Quality Control in Shipbuilding

Process

By
Tanawat Sirisatien
Head of Quality Assurance / Control
Bangkok Dock 1957 Company Limited
Introduce
Lloyd’s Register International (Thailand) Ltd.
Position: Senior Marine Surveyor
Service: 8 Years

Italthai Marine Limited

Position: Quality Control Manager
Service: 6 Years

Powerline Engineering PCL.

Position: Mechanical Engineer
Service: 4 Years

Graduation
King Mongkut's University of Technology North Bangkok, KMUTNB
Master degree: Welding Engineering
Khon Kaen University, KKU
Bachelor degree: Mechanical Engineering
Professional Engineer: สาม ัญวิศวกรเครือ่ งกล สก.3941
Agenda
1. Introduction quality control in Ship building and Ship repair
2. Quality control between Shipyard and Classification Society
- Plan approval process
- Material and equipment according to Class requirement
- Type of certificate for material and equipment
- Quality control
3. Quality control for Hull
4. Quality control for Machinery and Electrical
5. Quality control for Statutory
6. Ship entry to Class and Ship certificates
7. Ship in service and Classification Society
Introduction quality control in Shipbuilding
and Ship repair

Ship Construction Ship Repair

- Plan control - Docking control
- Material control - Material control
- Construction control - Method control
- NDE control - NDE control
- Test and trial control - Test and trial control
- Document control - Test report
Classification Society / IACS Member
Classification Society History

Coffee House: Edward Lloyd,

1760
 Classification Society Time Line
- The register society was formed in 1760 BC.
- First society is Lloyd’s Register of Shipping (LR)
- The condition of the hull was classified A, E, I, O or U
- Equipment was G, M, or B
- G, M and B were replaced by 1, 2 and 3
- 'A1', meaning 'first or highest class
- 100 assigned to all ships considered suitable for sea-going service.
- Hull Notation: +100A1, Oil Tanker, ESP, IWS, LI
- Machinery Notation: +LMC or [+]LMC or MCH
Classification Society Hull Notation
Classification and Statutory
Quality control between Shipyard and
Classification Society
 Plan Approval Process

Initial Assessment
Description of Vessel Plans appraisal according to
- Hull number - Contract
- Dimension - Notation
- Principal characteristics - Statutory / Flag requirement
Performance - Class rule and regulation requirement
- Speed - Hull
- Deadweight - Machinery and Electrical
- FO consumption - Statutory (Fire & Safety, Loadline,
Regulator requirements Solas, MARPOL, Etc.
- Classification and Statutory
Location
- Flag for registration of the
vessel Delivery
List of documents - Issue documents (DAD)
- Detailed specification - State plan status: AQS, AQP
- Plans - AQP to be closed prior project
completed
All of above were stated in
the construction contract
 Plan Approval Process
What plan require for appraisal?
Hull
- Midship sections showing longitudinal and transverse material.
- Profile and decks.
- Shell expansion.
- Oil tight and watertight bulkheads.
- Propeller brackets.
- Double bottom construction.
- Pillars and girders.
- Aft end construction.
- Engine room construction.
- Engine and thrust seatings.
- Fore end construction.
- Hatch coamings
- Hatch cover construction.
- Welding.
- Bilge keels showing material grades, welded connections and detail design
And other according to Class requirement. (LR/Ship rule/Pt.3/Sec.5/Item 5.2)
 Material and equipment according to Class
requirement
Material approval process, normally depend on Society requirements.
For LR Manufacture have two schemes.
1. The Materials Survey Scheme
2. The Materials Quality Scheme
The Materials Survey Scheme
- Materials according to Ch. 3 to Ch. 10 of LR Material rules
 Chapter 3 Rolled Steel Plates, Strip, Sections and Bars
 Chapter 4 Steel Castings
 Chapter 5 Steel Forgings
 Chapter 6 Steel Pipes and Tubes
 Chapter 7 Iron Castings
 Chapter 8 Aluminium Alloys
 Chapter 9 Copper Alloys
 Chapter 10 Equipment for Mooring and Anchoring
Material and equipment according to Class
requirement
System certify of the Material Survey Scheme

1. Approved manufacturers are to request a survey

2. All mechanical tests required by these Rules are to be witnessed

3. The specified tests and examinations are to be carried out prior

to the despatch of finished materials

4. Issue certificate under Manufacture certificatre

 Material and equipment according to Class
requirement
The Materials Quality Survey Scheme
System certify of Materials Quality Scheme
1. Manufacture approved similar of Material Survey Scheme
2. The manufacturer has a quality management system, which has been
certified as meeting the requirements of ISO 9001
3. The manufacturer's name will appear on the List of Approved Manufacturers
published by LR
4. Material Quality Scheme Certificate will be issued, which must be signed by
an authorised representative of the manufacturer.
Material and equipment according to Class
requirement
Type of LR Material Certificate

