Internship Training Report At

Cochin Shipyard Limited (CSL).

Submitted By:
Jishnu S Nambiar
19BME0362

B.Tech. Mechanical Engineering, VIT Vellore,

Vellore, Tamil Nadu,
 TABLE OF CONTENTS

I. PREFACE
II. INTRODUCTION
III. SAFETY
IV. SHIP BUILDING
V. SHIP DESIGN
VI. SHIP REPAIR
VII. INSPECTION AND QUALITY CONTROL
VIII. UTILITY AND MANAGEMENT
IX. PRODUCTION PLANNING AND CONTROL
X. ACKNOWLEDGEMENT
 PREFACE

This is the industrial training visit report prepared during the shipyard visit
training undertaken at COCHIN SHIPYARD LTD, Cochin, Kerala, as part of the
degree in B Tech Mechanical Engineering at VIT University, Vellore campus.
The theory of an industrial visit is important. The knowledge of engineering is
incomplete without the practical knowledge and practical application. This
industrial visit provides a golden opportunity to all the students, especially
engineering students who is not familiar with the functioning and the working
of project construction facility under our staff members and faculties. Hence
this report is designed with the objectives to gain practical know-how and is
undertaken at COCHIN SHIPYARD LTD.
 INTRODUCTION
A Shipyard is a place where ships are built and repaired. These can be yachts,
military vessels, cruise liners or other cargo or passenger ships. Dockyards are
sometimes more associated with maintenance and basing activities than
shipyards, which are sometimes associated more with initial construction. The
terms are routinely used interchangeably, in part because the evolution of
dockyards and shipyards has often caused them to change or merge roles.

Cochin Shipyard Ltd (CSL) is the largest shipbuilding and maintenance facility in
India. It is part of a line of maritime-related facilities in the port-city of Kochi, in
the state of Kerala, India.
Cochin Shipyard was incorporated in the year 1972 as a fully owned Govt of
India company. In the last three decades the company has emerged as a
forerunner in the Indian Shipbuilding & Ship repair industry. This yard can build
and repair the largest vessels in India. It can build ships up to 1,10,000 DWT
and repair ships up to 1,25,000 DWT. The yard has delivered two of India’s
largest double hull Aframax tankers each of 95,000 DWT. CSL has secured
shipbuilding orders from internationally renowned companies from Europe &
Middle East and is nominated to build the country’s first indigenous Air
Defence Ship. Shipyard commenced ship repair operations in the year 1982
and has undertaken repairs of all types of ships including upgradation of ships
of oil exploration industry as well as periodical layup repairs and life extension
of ships of Navy, UTL, Coast Guard, Fisheries and Port Trust besides merchant
ships of SCI & ONGC. The yard has, over the years, developed adequate
capabilities to handle complex and sophisticated repair jobs. The Shipyard also
trains graduate engineers to marine engineers who later join ships both Indian
and foreign as 5th Engineers. 100 are trained every year.
VISION
• Emerge as an internationally preferred shipyard to construct world class
Merchant and Naval ships, offshore vessels and structures.
• Be the market leader in India for ship repairs, including conversions and
up-gradation.
• To be admired for our achievements, respected for our ethics and
trusted for our service excellence by our valued customers.
MISSION
• To build and repair ships and off-shore structures to international
standards and provide value added quality engineering services.
• Sustain corporate growth in competitive environment.
• To adopt and undertake practices towards becoming a responsible
corporate citizen.
OBJECTIVES
• To sustain and enhance shipbuilding and ship repair activities through
technology up-gradation and capacity augmentation.
• To continuously endeavour to expand/diversify activities of the shipyard
including setting up new facilities.
• To carry out research & development in existing and emerging
technologies in shipbuilding processes.
• To move towards international benchmarking, benchmark with the best
shipbuilding standards followed in India.
• To motivate employees through improved specific training programs. To
adopt best practices for clean and safe environment. Ride the down time
with aggressive bidding and secure orders to maximize capacity.
• To ensure positive customer-oriented initiatives.
• To build a responsible corporate citizen image through CSR &
sustainability projects and compliance to corporate governance
principles.
 SAFETY

