintenance or repairs,
always follow proper lock out/tag out procedures. To isolate the
machine from energy sources.
 Distractions – Avoid distractions while operating machinery.
 Proper Training – Ensure all operators are properly trained on the
specific machinery they will be using.
 Emergency Stops – Ensure emergency stop buttons are accessible
and in good working order

56
  Supervision – If working with machinery that poses high risk ensure
proper supervision is in place.
 Never force machines – Do not attempt to force a machine to
perform task it is not design for.
 Safe speed – Operate machine at a safe speed and avoid sudden
movements.
SIMPLE MACHINES
When using simple machines like pulleys ensure they are secure before use
and handle sharp tools with care.
NLIFTING EQUIPMENT
When using lifting equipment, always check the equipment before use,
ensure the load is within the equipment’s capacity and be aware of
potentials hazards. Never bend down to lift a heavy load, ask for help.

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58