Asigmnet 1 - Shipyard
Asigmnet 1 - Shipyard
Asigmnet 1 - Shipyard
Assignment 1
TITLE PAGE
1.0 INTRODUCTION 1- 2
11.0 CONCLUSION 22
12.0 RECOMMENDATION 23
13.0 REFERENCES 24
1.0 INTRODUCTION
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Hence, it is also linked to other sectors including security, transportation, research
purposes, materials and the environment. Next, in maintaining the competence among the
rivals in the industry, the shipyard must ensure the processes occurred in the shipyard
flow swiftly. In fact, there are various types of shipyard layout implemented in the
industry.
For instance, the U and L shape. These two shapes are the alternative and ideal to be
practiced for the shipyard globally.
The main aim for this report is to identify main problems in the current shipyard that I
chose for this report, which is Besiktas Shipyard. Hence, introduce a better shipyard
layout that can enhance the efficiency and productivity in ship building process. This
report mainly highlights the root cause and a better implementation that can be practiced
at the shipyard.
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Shipyard X or known as Besiktas Shipyard is one of the best established ship building
and ship repair yards of Turkey with proven experience in building most sophisticated
specialised vessels up to 26,000 dwt and repairing any type of vessl up to 382 meters.
Besiktas Shipbuilding offers a wide range ships of including Offshore Support Vessels ,
Chemical Tankers , Tugboats , Workboats and Pilot Boats. In fact, Besiktas Shipyard is
the most active ship repair yard of the Mediterranean region having more than 150
dockings per annum with 3 graving and floating docks up to 382 m.
Besiktas Shipyard has more than 150 dockings per annum with 3 graving and floating
docks up to 382 m. Besiktas Shipyard is well equipped with pier space, workshop for
different trades and extensive area for building new Barges, CPO, Tug boats and SPOBs.
Shipyard X has 2 slipways, 3 dry docks, lay berths and shore cranes, a scrap area, a main
office, blasting and tank coating facilities, mechanical workshop, steel prefabrication
workshops, storage facilities, hull shop, new building pre-assembly, pipe workshop and
other facilities
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Figure 1: Besiktas Shipyard
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2.1 PROBLEMS IN SHIPYARD X’S LAYOUT
1. LIMITED SPACE
The whole area is governed by the space required for the various stages of the ship
building process. Such spaces should be of a size capable of accommodating the
proposed flow of materials through them. The size of the various spaces should be
sufficient enough, where there is a level workload through the production process.
In practice, the workload is not level and it is normal to incorporate buffer areas
where materials may be stored before moving on to the next stage in the process.
The amount of space required for the various stages can be estimated by
considering the building programme of the yard. So, it is necessary to plan a new
production planning, possible re-allocation of some areas and changes in basic
construction techniques to enhance the flow of material through every shops.
Ship yards are the places where a big scale work happen. The machinery used is
massive, which often requiring immense skill and strength to be handled. A minor
discrepancy while working at such machinery can prove to be extremely fatal for
any shipyard worker. The actual amount of mechanisation and automated
machinery will rely on the capital expenditure available, availability of workforce
and the wage level of the area or country.
3. DESIGN OF SHIPYARD
The design layout of shipyard need to be relevant in ensuring the work flow of
building process able to run swiftly, without any delay and major circumstances. If
the section in the shipyard is not properly positioned or placed, it will cause delay
in shipbuilding processes. For instance, warehouse is located far away from
outfitting workshop, it can cost time in delivering materials from warehouse to the
workshop.
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4. MATERIALS HANDLING
The speed, direction and efficiency of material flow will depend on the type of
transportation used in the shipyard. Ironically, the materials handling equipment
should be kept at a minimum level. It is necessary for the correct item is deposited
in the correct place at the correct time using least effort and cost to obtain an
efficient work flow process.