12 Major Safety Rules are:

1. Discuss safety matters in tool box meeting.
2. Follow permit to work instructions.
3. Keep warning boards to inform co-workers about unsafe conditions.
4. Find a way to keep workplace neat and safe.
5. Use certified scaffolding only.
6. Foot Body Harness at height.
7. Obtain safety entry permit before entering into confined spaces, follow
gas management rules.
8. Use ELCB Electrical boards only.
9. Use inspected & certified lifting tools, tackles, gas hoses and electrical
appliances only.
10. Never do hot work & painting work simultaneously.
11. Never leave things carelessly strewn around.
12. No mobile phones while driving vehicles at workplace.
 SHIP BUILDING

Mainly divided into sections as shown below:

FLOW PROCESS
FACILITIES IN SB:
Dock No 2

The Dock No.2 of 255 x 43 x 9 M is available for building ships up to 1,10,000

DWT. This dock and the grand assembly area are served by two Gantry crane
(300 T and 150 T) and two LLTT cranes (50 T).

Steel Stock Yard

The steel stockyard has an area of 13,000 Sq. aided with two gantry cranes of
25T each and one semi-gantry crane of 25 T. It is directly linked to the rail lines
as well as to the waterfront, in addition to road connections. This enables steel
to be brought in through wagons, barges or trucks.

Hull Shop
The Hull Shop is self-contained with infrastructure required for fabrication of
hull blocks up to 50 T. The shop is provided with EOT cranes (50 T) for along
the bay movements and gantry crane (20 T) and trailers for across the bay
transfer of materials.

Other Major equipment’s/facilities

• C.N.C. Cutting Machine
• Plasma Cutting Machine
• Shot Blasting Machine
• Automatic Painting Machine
• 1200 T Hydraulic Press
• Line Heating Techniques for curved shell formation
• F.C.B. One side welding for large panels
• Semi-automatic CO2, Gravity welding machines
• Semi-automatic CO2, Gravity welding machines
• Electro Slag welding
• 150mm Pipe Bending Machine
• Pipe Coaster (1.2 m dia capacity)
• 150 tons transporter
Assembly Shop
This shop has telescopic sliding roof with gantry cranes of 300 T and 150 T
which spans over it and building dock. Hull blocks up to 450 T can be
jumboized here and erected in the building dock using the gantry crane. In
addition, two 20 T capacity EOT cranes are there in the shop.

Pipe and Sheet Metal Shop

The pipe shop is provided with all the necessary equipment for bending,
cutting, welding and pickling of pipes. The sheet metal shop handles all the
light steel fabrications, trunking etc.

