Institute of Shipbuilding Technology Implant Training

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INSTITUTE OF SHIPBUILDING TECHNOLOGY IMPLANT TRAINING

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CHAPTER-1 INTRODUCTION
CHOWGULE SHIPBUILDING DIVISION
-SBD YARD LOUTULIM
-SBD YARD RASSAIM
-GADEGALLY PLANT (PLATE AND PIPE PREPARATION PLANT)
-WAREHOUSE VERNA
The two Shipyards of Chowgule (one at Loutulim and the other at Rassaim) are
located at a distance of 7 k.m. from each other.They have a Plate preparation and
Pipe bending Plant which is situated at Gadegally.Three Goliath Cranes are present
(two at Loutulim Shipyard & one at Rassaim shipyard) each of 60 Tons capacity and
Two tower cranes are present, each one at the two shipyards.
An Investment of Approximately INR 110 Crores (INR 1100 Million) was made for
creating the SHIPBUILDING DIVISIONS. This is apart from land and other basic
Infrastructure that already existed.
It has been estimated that the Chowgule shipbuilding divisions of both Rassaim and
Loutolim can deliver up-to 9 Ocean going multipurpose general cargo vessels per
year of around 5500 DWT each and One Offshore Patrolling Vessel Hull structure
which is of 2450 DWT.
For the past several Years, CCPL have been participating in various Trade shows such
as INMEX (Mumbai, India), SMM (Hamburg), Gulf Maritime Expo (Sharjah), Posidonia
2010 (Greece), Korea Marine tech (South Korea), Sea Japan (Japan).
The Chowgule Company Pvt Ltd is ISO 9001:2008 Quality System Compliant.

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The Loutolim yard is the main Yard for ship Construction since it has an Estimated
Area of about 42,000 square meters which is larger than the area of the Chowgule
yard at Rassaim.Covered shed for hull block fabrication and manufacturing of cargo
hatch covers are present at the Loutulim Yard. It has an End Launching Sequence Bay
with a Slip-way Rail length of about 220 meters.

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FACILITIES AT THE LOUTULIM YARD.
1) Two construction bays - 130m X 25m and 90m X 36m.
2) 2 X 60t Goliath crane one in each bay with height of 23m
3)Covered fabrication shed - 120m X 22.5m
4) Overhead cranes - 4 X 10ts, 1 X70 tons
5) Hatch cover fabrication shed - 82m X 25m
6) Overhead cranes in shed - 2 X 25 tons
7)Jib cranes - 8 X 1 ton
8) Jetty for outfitting
9) Tower crane - 16 tons @ 17m & 3.1tons @ 55m
10) Mobile cranes - 3 tons to 100 tons
11) Hydraulic positioning equipment for blocks of 600 ton maximum
12) Motorized side transfer trolleys

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13) 50 Tons Transporter (for transporting blocks/sections within the Shipyard)
Other Facilities Include ;
 Cherry picker with telescopic booms - 3 nos.
 Platform scissor lift - 1 nos.
 Welding machines
 CO2 - 157 nos.
 Automatic CO2 machines (Noboruders) - 38 nos.
 Submerged arc welding machines - 4 nos.
 Inverters - 65 nos.
 Rectifiers - 48 nos.
 TIG - 6 nos.
 Gauging - 3 nos.
 Stud welding - 6 nos.

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Area Statement:
1. Area of the Plot. 52,075.00 sq.m
2. Net effective Plot area. 52,075.00
3. Covered Area of Existing shed. 2901.38 sq.m
4. Plot coverage of existing shed. 5.57%
5. Covered area of permanent buildings. 2949.50 sq.m
6. Plot coverage of permanent buildings. 5.66%
7. Covered area of Temporary structures.(shed & containers) 3247.80 sq.m
8. Plot coverage of temporary structures. 6.24%
9. Total Plot Covered Area 9098.68%
10. Total Plot Coverage 17.47%
11. Floor area of Existing Shed a)Ground Floor 2901.38
12. Floor area of permanent Buildings. a)Ground floor 2949.50 sq.m
b)First floor 972.66 sq.m
13. Floor area of Temporary Structures(shed & containers).a)Lower floor 3247.80 sq.m
b)Upper floor 330.0. sq.m
14. Floor area ratio of (Existing Shed) 5.57 %
15. Floor area Ratio of (Permanent Buildings) 7.54 %
16. Floor Area ratio of Temporary structures (shed and containers) 6.87 %
17. Total Floor Area Ratio 19.98 %

