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TOPIC 4: SHIPYARD PRACTICES
SHIPYARD v Demand of shipping transportation increasing Ø Creating pressure on shipbuilding industries �Place where ships are repaired and built. �Constructed nearby the sea or tidal rivers to allow easy access for the ships. �The site of large shipyard will contain many specialized cranes, dry dock, slipways, dust-free warehouse, painting facilities and extremely large areas for fabrication of the ships.
SHIPYARD AND SHIPBUILDING § Main Objectives of the shipyard Ø Economical productions Ø Ensure the safe working environment Ø Environment friendly activities of the shipyard § Main purposes of the ship building Ø Transfer goods, materials , animals etc Ø Safely, economically and timely Ø Environment friendly ship operation
FACTORS ESTABLISHING SHIPYARDS § Huge opportunities: Ø Good Geographical position Ø Shipyard location & layout Ø Good communication facilities Ø Many inland shipping routes Ø Low labor cost Ø Friendly working environment Ø Well trained workers for design and manufacturing
Systematic Shipyard Layout (Flow of materials)
Present Condition of Shipyard Layout (Flow of materials)
SHIPBUILDING PROCESS 1. 2. 3. 4. 5. 6. 7. Design Steel Cutting Block Assembly Painting Block Erection Launching & Outfitting Sea trial & Delivery
Design Part Basic design • Basic modeling(Speed, loadage etc. . ) • Flow analysis Hull design • Structure & Fatigue strength analysis Outfitting design • Pipe laying & Electrical wiring • Engine room design
Design Part ◈ Basic design 1. A basis modeling which taking a carrying capacity and speed 2. A performance assessment to a computer simulation. 3. And computer float analysis
Design Part ◈ Hull design 1. The design are firm to the iron board of the at least to the maximum and to develop fast speed. 2. Many simulation about the body of ship structure and computation need.
Design Part ◈ Outfitting design 1. A machinery and tools of the boiler room conduit install task. 2. install the cabin interior, the Electrical wire and pipe.
Steel Cutting • Steel Cutting The work that the steel place is automatically cut based upon production design in information
Steel Cutting • Cutting Progress 1. Marking by NC machine 2. Marked steel
Steel Cutting • Cutting Progress 1. 3. Cutting 4. In order assembly pregress
Steel Cutting • Cutting Equipment Gas based cutter Major method, by oxygen- acetylene gas
Steel Cutting • Cutting Equipment Laser cutting Cutting that use molting, evaporation and high-handed gas It`s method that can cut 5~7 mm steel for the present In oder to apply, need to more development than now
Block Assembly ØSynthesis of Piece Assembly, Sub Assembly, Cutting/Bending and so on work that assemble area of ship hull space.
Image in block assembly factory Image that set Pin Jig on curved surface of ship hull
On bottom of a ship department traveling sale frame sticking Image that is built on Tank Top’s upside. Flat position of welding is proceeded because do turnover after attach traveling sale here
Image that stern tube block is worked Some innards and block assembly together worked image Manufacturing Process Gyeongsang National University
Image that move block by Heavy Lift Transporter Image of block that come by painting shop for painting
Painting Surface Inspection Surface preparation Painting Dry Final inspection (Block) Dry Touch up
Painting Block Assembly Inspection for 2 nd surface preparation Touch up High pressure steam cleaning Dry Inspection (Hull exterior) Launching External painting
Block Erection �The process of building a ship afterwards the welding, after moving the blocks (which was made on the ground) by using the Gantry Crane.
PE : Pre-Erection �PE : Pre-Erection - PE is the process of making large before moving blocks to the dock.
Keel Laying & Lord Point �Keel Laying - The standard block in the Erection process �Lord point - The connection point between the wires and the block.
Floating Dock SLS : Skid Launching System - Samsung Heavy Industries - STX Shipbuilding
Land Building - Hyundai Heavy Industries DAM - Hanjin Heavy Industries
Launching �Major Methods 1. Slip-way launching 2. Float-out launching 3. Lift-on launching
Outfitting • Methods Each mechanic part assembling & pipe laying & electronic equipment installing.
Sea trial & Delivery < Sea trials > Once the construction of the vessel is completed a sea trial is conducted in the presence of the ship’s owner register of shipping.
THE AMOUNT OF FUEL CONSUMED TEST SPEED TEST THE TEST LISTS OF SEA TRIAL TURNING TEST STEERING TEST ACCELERATION TEST
Naming Ceremony < Naming ceremony > Once the vessel is completed, it is named, and this naming process is called Naming ceremony.
Problems occur on shipbuilding industry Ø lack of infrastructures and equipment's facilities, Ø lack of skill workers and knowledge Ø improper governmental activities and dedication. Ø Lack of technology
ENVIRONMENTAL ASPECT �An environmental aspect is define as an element of facility’s activities, products or services that can or does interact with the environment. �An environmental impact is define as any change to the environment, whether adverse or beneficial, resulting from facility’s activities, products or services.
Environmental Aspect Environmental Impact(s) Emissions of volatile organic compounds (VOCs) Air pollution, smog Discharges to stream Degradation of aquatic habitat and drinking water supply Spills and leaks Soil and groundwater contamination Electricity use Air pollution, global warming Use of recycled paper Conservation of natural resources
Environmental factors of Shipyard activities u. During hull preparation for painting the wash water including Øthe removing marine growth on hull and old paint Øhigh levels of heavy metals üContaminants with the nearby waters. u. During repairing of old ships ØWastages, sewage, oily things ØCoating of the hull, ballast and bilge water üpollute marine environment u. Paint stripping and painting activities are significant sources of pollution Ø Solvent-based paints including volatile organic compounds(VOCs), anti-fouling regulated hazardous