LR Manufacturer's
certificate
Certificate validated by LR

Manufacturer's
certificate issued
Manufacturer's
under the
certificate
Materials Quality
Scheme
 Material and equipment according to Class
requirement

LR Certificate
This type of certificate is issued by
LR based on the results of testing
and inspection being satisfactorily.
 Material and equipment according to Class
requirement

Manufacturer's certificate
validated by LR
- Under Material Survey Scheme
- Product certificate must
authorise by attending Surveyor
Material and equipment according to Class
requirement
Manufacture certificate under material survey scheme
 Material and equipment according to Class
requirement

Manufacturer's certificate
issued under the Materials
Quality Scheme
 Quality Control During Construction Process
(Shipyard Process)
Shipyard Quality
- Shipyard Standard
- Rule and regulation
- Method
- ITP
- WPS & PQR
Standard - Test procedure
- Welding equipment - Etc.
- Lifting
- Transportation
- Workshop
- Etc.
- Welder
- Fabricator & Fitter
- Inspector
- Contractor
- NDE
- Etc.

Facilities
Workmanship
condition
Quality Control for Hull
 Hull Survey
• Contract review
• Team member
Before • PSPM (Pre Site Project Manager) Note
Construction • Survey budget

• Material Survey
• Cutting, Assembly, Fabrication, Erection
During • Plans and comment status control
Construction • Structure and weld test: NDE, Tank test Etc.

• Certificates
• Budget summary
• All of hull report: NDE, Comment, DAD status etc.
After
Construction • As built
• Service feedback
 Material On Site Survey (Major)

Steel Plate
- Identify on plate compare with product
certificates: Grade, heat no., size
- Stamp on plate
- General examination: damage, thickness,
dimension, stock condition
 Material On Site Survey (Major)

Welding Consumable
- IACS approved
- Appropriate grading
- Certificate
 During Construction
Support documents
1. Marine Design Appraisal Document, AQP & AQS
2. Plan updated
3. IACS No.47 (Shipbuilding and repair quality
standard)
4. Shipyard standard
5. ITP (Inspection Test Plan)
6. Rule and regulation intend to survey
 During Construction
Block Fit-Up and Assembly
1. Edge preparation
2. Structure Alignment
3. Confirmation structure and member
4. Welding visual inspection before painting work
5. NDE (PT, RT, UT)
6. Forming
7. Dimension check
 During Construction
Hull Erection
1. Mismatch and Alignment of each structure member
2. Distortion and deformation
3. Welding and NDE
4. Finish work
 During Construction
Welding and NDE
Essential things
- WPS and PQR
- WQT (Welder Qualification Test)
- NDE plan approved
- NDE procedure approved
- Appropriate NDE method
- NDE operator certificate (Level I, II and III)
- NDE report
During Construction
NDE Plan
During Construction
Hull survey failed-1
During Construction
Hull survey failed-2
During Construction
Joint preparation poor
During Construction
Welding defect
Structure Test
Tank leak test

Tank air test @ >

0.2 bar

Fillet weld air test

 Quality control for Machinery and Electrical
Machinery under survey
• Main propulsion engines including their associated gearing, flexible couplings,
scavenge blowers and superchargers.
• Boilers supplying steam for propulsion or for services essential for the safety or the
operation of the ship at sea.
• Auxiliary engines which are the source of power for services essential for safety or for
the operation of the ship at sea.
• Steering machinery.
• Athwartship thrust units, their prime movers and control mechanisms.
• All pumps necessary for the operation of main propulsion and essential machinery,
e.g. boiler feed, cooling water circulating, condensate extraction, fuel oil and lubricating
oil pumps.
• All heat exchangers necessary for the operation of main propulsion and essential
machinery, e.g. air, water and lubricating oil coolers, fuel oil and feed water heaters, de-
aerators and condensers, evaporators and distiller units.
• Air compressors, air receivers and other pressure vessels necessary for the
operation of main propulsion and essential machinery.
• All pumps essential for safety of the ship, e.g. fire, bilge and ballast pumps.
• Valves and other components intended for installation in pressure piping systems
having working pressures exceeding 7 bar.
• Alarm and control equipment
• Electrical equipment and electrical propelling machinery
Quality control for Machinery and Electrical
Machinery Survey
Quality control for Machinery and Electrical
Electrical under survey
“Electrical propelling machinery and associated equipment together with auxiliary
services essential for the safety of the ship are to be installed in accordance with the
relevant requirements of this rule, surveyed and have tests witnessed by the Surveyors”
air compressors electric starting thrusters
for oil engines systems for
engines
air pumps feed water valves which are required to
pumps be remotely operated