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Double Bottom Fabrication Process
Stations :1A-6A
Time Taken :20 days
Work on Stations:
I 1A 2A 3A Double bottom Pre-Fabrication 5 Days
II 4A Double bottom Assembly 5 Days
III 5A Double bottom Assembly/Welding 5 Days
IV 6A Double bottom Toppling/Welding 5 Days
PRE-FABRICATION
It is a process in which all the parts required for fabrication of the Double bottom
tanks are fabricated.All the Pre-Fabrication work is carried out on station 1A,2A and
3A. This altogether takes 5 days.
Fabrication Protocol followed here in Chowgule is:
1). Station 1A-
 Scantling Check of Bottom plates and Longitudinals.
 Laying of bottom plates on skids
 Bottom plate fitment
 Diagonal check
 SAW welding of Bottom Plate Seam joints.
 Diagonal check after welding.

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 Verification of longitudinals and Frame lines.
 Fitments of Longitudinal using Vacuum hydraulic fitter.
 Welding of Longitudinal with Automation welding wagon.
 Dry survey.
 Painting of weld seams.
2). Station 2A-
 Scantling Check of Tank Top Plates & Longitudinals.
 Laying of Tank top plates on Skids.
 Tank-top plate fitment.
 Diagonal Check.
 SAW welding of Tank top plate Seam joints.
 Diagonal Check after welding.
 Verification of Longitudinal and frame lines.
 Fitments of Longitudinals using vacuum hydraulic fitter.
 Welding of Longitudinal with Automation Welding wagon.
 Dry Survey.
 Painting of Weld Seams.

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3). Station 3A-
 Scantling Check of all the Components.
 Fitment of Flat bars,brackets on frames and Longitudinal Girders.
 Welding of Flat bars,brackets on frames and Longitudinal Girders.
 Dry Survey.
 Painting of Weld lines
4). Station 4A-
 Laying of Tank-top pane.
 Laying/Fitment of prefabricated longitudinal girders.
 Laying/Fitment of Prefabricated frames.
 Pre-stressing at center (10mm) & Locking.
 Flat welding
 Dry survey.
5). Station 5A-
 Pre-stressing at Center (10mm) & Locking.
 Vertical welding.
 Bottom panel fitment.
 Bilge plate fitment.
 Bilge plate Ceramic welding.
 Dry survey.
6). Station 6A-
 At this Station the Double bottom Tank is Toppled by using EOT crane (70+32).

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 This is done in order to weld in Flat position,since its difficult to weld in Over
head position.
 This is the finishing Station.
 This takes 5 days to Complete.
 Final dry survey of the block is carried out.
 Then the block is taken out using the Transporter.\
This is whole process that is being carried out in the Chowgule Shipyard in Loutulim
in order to Fabricate a Double Bottom.

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WING TANK FABRICATION PROCESS
Stations :1B-6B
Time taken :16 days.
Work on Stations:
I 1B 2B 3B Wing Tank Pre-Fabrication. 4 days
II 4B Wing Tank Assembly 4 days
III 5B Wing Tank Assembly/Welding 4 days
IV 6B Wing Tank Toppling/Welding 4 days
Fabrication of Wing Tank:

Represented by side B consists of total 6 stations. This takes 16 days to complete.
The activity takes place at total 6 stations as given below.
1. Station 1B (prefabrication)
4. Station 4B (Assembly)
Erection Sequence:
1. Side shell
2. Frames
3. Brackets
4. Main deck
5. Raised deck
6. Inner shell

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Side shell is shifted to station 4B. After fitting frames, flat welding is carried out
(kx-200). Water level is to be done and then vertical welding is carried out. Inner
shell is to be placed and fitting is started. Dry survey is carried out. This takes place in
4 days.
Station 5B
Flat welding is done. Hatch combings are fitted and welding hooks are welded. So
the section can be lifted by crane and then toppled at station 6. The dry survey is
carried out.
Station 6B
Section is toppled and remaining welding is completed in all manners.
Then supporting Flat bars are fitted which helps during erection. Then dry survey is
carried out.

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Ongoing Projects:
Samarth-class offshore Patrol Vessel.