1 12 13
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19 21 29
22 28
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26 27
25 23
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1. Head office workshop
2. Offices/guest rooms 22. Prefabrication/ cold forming
3. Offices/dining hall workshop
4. Warehouse 23. Prefabrication workshop
5. Outfitting workshop 24. CNC cutting/ prefabrication
6. Pipe workshop workshop
7. Paint hall 25. Steel and pipe storage area
8. Outfitting workshop 26. Block production area
9. Mechanical workshop 27. Slipway 160mx 36m/ workshops/
10. Grid storage/ compressor room sub. Offices
11. Subcontractor offices 28. Block production/shipbuilding flat
12. Owner rep. offices/GHSE office zone
13. Fast boat station 29. Block production/shipbuilding flat
14. Denture-eskihisar boat station zone
15. Warehouse 30. Slipway 175mx 28m
16. Chemical separation plant 31. Block production area
17. Pipe bending workshop 32. Steel and pipes storage
18. Main gate 33. Hatch cover repair area
19. Warehouse 34. Hatch cover repair area
20. Maintenance workshop 35. Parking area
21. CNC Cutting/ prefabrication
As we can see in figure 2 of the layout, this shipyard arrangement is designed with overall
safety measure and it also uses the modular design approach where all stations are arranged a
ccordingly. The processes start from the stockyard where all materials are stored and then
process in the machinery workshop until the block is assembled. The completed ship will
start directly to the sea at the slipway. The main offices of the administration are close to the
slipway so they can effectively monitor the shipbuilding process. This shipyard layout is
inspired by the Singapore-based Gulf Shipyard, where the modular construction approach
was implemented. This shipyard is not just capable in ship repair and maintenance but also
can build a ship.
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4.0 FACILITIES FOR SHIPYARD X
Besiktas shipyard is fully equipped with safety equipment for safety purposes. Fire
extinguisher is located 4-5 boxes in each workshop in each design of the building
shown above. Emergency alarm and camera will always be in the shipyard compound
everywhere.
The main administration office is located right after the main entrance to the business
where management and management staff perform their duties. Main office location i
s a bit far from fabrication workshops and machine workshops to avoid noise hazard
from that location.
4. Cafeteria
Cafeteria is one of the facilities for the manpower to have a meal, making it easy for
them to eat rather than go outside, which will waste time and reduce shipbuilding
process efficiency. The cafeteria serves breakfast and dinner, with international TV
channels, billiard and table tennis.
5. Guestroom
The Shipyard has a modern guest room floor with 15 rooms available for comfortable
accommodation of clients. These rooms are offered free of charge during the repair of
vessels.
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6. Warehouse/Stockyard
Warehouse / stockyard is a place where materials received from external sources such
as plates, steels and other materials are stored before being transported or transferred
to the different workshop.
7. Machinery Workshop
Machinery workshop is where machinery such as CNC and Cam are used to produce
high-precision machine parts such as parts of the screw and nuts.
8. Fabrication Workshop
Fabrication workshop is where materials that used as the structure of ships are cut,
rolled, bent and pressed. This workshop is facilitated with gantry crane in order to lift
heavy materials. Furthermore, this workshop provided with welding bay, where all the
materials are being weld to join the necessary parts either by using machinery or
manpower.
It is an area of final block assembly. The aft, hull and fore of the ship will assemble
together. The block erection can be done by moving the block from the block buffer
area using gantry crane. Then, the welding processes took place to combine all the
block and produce a new complete ship body.
18. Slipway
Slipway is the facilities used to launch the ship following completion of the
shipbuilding process. Usually, the slip used end-way launching to launch the ship and
most of the shipyard using this concept if sufficient internal water area is available.
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Besiktas Shipyard always strive to be the best shipyard in Turkey. Therefore, they have
the latest, technologize and automatize machinery and equipment used at the yard. The
Shipyard’s jetties are deep enough to accommodate every kind of repair vessels in
premises. A total of one floating crane, two jib cranes, three tower cranes, gantry crane on
graving dock, two jib cranes on floating dock with capacities ranging from 20t to 80t, are
available at berths and docks.
The total berth length is about 1.875 meters with an average draft of 11 m. The depth in
yard’s area ranges from 8 meters to 16 meters.
1. Slipway
A slipway, also known as boat ramp or launch, is a ramp on the shore by which
ships or boats can be moved to and from the water. They are used for building and
repairing ships and boats, and for launching and retrieving small boats on trailers
against the greased ramp would require too much force. Therefore, for dry-
docking large ships, one must use carriages supported by wheels or by roller-
pallets. These types of dry-docking installations are called "marine railways".
Nevertheless the words "slip" and "slipway" are also used for all dry-docking
installations that use a ramp.
1. Welding workshop
This is where all materials or cut parts are fabricated into sub-assemblies. Various
type of welding process are carried out here such as, MMAW, GMAW and GTAW.