automatic fire detection ventilating fans for engine

sprinkler systems and alarm and boiler rooms
systems
ballast pumps lubricating oil watertight doors
pumps

bilge pumps inert gas fans windlasses

and scrubber

cooling water lighting systems power sources and supply

pumps systems for supplying

communication oil separators

systems

electric propulsion steering gear

equipment
Quality control for Machinery and Electrical
Electrical Survey
 Quality control for Statutory
Statutory Items
 Load Line: Ship length > 24 m.
 Quality control for Statutory
 SOLAS: RMS Titanic Sink
 Quality control for Statutory
Chapter of SOLAS: Ship GT > 500 GT
- Chapter I – General Provisions
- Chapter II-1 – Construction – Subdivision and stability, machinery and
electrical installations
- Chapter II-2 – Fire protection, fire detection and fire extinction
- Chapter III – Life-saving appliances and arrangements
- Chapter IV – Radiocommunications
- Chapter V – Safety of navigation
- Chapter VI – Carriage of Cargoes
- Chapter VII – Carriage of dangerous goods
- Chapter VIII – Nuclear ships
- Chapter IX – Management for the Safe Operation of Ships
- Chapter X – Safety measures for high-speed craft
- Chapter XI-1 – Special measures to enhance maritime Safety
- Chapter XI-2 – Special measures to enhance maritime security (ISPS Code)
- Chapter XII – Additional safety measures for bulk carriers
- Chapter XIII - Verification of compliance
- Chapter XIV - Safety measures for ships operating in polar waters
 Quality control for Statutory
 MARPOL
- Annex I: Prevention of pollution by oil & oily water
- Annex II: Control of pollution by noxious liquid substances in
bulk
- Annex III: Prevention of pollution by harmful substances
- Annex IV: Pollution by sewage from ships
- Annex V: Pollution by garbage from ships
- Annex VI: Prevention of air pollution from ships
 Ship Entry to Class
First Entry Process

Class
Excusive
review case

FE inform SDO issue

FE reports FE
Prior project able to Cert. of
submit to Specialist
completion issue Cert. Class to
FE review
of Class ship

Ship data
base
uploaded to
system
 Ship Certificate
Type of Ship Certificate

Class Certificate Statutory Certificate

1. Certificate of Class 1. Load Line Certificate
2. Lifting Appliance Certificate 2. SAFECON Certificate
3. Hull Completion Certificate 3. Safety Equipment Certificate
4. Cargo Ship Safety Radio Cert.
5. IAPP Certificate
6. IOPP Certificate
7. Other Flag Certificate
8. Tonnage Certificate
Ship In Service
Periodical Cycle
 Periodical Survey
 AS: Annual Survey
 DS: Docking Survey
 ES: Engine Survey
 ITMS: Intermediate Survey (ESP)
 ITSS: Intermediate Survey
 SS: Special Survey
 IWS: In Water Survey
(See details in attached sheet)
Survey for Existing Ship Preparation
Tool for survey
1. Ship window status (Survey System)
2. Memorandum and Condition of Class (COC)
3. Country file
4. Survey check list (AS, ITSS, DS, Statutory)
5. MTN (Marine Technical Notice)
6. E-mail communication
7. DCE and DCG instruction (if any)
8. Service supplier database (LSA, Radio, IWS, TM)
 Docking Survey
1. Anchors and chain cables
2. Forward area
3. Bottom and side shell
4. Tail shaft and propeller
5. Stern frame and rudder
 Hull Damage Survey
Survey
1. Damage verify at onboard
2. Master statement report
3. Surveyor consider: Repair or Not Repair
4. If not repair, COC 3 months to be imposed
5. If repair, Permanent or Temporary repair which
one to be used
6. If temporary repair, watertight integrity need to be
confirmed with imposed COC
7. If permanent repair, all material and welder
certificate must approved by Class and NDE need
to be carried out
8. Surveyor report to be issued to client
Hull Damage Case
Machinery Damage

Propeller Crack Case

Propeller Repair Zone

Severity zones in all

propeller blades
 Survey Reporting
1. Attendance Surveyor survey report
- Narrative with clearly wording
- Action with ship memorandum
- Docking and repair report
- Flag and DCE/DCG agreement
- Fee report
- Survey checklist (If any)
- Ship certificate in case of amend/re-issue/short
term or full term
2. Survey report will review by Vetter Surveyor
3. Surveyor will release by Vetter Surveyor
4. Cert. check and error will issue by Vetter Surveyor
5. Survey report will update in Ship database and send to
ship Client.
 Q&A

Thank you for your

attention