Quays: CSL has totally three Quays having almost a length of 1 KM.
Types of Welding:
• MMA/SMAW: Shielded metal arc welding (SMAW), also known as
manual metal arc welding (MMA or MMAW), flux shielded arc welding
or informally as stick welding, is a manual arc welding process that uses
a consumable electrode covered with a flux to lay the weld. An electric
current, in the form of either alternating current or direct current from a
welding power supply, is used to form an electric arc between the
electrode and the metals to be joined. The workpiece and the electrode
melts forming a pool of molten metal (weld pool) that cools to form a
 joint. As the weld is laid, the flux coating of the electrode disintegrates,
giving off vapours that serve as a shielding gas and providing a layer of
slag, both of which protect the weld area from atmospheric
contamination.
• SAW: Submerged Arc Welding (SAW) is a joining process that involves
the formation of an electric arc between a continuously fed electrode
and the workpiece to be welded. A blanket of powdered flux surrounds
and covers the arc and, when molten, provides electrical conduction
between the metal to be joined and the electrode. It also generates a
protective gas shield and a slag, all of which protects the weld zone.
• GMAW: Gas metal arc welding (GMAW), sometimes referred to by its
subtypes metal inert gas (MIG) and metal active gas (MAG) is a welding
process in which an electric arc forms between a consumable MIG wire
electrode and the workpiece metal(s), which heats the workpiece
metal(s), causing them to fuse (melt and join). Along with the wire
electrode, a shielding gas feeds through the welding gun, which shields
the process from atmospheric contamination. The process can be semi-
automatic or automatic. A constant voltage, direct current power source
is most commonly used with GMAW, but constant current systems, as
well as alternating current, can be used. There are four primary methods
of metal transfer in GMAW, called globular, short-circuiting, spray, and
pulsed-spray, each of which has distinct properties and corresponding
advantages and limitations.
• TIG: Gas tungsten arc welding (GTAW), also known as tungsten inert gas
(TIG) welding, is an arc welding process that uses a non-consumable
tungsten electrode to produce the weld. The weld area and electrode
are protected from oxidation or other atmospheric contamination by an
inert shielding gas (argon or helium). A filler metal is normally used,
though some welds, known as autogenous welds, or fusion welds do not
require it. When helium is used, this is known as heliarc welding. A
constant-current welding power supply produces electrical energy,
which is conducted across the arc through a column of highly ionized gas
and metal vapours known as a plasma. GTAW is most commonly used to
weld thin sections of stainless steel and non-ferrous metals such as
aluminium, magnesium, and copper alloys.
TECHNOLOGIES IN SB:
Advance Out-fitting and Painting
CSL has introduced the latest Japanese Integrated Material Management
concept in which at the basic design stage itself not only all high value and long
lead items that go into the ships are identified, but also the method of
outfitting viz. Unit/On block/On board is also finalized. Portable painting sheds
are used for efficient and fast painting of the hull blocks.

Tie ups
The tie-up with the renowned shipbuilder M/s Ishikawajima Harima Heavy
Industries (IHI), Japan and with Shipping Research Services (SRS), Norway for
building Crude Oil Tankers have provided exposure to the latest ship building
technology adopted in Japan and Europe and hence the confidence to take up
more challenging jobs.

Trigon based in house capabilities

CSL uses the 'state of the art' TRIBON shipbuilding package for undertaking
basic design, structural, machinery and electrical design. With over 80
workstations, and fully trained personnel, CSL has world class capabilities to
undertake ship designs. 3D hull, piping and electrical models are created
leading to error free and optimum ship designs. Information for various NC
equipment is also generated on these systems.

Quality Control and Testing Laboratory

From the very inception of the yard itself, strict quality control techniques had
been adopted. As a result, quality of the ships constructed at CSL have been
very good and lauded by ship owners and classification societies. CSL has in its
premises a well-equipped laboratory capable of undertaking all NDT tests. The
laboratory is approved by various classification societies.

Marine Coating Shop

Four Nos. Blast / Paint Shops of size 20 x 20 x 11 m are equipped for blasting
and painting of fabricated units in controlled and favourable ambient
conditions. Blasting using graded copper slag and Painting using modern airless
spray-painting machines are carried out to provide the most effective coatings
on steel structures. The entire methodology, process and finished surface are
checked and vetted by well qualified and experienced personnel from CSL and
the paint manufacturer.

SHIP DESIGN
The ship design department is the department of designing of ships. It means it
realizes the expectations of the owner about his ship. The designing process
can mainly be divided into two: - Primary designing and Detailed designing.
Every ship is designed under the rules and regulations of The International Ship
Building Committee.
A vast no of diverse ships are made every day. Design team mainly collect all
their works as tenders. Most of the projects are done in collaboration with
other companies.

PROCESS MAP

BASIC DESIGN
For a ship to work, following factors have to be looked into: An intact hull,
power to travel, use of the vessel

