hull new construction - sept 2006

MARINE TRAINING SERVICESLLOYDS REGISTER

Hull New Construction Surveys

Some key points to consider during Hull New

Construction at the BUILDING YARD


Agenda

Review of LR Responsibilities during a New Construction Project Project Management and Survey Team Liaison with Owners Site Team The Basic Essentials Data and Document Control Key Data

Fundamentals of Shipbuilding Quality Procedures and Standards New Building Surveys Construction Monitoring Procedures


Project Management and Survey Team

Project Manager for each project Ensures contractual requirements are satisfied Acts as main point of contact for owners and shipyard Co-ordinates all survey/inspection activities Ensures all problems/issues are resolved Monitor progress and time spent Arrange deliverable certificates and reports

Team of professionally qualified surveyors Hull construction surveyors Machinery construction/installation surveyors Electrical/control surveyors NDE specialists & metallurgists


Liaison with Owners site Team

Start-up meeting with owners team Technical briefing for owners supervision team Co-ordinated approach for monitoring and survey activities Outstanding issue list following sea trials Issue full term certificates Close down meeting/follow up actions


The Basic Essentials

The Request for Services (Form 2500):Contains what LR is contracted to deliver and is our legal contract.

Key Event Dates (Steel Cutting, Keel Laying, Launch, Delivery):Impact on stage payments, Statutory Regulations and preparation of deliverables.

Division of work:Who does what, (London Office, Local P.A., Site Surveyor, Other LR Offices) and Extant Instructions, Checklists, Reports, Flag state authorisations.


Data and Document Control

Requested plans for approval are submitted on time and any

amendments dealt with - maintain a master lists, up to date checklist.

Design Appraisal Document (DAD)s complied with and any

outstanding items closed.

Correspondence (incoming/outgoing) recorded as necessary dealt

with.

Demonstrate compliance with LRs Quality Procedures (CM 02-04-01)


Key Data

Special steel locations - High Tensile, through thickness, forgings, castings

Construction Monitoring Locations for Ship Right Notation.

Structural Details- Alignment, Gaps and Edge preparations

Welding Details- Leg-Lengths, Throat, Thickness, Full and Partial Penetration, Spec Techniques


Shipyard Procedures & Standards

Building Standards

Shipbuilding Quality Standard IACS Shipbuilding and Repair Quality Standard

Weld Procedures Specifications (WPS)

Welders Qualified to recognised standards Approved Welding Procedures different grades & processes Approved Welding Consumable Approved Shop Primers being used



Non Destructive Examination NDE Plan to be approved by surveyor in accordance with the Rule

Requirements for the NDE - based on length of butts and seams and number of intersections

Usually a mixture of RT, UT & MPI To be recorded and evaluated

NDE as part of the quality control procedures

Production NDE (usually UT) Start and end of all submerged arc welding runs

Suitable NDE Qualified operators and procedures

Reviewed NDE Procedures



Tank TestingApproved Tank Testing Plan All Tank Boundaries to be tested to confirm that their design and construction is satisfactory. All pressure gauges to be calibrated.

Air Leak Tests The application of a protective coatings is not allowed prior

to test excluding the shop primer Air pressure be raised to 0.2 bar for 1hour and then lowered

to 0.15 bar Hydrostatic Strength Tests (Structural Testing) Hose Testing: Max distance of 1.5m (not less than 2.0bar) Fillet Weld Air Tests Vacuum Leak Tests IACS UR-S14 Testing Procedures for Watertight Compartments IACS Recommendation No. 72 Confined Space Entry


Tank Testing - Fillet Weld Air Tests


Tank Testing Vacuum Leak Tests


Structural Testing

Rules to be complied with - See Part 3 for details

Correct air pressures/hydrostatic test heads applied - Do Not Over

Pressurise - Danger

Gauges calibrated and working correctly

Vacuum Boxes and fillet air testing

Listen and look for BIG and SMALL leaks

Deformation during and after testing


The New Building Project - Hull Construction

Materials Forming Block Surveys Pre-erection Surveys Dock Erection joints Surveys Patrols of work in progress Construction Monitoring Procedures Deck house and Accommodation Anchoring and Mooring Equipment Other items


Materials

From stockyard to production, there needs to be clear identification

of different grade of plates and sections: Visible colour coding and

marking

Spot check material scantling during routine patrols and surveys

Insert plates/partial renewals must be correct grade for the locations

Handling of special steels: avoid contamination and damages

stainless steel and aluminium

Identification and Traceability


Typical Steel stockyard with plates stored in the as rolled condition.


Steel plate entering the shotblast and primer treatment line.


Steel plate immediately after shotblasting and priming.


Steel plate marking after blasting and priming. Marking is done automatically by machine.


Transferring identification marks and correct grade manually - just after blasting and priming.


Forming (Hot & Cold)

Correct procedures need to be applied

Operators need to be properly trained and experienced

Verify that heating is being monitored during the process : Use of Tempel sticks and/or temperature probe

Use guidance notes and work instructions.