The sub larger assemblies with compartments, piping system, and larger assemblies
are being formed into block assemblies or modules, which these process are carried
out either manually or automatically
This is a place where materials are rolled, cut, pressed, bent and so on. In the
shipyard, it is more to a closed fabrication areas of more than 10.000sqm. It is
equipped with three CNC plasma cutting machinery with up to 100 mm thickness.
The crane capacities and heights are designed to build the ship blocks in sections
inside the workshop.
The capacity of steel production is 30 tons per day, reaching an annual figure of
12.000 tons. The lifting capacity is max 80 tons/total of 12 cranes and the internal
height is 30 meters.
Figure 5: The Steel prefabrication Workshop
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3. Mechanical Workshop
The workshop has a wide range of machinery to handle mechanical repairs of engines,
pumps, heaters, boilers, compressors and gears. Experienced technicians able to carry
out turbocharger overhauling, reconditioning, retubing, boring, lapping and machining
of parts in our facilities. The Shipyard also cooperates with licensed workshops for
special tasks such as crankshaft machining.
4. Pipe Workshop
The pipe workshop is a place where a fabrication of steel, stainless and copper pipes
for cargo etc. are being conducted. The pipe workshop has 1.500sqm closed area. The
huge capacity of workshop enable workers to conduct the fabrication of steel,
stainless and copper pipes for cargo, ballast, heating and hydraulic systems. The
workshop is capable of cold bending and high quality pipe fabrication with
experienced workers. Stainless steel and mild steel pipe works are manufactured in
two separated floors to ensure every space are well-used.
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5. Painting Workshop
This is a place where all of painting works are being done. The painting workshop has
a huge working area which can fit a large capacity vessels and parts for painting work.
The painting workshop area includes the most modern equipment providing painting,
blasting, scraping facilities without being affected by dust, humidity and temperature.
Two closed blasting and painting facilities of 2,000sqm enable blasting and painting
processes to be carried out simultaneously regardless of the weather conditions. The
Shipyard has comprehensive facilities and experienced team of workers for all kind of
blasting works, painting, hydro-jetting up to 2.500 bars and internal tank blasting and
coating.
Shipbuilding and repair industry is not an easy jobs to handle. Every process
need a well-planned and organized work plan in ensuring the safety of workers and
the work flow can moves swiftly. As shipyard industry is one of the most risky
industry in the world, a lot of consequences and accidents can occur along the work
process. Therefore, various type of safety measures need to be considered by the
organization and workers, which need constant caution. In fact, the work environment
of shipyard is not comfortable to work in especially for an individual who has allergy
and other serious diseases.
Besides that, while at other times, it can be extremely cramped spaces; mere
fall can be high enough to cause fatal injury and even death. Cramped spaces
(confined spaces) are one of riskiest places to work in as it has a high hazard risk. A
shipyard worker is often at risk of physical injury to limbs, heads or other body parts
while working in such small spaces, along with more serious problems such as
suffocation, asphyxiation, etc. The first problem they face is the extreme nature of
shipyard workers ' working conditions. Also, in such small spaces, high pressure can
often cause much more severe and permanent damage such as rupture of the eardrum.
Shipyard workers often complain about their hearing abilities because they are
constantly working under conditions of high pressure.
In the shipyard industry, there is a no nine-to-five job which means there is no
fixed timings or schedule. The flow of work can be changed drastically in accordance
with any circumstances that occur along the whole process. The extreme nature of
their job means the workers have to be available at all times .The erratic time
schedules make this job harder than it already is, and definitely adds to the woes of
workers. Sometimes they even must work for several hours together without much
rest. This situation, had impact the workers both physically and mentally. Workers
will be fatigued, stressed and easily get sick.
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In a shipbuilding overview, design is the initial step. The design considerations vary
widely for different types of ships. Ships may carry materials or people, may be
surface or underground ships, may be military or commercial, and may be powered by
nuclear or non-nuclear power. In the design phase, consideration should be given not
only to normal construction parameters, but also to the safety and health hazards
associated with the construction or repair process. Furthermore, it is necessary to
address environmental issues.
Stainless steel plate is the basic component of ship building. The plates are cut,
shaped, bent or otherwise produced in accordance with the design's desired
configuration. The plates are typically cut to different shapes by an automatic flame
cutting process. These shapes can then be welded together to form beams I and T and
other members of the structure.