Main Certification Agency - IRS

 SHIP REPAIRING
The only Shipyard in India which can repair ships up to 1,25,000 DWT and the
only yard which can repair an Air Defence Ships. CSL can undertake complex
and sophisticated repairs to Oil Rigs; & ships of Navy, Coast Guard & Merchant
Navy. The shipyard started offering ship repair services in 1982 and has
undertaken upgrades and repairs for all types of ships including ships for the
oil exploration industry as well as scheduled maintenance and life extension
for ships of the Indian Navy, Indian Coast Guard, the Union territory of
Lakshadweep, Fisheries and Cochin Port Trust, SCI and the Oil and Natural Gas
Corporation (ONGC). It has performed major overhauls for the aircraft carrier,
INS Viraat. Recently CSL was awarded major maintenance and upgrade orders
from ONGC. This included major overhaul of three rigs, Mobile Offshore
Drilling Unit (MODU) Sagar Vijay, Mobile Offshore Drilling Unit Sagar Bhushan
and Jackup rig Sagar Kiran.
The overall ship repair activities are subdivided into three:
• Hull repair
• Machinery repair
• Electrical repair

Some major repair projects:

• Major upgradation of Mobile Offshore Drilling Unit‘Sagar Vijay’ of ONGC.
The upgradation increased the drilling capacity of the vessel from 300 M
to 900 M
• Maintenance and repairs to the Aircraft Carrier"INS Viraat"of Indian
Navy
• Repair and maintenance of tankers and bulk carriers of Shipping
Corporation of India.

FACILITIES IN SR
Dock No. 1:
The repair dock of 270 x 45 x 12 M can accommodate ships up to 1,25,000
DWT. The dock has high-capacity discharge pumps to drain it in less than three
hours. It is served by three LLTT cranes, one of 40 T and two 10T capacity.

Quay Shops:
There are three quays of 280 M length with 15 T cranage, 208 M length with 10
T & 5 T cranage and 460 M length with 20 T cranage. The quays have adequate
service lines of oxygen, acety-lene, compressed air and power connections.

Engine and Machine Shop:

This shop is equipped with modern machine tools like Plano -miller (up to 30 T)
Bar Boring equipment (up to 300 mm dia), Inside Grinding machine (up to 300
mm dia), Heavy Duty Lathes (up to 12M length), Horizontal Drilling machine (
up to 100 mm boring & 600 mm drilling), Shrinkage equipment (up to 6 M x
900 mm O.D), Cylindrical Grinding machine (630 mm dia x 2 T), Horizontal
Boring machine (up to 560 mm dia), Dynamic Balancing machine (up to 3 T)
etc.
Electrical Shop:
• Maintenance of Motors, Generators, Transformers.
• In maintenance of Motors, there is mechanical work and electrical work.
• Works include Checking Bearing, Rotor Balancing, Trueness and
Levelling.
• Has 2 teams: Project Team (that goes onboard) and the other team (that
works on shop)

Instrumentation Shop:
• Mainly calibration works of pressure, temperature, flow and level are
done here.
• Switch, Gauge etc are calibrated using electrical calibrators, pump-like
machines, etc.
For high accuracy calibration, Dead Weight Anchor Gauge Tester is used
• Transmitters are also calibrated here. Small transmitters are used for
basic works. In high-risk areas, explosive resistant transmitters are also
used.
• On Board works are done using portable calibrators

Electronics Shop:
• Usually calibration of ammeter, voltmeter, Frequency measuring,
Generator paralleling, etc.
• Fire Safety Alarms are also prepared and calibrated here.
• All communication and entertainment devices are calibrated here.
• Works for both Ship Building and Repairing department.

Ship Wright Wood Shop:

• They focus mainly on the wooden works in the whole ship
• Which includes accommodation, insulation & panelling, base of radar
and engine shaft
• They have separate sections for ship building and ship repairing