The Samarth-class offshore patrol vessel are a series of six offshore patrol vessels
(OPV) being built by Goa Shipyard Limited for the Indian coast Guard.
Specification
The S-class is 105 meters (344 ft 6in) long with a displacement of 2350 tonnes.
Features include Integrated Bridge System (IBS), Integrated Machinery Control
System (IMCS), Power Management System (PMS) and High Power External fire
Fighting System. They are designed to carry one twin engine Light Helicopter and five
high speed boats including two pal-finger QRIBs for fast boarding operations, search
and rescue, law enforcement and Maritime patrol. This S-class vessel is also capable
of carrying Pollution Response Equipment (PRE) to combat oil spill contamination at
Seas.
General Characteristics:
Type: Patrol Boat
Displacement: 2450t (2410 Long tons;2700 short tons)
Length: 105m (344ft 6in)
Beam: 13.6m (44ft 7in)
Draught: 6.2m (20ft 4 in)
Installed Power: 2x20-PA6B-STC Engines (9100kW )12200 HP
Propulsion: 2x Controllable Pitch Propellers.
Speed: 23 Knots (43Km/h)
Range: 6000 Nm (11000 Km,6900mil) at 12Kn

(22Km/h)

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Endurance: 20 days (480 HOURS)
Complement: 18 Officers and 108 Sailors
Armament: 1x30mm CRN 91 Naval Gun 2x12.7mm HMG

(Hand Machine Gun)

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Block fabrication:
The blocks at the Chowgule shipyard are Constructed in 2 ways. Block
10,20,30,80,100 are constructed in upside down manner on a flat leveled skid
prepared by cutting flat angled bars which are marked at an equal level using the
water level method, the platform deck are fist fitted on the skids and then all the
structural members are fitted step by step for example: bulk

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1

INSTITUTE OF SHIPBUILDING TECHNOLOGY IMPLANT TRAINING

CHOWGULE SHIPBUILDING DIVISION

-SBD YARD LOUTULIM

-SBD YARD RASSAIM

-GADEGALLY PLANT (PLATE AND PIPE PREPARATION PLANT)

INSTITUTE OF SHIPBUILDING TECHNOLOGY IMPLANT TRAINING

INSTITUTE OF SHIPBUILDING TECHNOLOGY IMPLANT TRAINING

FACILITIES AT THE LOUTULIM YARD.

1) Two construction bays - 130m X 25m and 90m X 36m.

2) 2 X 60t Goliath crane one in each bay with height of 23m

3)Covered fabrication shed - 120m X 22.5m

4) Overhead cranes - 4 X 10ts, 1 X70 tons

5) Hatch cover fabrication shed - 82m X 25m

6) Overhead cranes in shed - 2 X 25 tons

7)Jib cranes - 8 X 1 ton

8) Jetty for outfitting

9) Tower crane - 16 tons @ 17m & 3.1tons @ 55m

10) Mobile cranes - 3 tons to 100 tons

11) Hydraulic positioning equipment for blocks of 600 ton maximum

12) Motorized side transfer trolleys

INSTITUTE OF SHIPBUILDING TECHNOLOGY IMPLANT TRAINING

13) 50 Tons Transporter (for transporting blocks/sections within the Shipyard)

Other Facilities Include ;

 Cherry picker with telescopic booms - 3 nos.

 Platform scissor lift - 1 nos.

 CO2 - 157 nos.

 Automatic CO2 machines (Noboruders) - 38 nos.

 Submerged arc welding machines - 4 nos.

 Stud welding - 6 nos.

INSTITUTE OF SHIPBUILDING TECHNOLOGY IMPLANT TRAINING

1. Area of the Plot. 52,075.00 sq.m

2. Net effective Plot area. 52,075.00

3. Covered Area of Existing shed. 2901.38 sq.m

4. Plot coverage of existing shed. 5.57%

5. Covered area of permanent buildings. 2949.50 sq.m

6. Plot coverage of permanent buildings. 5.66%

7. Covered area of Temporary structures.(shed & containers) 3247.80 sq.m

8. Plot coverage of temporary structures. 6.24%

9. Total Plot Covered Area 9098.68%

10. Total Plot Coverage 17.47%

11. Floor area of Existing Shed a)Ground Floor 2901.38

12. Floor area of permanent Buildings. a)Ground floor 2949.50 sq.m

b)First floor 972.66 sq.m

b)Upper floor 330.0. sq.m

14. Floor area ratio of (Existing Shed) 5.57 %

15. Floor area Ratio of (Permanent Buildings) 7.54 %

17. Total Floor Area Ratio 19.98 %

INSTITUTE OF SHIPBUILDING TECHNOLOGY IMPLANT TRAINING

Double Bottom Fabrication Process

Time Taken :20 days

I 1A 2A 3A Double bottom Pre-Fabrication 5 Days

II 4A Double bottom Assembly 5 Days

III 5A Double bottom Assembly/Welding 5 Days

IV 6A Double bottom Toppling/Welding 5 Days

Fabrication Protocol followed here in Chowgule is:

1). Station 1A-

 Scantling Check of Bottom plates and Longitudinals.