The plates will then be sent to manufacturing shops where they will be joined into
different units and subassemblies. At this juncture, the units are assembled and
integrated with piping, electrical and other utility systems. The units are assembled
using either manual or automatic welding or a combination of the two. Several
welding process types are used. The most common is stick welding, where the steel is
joined by a consumable electrode. Other welding processes use arcs protected by inert
gas and even non-consumable electrodes.
In addition, quality control inspections and tests such as radiography, ultrasonic and
other destructive or non-destructive tests must be carried out on units and welds.
Those welds found to be defective must be removed and replaced by grinding, arc-air
grouping or chiseling. At this stage, to ensure proper profiling, the units are blasted
abrasively and painted. Brush, roller or spray gun can be used to apply paint. Spraying
is used most frequently.
The larger units completed are then moved to the graving dock, shipway, or final area
of assembly. Here, the vessel is formed by the larger units. Again, there is a lot of
welding and fitting. The vessel will be launched once the hull is structurally complete
and watertight. This may involve sliding it from the shipway it was built into the
water, flooding the dock it was built into, or lowering the vessel into the water. Great
celebration and fanfare almost always accompany launches.
It enters the equipment phase after the ship is launched. It takes a lot of time and
equipment. The work includes cabling and piping fitting, galley and accommodation
furnishing, isolation work, electronic equipment installation and navigation aids, and
propulsion and ancillary machinery installation. A wide range of skilled trades
perform this work.
The ship undergoes both dock and sea tests after completion of the outfitting phase,
during which all the ship's systems are proven to be fully functional and operational.
Finally, the ship is delivered to the customer after all testing and related repair work is
performed.
Steel fabrication
A detailed discussion of the steel fabrication process follows. It is discussed in the context of
cutting, welding and painting for each materials.
Cutting
The shipyard's "assembly line" begins in the steel storage area. Large steel
plates of different strengths, sizes and thicknesses are stored here and are ready for
manufacture. The steel is then abrasively blasted and prepared with a construction
primer that preserves the steel during the various construction phases. The steel plate
is then taken to a manufacturing facility. Here the steel plate is cut to the desired size
by automatic burners. Then the resulting strips are welded together to form the
vessel's structural components.
Welding
Most ships ' structural frame is made of different grades of mild and high-
strength steel. Steel provides the required formability, machinability and weld ability
in combination with the necessary strength for ocean-going vessels. Although
aluminum and other nonferrous materials are used for some superstructures (e.g.
deckhouses) and other specific areas within the ship, various grades of steel
predominate in the construction of most ships. Other materials found on ships, such as
stainless steel, galvanized steel and copper-nickel alloy, are used for a variety of
purposes of corrosion resistance and to improve the integrity of structures. However,
in much less quantity than steel, nonferrous materials are used. Usually the more
"exotic" materials are used in shipboard systems (e.g. ventilation, combat, navigation
and piping). These materials are required to perform a wide range of functions
including ship propulsion systems, backup power, and kitchens, fuel transfer pump
stations, and fighting systems.
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Painting takes place at almost every shipyard location. The shipbuilding and
repair nature requires the use of several types of paints for different applications. Paint
types range from water-based coatings to epoxy coatings with high performance. The
type of paint required for a particular application depends on the environment the
coating will be exposed to. Simple brushes and rollers, airless sprayers and automatic
machines range from paint application equipment. In general, the requirements for
shipboard painting are in the following areas: Underwater (hull bottom)
Waterline
Topside superstructures
Internal spaces and tanks
Weather decks
Loose equipment.
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11.0 RECOMMENDATION
The success rate of shipyard depends on the decisions and measures taken at
the design stage. Their capacity includes the design of the process and other necessary
systems such as design of civil, structural, mechanical and electrical systems. They
also have such great infrastructure facilities as dock gates, ship lifts, floating docks,
ship launch systems, piers, quays, breakwaters, dredging, manufacturing halls, and
offices. Moreover, the shipyard can maximize their output and efficiency by redesign
the layout of shipyard in a better way.
The size of this shipyard is designed for team purposes, which means that their
multidisciplinary project teams can be assembled to provide their joint experience to
all detailed requirements for shipyard infrastructure design, improving performance,
and reducing construction and maintenance costs. Before that, the initial concept
designs plays a crucial part, where it will help customers finalize their decisions
before they commit to the final detailed design of the facility. The design concepts
components are often interchangeable in the best shipyard, which means customers
can combine attributes from two or more concepts to arrive at the customer's choice
concept.
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12.0 CONCLUSION
13.0 REFERENCES