Pipe Shop:
• Mainly 2 types of pipes, seam (bevelling, electric resistance welding) and
seamless
• Joining and coupling works are done here
 • Types of Joints:
o Flange Joint: A flange joint is a connection of pipes, where the
connecting pieces have flanges by which the parts are bolted
together. Although the word flange generally refers to the actual
raised rim or lip of a fitting, many flanged plumbing fittings are
themselves known as flanges.
o Ermeto Coupling: Ermeto Fittings are tube or pipe fitting type that is
used in various industrial applications across the world. These fittings
suit best to be used in high pressure applications such as pneumatic
lines and hydraulic line. The fittings offer an excellent general
characteristic that makes it highly popular and efficient fitting
material in industries. The product offers excellent corrosion
resistance, good stability, improved durability, excellent construction
and tolerance for high temperature.
o Collar Joint: A collar joint is an intentional gap between multiple
wythes of a masonry wall. This parapet wall was constructed with
two wythes of brick with a large collar joint between them. The idea
behind the use of collar joints is a good one.
• Various methods to check pipe pressure and stability and clean them
are:
o Pressure washing pump machine: Pressure washing or power
washing is the use of high-pressure water spray to remove loose
paint, mold, grime, dust, mud, chewing gum and dirt from
surfaces and objects such as buildings, vehicles and concrete
surfaces. The volume of a mechanical pressure washer is
expressed in gallons or liters per minute, often designed into the
pump and not variable.
o Pipe testing machine: The test specifies a method for
determination of the resistance to constant internal pressure at
constant temperature. The test samples are kept in an
environment at a specific constant temperature, which can be
either water ("water-in-water" test), another liquid ("water-in-
liquid") or air ("water-in-air" test).

Other Facilities:
• Hauling Carriage for safe docking and un-docking of ships.
 • High Pressure Water Jet for hull cleaning.
• Blasting and Painting of conventional, epoxy and SPC systems.
• Hauling Carriage for safe docking and un-docking of ships.
• Facility for Boiler re-tubing.
• Facility for Tank Coating.
• Electric shop for overhauling of motors and testing.
• Pipeline supply of compressed air, oxygen and acetylene.

EXPERTISE IN SR
Afloat Repairs
The yard has a team of experienced Engineers and skilled workmen exclusively
for undertaking afloat repair jobs.

Afloat Repairs: Availability of Sub-Contractors

A captive pool of competent sub-contractors are readily available and can be
engaged for various jobs at very short notice.

Workmanship
The quality of workmanship is of very high order and the owners on many
occasions have gone on record, appreciating the quality work done in CSL.
Many vessels have been repaired and handed over, ahead of schedule.

Experience
CSL has successfully undertaken repairs to more than a thousand ships
belonging to a wide variety of clients including Shipping Corporation of India,
Indian Navy, ONGC, Dredging Corporation of India, Union Territory of
Lakshadweep Administration, Fisheries Survey of India, Ethiopian Shipping
Lines, Transocean Offshore Deepwater Drilling Inc and vessels belonging to
various ports of India.
 INSPECTION & QUALITY MANAGMENT
CSL takes immense pleasure in introducing themselves as a leading Material
Testing Laboratory in Kerala in the field of Chemical, Mechanical, and Non-
Destructive testing of metals and Welds, alloys, etc. The Laboratory was
established in 1972 in the premises of Cochin Shipyard Limited, fully owned
Government of India Company. Cochin Shipyard Limited is situated adjacent to
the Port of Cochin in the West Coast of India and in the heart of Ernakulam
(Kochi) city.
The laboratory is an independent test house and all sections of the laboratory
have been designed and equipped with instruments to cater for Quality
Assurance activities of Cochin Shipyard and to extend similar services to the
neighbouring institutions, industries and Government organizations.
CSL has acquired credibility for quality, reliability and promptness of service
over the years. CSL vigorously maintains a high degree of accuracy in their
testing services.

NABL ACCREDITATION
Some of the activities of the laboratory are accredited by NABL (National
Accreditation Board for testing and calibration Laboratories), Department of
Science and Technology, Govt. of India for testing facilities in the field of
Mechanical and Chemical Testing in accordance with the standard ISO/IEC
17025.

IQC LAB
IQM Lab at CSL makes use of Universal Testing Machine and Electron
Spectroscopy along with various machines for testing ship materials to ensure
highest Quality Possible.