Template to be used to verify the shape of curvature to steel plate and structural members


Plates being Line heated prior to application of water to shape and form the plate to the required curvature .

Hot Forming Line Heating


Wooden template being used to check the shape of a side shell plate during Line heating .

Hot Forming Line Heating


Cold Forming Mechanical forming


Block Surveys

Verify structural details against approved plans to ensure:

the working drawings comply with approved Plans

welding details and quality visual, leg-length & throat

plate and section edge preparations for fit to next unit

W.T. /O.T. Boundaries for penetrations missing members collars, bkt, etc.

Positions of air and drain holes should not in high stress areas and placed in correct places for drainage and pressure relief

alignment, deformation, unsupported structure


Numerical Control steel cutting. This is the first stage of the block where the piece parts are cut from the parent plates.


Piece parts from parent plate now arranged ready for sub assembly of block sections.


Automatic fillet welding of stiffeners for sub assembly.


Submerged Arc Welding for plate joints. Note run off plate at the end of the weld.


Transportation of sub-assembly to the block construction shop


Typical double bottom block


Pre-erection Survey

Alignment, deformation, any unsupported structure and welding

Lifting lug positions and removal - MPI testing of areas effected to

verify possible cracks due to stress and notches.

Structural testing in way of outfitting is completed or noted for later

- before insulation, pipe, cable, machinery equipment and etc are

fitted and access to weld is not possible


Pre-erection of fore body section

Four individual units brought together to form one single block

Lifting lugs will also be removed after erection


Typical Pre-erection for Aft body / Machinery space


Typical pre-erection for side shell


Pre - erection of a very large section of main hull and LPG tank


Erection joints Survey

Alignment, deformation, unsupported structure welding and missing

members

Fairing aid positions Not on stress areas

Bad workmanship/practices - wide gaps, excessive force, Backing plates

Adverse environmental conditions

Welding in rain Wind blowing away shielding gas Steel temperature too low in winter


Typical erection of double bottom blocks being placed in the building dock (Oil Tanker) .


Typical erection of double bottom blocks (Oil tanker) laid out in the dock bottom ready for fairing .


Typical lower hopper joint to double bottom(Oil Tanker). This is a Critical location


Typical erection joint of double bottom to longitudinal and transverse bulkheads (Oil Tanker).


Typical erection joints forward - Longitudinal bulkhead and lower hoppers to double bottom (Oil Tanker) .


Typical erection joint of forward side shell to double bottom (Container Ship)


Patrols of work in progress

Carry out regularly, daily if possible

Tell the yard and owners that you do patrols

Vary your routine, time and places

Mark up with chalk or paint any problems you find and report

them to QC

Follow up any problems identified


Ceramic baking strip fitted at the root of a full penetration weld


Ceramic backing strip viewed from the root side of the weld .


Poor root weld after removal of the ceramic backing strip .


Arc air gouging of a shell butt prior the root sealing run


Shell butt weld after arc air gouging


After repairing of shell butt weld


Construction Monitoring Procedures

LR ShipRight Procedure ShipRight (CM) assigned as a class notation Mandatory Part of ShipRight procedures involving

Materials Alignment Welding Construction procedures

Objective To ensure that special attention is given to critical joints

to avoid stress concentrations



Construction Monitoring Plan Approved - by PAS Critical locations identified at design approval stage tolerances

for fit up, gap, etc

Enhanced alignment tolerances specified by LR Shipyard develops working procedures to control fit-up at these

locations

Shipyard controls checked by the surveyor at the critical locations by monitoring & direct inspection

This procedure is unique to LR



MidshipSection Plan showing location of Critical Areas


Construction Monitoring ProceduresMidship Section Critical Areas


Surveyor confirming that the 100mm reference mark (to indicate position of girder under)


Close up of same location as previous slide


Same reference mark (100mm) for hopper joints alignment to double bottom girder


Another typical example of a Critical joint at the connection of the tank top with the longitudinal bulkhead transverse web brackets


Typical transverse end bracket toe or side shell frame lower bracket toe at the connection to the double bottom tank top or lower hopper plating


Deckhouse and Accommodation

Fire protection and detection as per approved plans

Crew Accommodation (as per Flag State)

Routing of cables and pipes

Structural compensation


Typical complete Deckhouse being erected as single unit.

Theses units are often constructed outside the shipyard at a specialist contractor.


Anchoring and Mooring Equipment

Verify supplied anchors and cables against approved equipment plan

Anchors and cables from approved works with LR Certificates

Certificates verified with the marking on the equipment

Check Rule requirements for Mooring lines


Anchoring and Mooring Equipment


Other Items

Keel Sights (Especially on slipways )

Principal Dimensions (L.B.D.) , Draft Marks (FWD and AFT for Tonnage, Midships not required)

Non-LR certified materials (other IACS members) Should not exceed 10% of lightship

Outfitting (pipe supports in tanks and on deck)

Bilge Keels and their attachments


If all goes well with the Project then LR is the winner and the Client comes back


Building better business

Working together to improve business performance

hull new construction - sept 2006

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