Universal Testing Machine (UTM)

A universal testing machine (UTM), also known as a universal tester,materials
testing machine or materials test frame, is used to test the tensile strength and
compressive strength of materials. An earlier name for a tensile testing
machine is a tensometer. The "universal" part of the name reflects that it can
perform many standard tensile and compression tests on materials,
components, and structures (in other words, that it is versatile).
Electron Spectroscopy
Electron spectroscopy refers to a group formed by techniques based on the
analysis of the energies of emitted electrons such as photoelectrons and Auger
electrons. This group includes X-ray photoelectron spectroscopy (XPS), which
also known as Electron Spectroscopy for Chemical Analysis (ESCA), Electron
energy loss spectroscopy (EELS), Ultraviolet photoelectron spectroscopy (UPS),
and Auger electron spectroscopy (AES). These analytical techniques are used to
identify and determine the elements and their electronic structures from the
surface of a test sample. Samples can be solids, gases or liquids.
Chemical information is obtained only from the uppermost atomic layers of the
sample (depth 10 nm or less) because the energies of Auger electrons and
photoelectrons are quite low, typically 20 - 2000 eV. For this reason, electron
spectroscopy is a technique for surface chemical analyzes.

UTILITY & MANAGEMENT

Cochin Shipyard Limited has a very effective maintenance department which
takes care of all the machinery assets and its activities. U&M department
provides support to the technical department by providing tools, equipment
and providing infrastructural facilities.
The U&M department is sub-divided into four:
• Mechanical maintenance
• Electrical maintenance
• Civil maintenance
• Electronics maintenance
Pump House
Garage
U&M garage at CSL maintains and repairs a variety of vehicles ranging from
forklifts and armoured cars to 120T grove and non-movable Cranes. It does
periodical checkups as preventive maintenance and also deals with breakdown
maintenance.

grove crane cometto

 Fixed Crane.

PLANNING AND PROCESS MANAGEMENT

Ship construction is a complex and lengthy process that demands careful
planning and timely decision-making. Plan, optimize and validate ship
construction processes before building. Use a broad range of tools to
streamline your process planning workflows, automate non-value-added
planning tasks and validate the best shipbuilding plan. These tools facilitate
process design and sequencing, production BOM and BOP management, time
management, 3D shipyard layout and ergonomic analysis. Control ship and
production lifecycles from process planning and detailed engineering to full
production by connecting the entire value chain to realize the best production
strategy.
Demands on shipbuilders continue to increase ship and process complexity
with increased regulations, the need for global construction and sourcing to
meet local demands and competitive pressures that result in reduced margins.
Today’s shipbuilders need to ensure rapid delivery of highly reliable, high
quality and safe ships. To accomplish this, they must move construction
process planning and simulation upstream. If not, increasing complexity results
in most issues and changes being caught in the final steps of ship development
and delivery, when they are the costliest to fix. Shipbuilders must improve
collaboration between engineering and production to control all aspects of the
ship development process so that shipyards can build their ships right the first
time – reducing rework during sea trials and final acceptance testing.
Shipbuilders must employ advanced, process-driven techniques to build ships
that meet or exceed customer expectations and ensure that constraints are
considered during the early stages of ship development. Our solutions allow
shipbuilders to digitalize the shipbuilding process and shipyards to maximize
productivity, increase profitability and realize the best ships.
 ACKNOWLEDGEMENT

Industrial training at COCHIN SHIPYARD LTD has been a great learning

experience for me. The theoretical knowledge that I gained during my two
years of study at VIT Vellore, Vellore has been complemented effectively due
to the guidance and support provided by our staff members and faculties. I
learned that practical knowledge can only be gained by performing the process
yourself or by witnessing the process under guidance. The shipbuilding process
at COCHIN SHIPYARD LTD is an amazing one. It is mesmerizing to see a bunch
of plates and pipes eventually turning into a massive Vehicle that soars
through the sea. CSL has been serving to Indian and international clients with
ease and from the moment I stepped into the premises of CSL it was evident
why they are so succesful. INS VIKRANT was a great sight for me to witness and
I thank CSL for providing me that opportunity. I got to visit NALANDA and RV
SINDHU SANKALP and I am very thankful for that opportunity. I would like to
thank all the members and staffs of Cochin Shipyard Ltd. for granting me An
amazing internship opportunity and for guiding me through even during the
tough pandemic times.