ROLE OF QUALITY CONTROL IN SHIP BUILDING

A Mini Project report submitted in partial fulfillment of Requirements for the award of the degree of

BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING

BY K.V.MANI KUMAR[09815A0302] S.HARISH [08811A0348] Y.DHANARAJU[08811A0360] O.S.SANTOSH KUMAR[08811A0342] M. YAMUNA RAO[08811A0337]

AVANTHI INSTITUTE OF ENGINEERING AND TECHNOLOGY (An NBA Accredited Institution)

Tamaram, Makavarapalem, Narsipatnam, VISAKHAPATNAMAM-531113

Under the Esteemed Guidance of

Mr. S.K.DURGA PRASAD

B.com, D.Met., B.E(Indl. Engg), MBA(Mktg), MBA(HRM)

ENGINEER, QUALITY CONTROL HINDUSTAN SHIPYARD LIMITED VISHAKHAPATNAM Page 1 of 39

ACKNOWLEDGEMENT
We express our deep sense of gratitude to Dr. C.P.V.N.J. Mohan Rao, principal and Mr. N.Rajendra, HOD of Mechanical of AVANTHI College of Engineering, for encouraging us to carry out mini project work at HSL and the completion of project. We are very much thankful to C.BABU RAO, Sr. P.O, TRAINING DEPARTMENT, HINDUSTAN SHIPYARD LIMITED for providing this opportunity and their support to do project work at Q.C department in HSL. We express our deep sense of gratitude to Sri. M.V.V.S. GUPTA Chief Manager of QUALITY CONTROL Department, K.AKKULAPPA, Manager of QUALITY CONTROL and all Technical and Non- Technical staff of HSL, who encouraged us in the completion of project. We wish and express our sincere gratitude to our guide MR. S.K. DURGA PRASAD, Engineer and also MR.V. ABBAI, Engineer and MR.V.L. ACHARI, Asst. Supervisor for their guidance and suggestions throughout the project, without which we would not have been able to complete this project successfully. We extend our thanks to all our friends for their moral support and encouragement; last but not least we thank our parents and relatives who inspired us to do the best in our project.

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CONTENTS
1. INTRODUCTION TO SHIPYARD 2. ABOUT QUALITY 3. INSPECTION DEPARTMENT 4. YARD PROCESS 4.1 HULL SHOP 4.1.1 Introduction 4.1.2 Work instructions of hull shop 4.2 PRE-FABRICATION 4.2.1 Introduction 4.2.2 Work instructions of pre-fabrication 4.3 ERECTION 4.3.1 Introduction 4.3.2 Work instructions of erection 4.3.3 Pressure testing/flood testing/leak testing 5. NON-DESTRUCTIVE TESTING(NDT) METHODS 5.1 Radiographic testing 5.2 Ultrasonic testing 5.3 Magnetic particle testing 5.4 Liquid penetrate testing 6. CONCLUSION

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INTRODUCTION
Ship is a huge structure and colossal in size consists of high technical equipment and powered by diesel engines and with other gear to cater the needs of transport of men and material to continental to continental, port to port by sea routes. Ship construction is a complex activity, for this purpose manufacture the Hindustan shipyard is having a well developed infrastructural arrangements with established organization of employees of various categories and construction procedures and well planning and also important industrial local environment and good support of the government.

BRIEF OF HINDUSTHAN SHIPYARD LIMITED

The HINDUSTAN SHIPYARD is a pioneering industry in public sector organization owned by the government of India and recently this organization is taken by Ministry of Defence (MOD) from Ministry of Surface and Transport (MOST). HSL is one of the five major shipyards in our country, owned by government of India. They are the 1. 2. 3. 4. 5. Hindustan Shipyard Limited (HSL) Cochin Shipyard Limited (CSL) Garden Reach Ship Building Engineering (GRSE) Mazagon Dock Limited (MDL) Goa Shipyard Limited (GSL

Among them Hindustan Shipyard was first established ship building yard in our country. This was one of the biggest mile stones in the history of public sector development in India The HINDUSTAN SHIPYARD LIMITED in Vishakhapatnam is one of the five major shipyards in our country. It was established by NAROTTAM MORARJEE and WALCHAND AND HIRACHAND. The foundation stone was laid on 21st June 1941 by Sri BABU RAJENDRA PRASAD the first President of India in at Visakhapatnam of Andhra Pradesh at latitude 1748 north and 83 17 east. The construction of the shipyard was completed in 1945. The first ship commenced in 1946. So far Hindustan Shipyard has built and delivered 164 vessels aggregating 1.3 million DWT of the nation. Shipyard has built in the course of construction has big ships, Training ships, Drill ships, Offshore patrol vessels & support cum-stand by vessels. Floating cranes etc., of different designs.
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At present shipyard is capable to build bulk carrier up to 80,000 DWT, presently 53,000 DWT Bulk carriers are under construction stage.The Hindustan shipyard limited with expertise skilled man power & sound technology of hull engineering & outfit engineering. Electrical backup facility & also offers excellent ship repairs and dry dock. The dock also has got the necessary infrastructure facilities under take intricate repairs to different types of vessels & can accommodate different types of vessels up to 57,000 DWT to 70,000 DWT subject to certain limitation. Adjacent to the dry dock, a wet-basin constructed in 1975 to undertake afloat repairs of various vessels. Both ship building and ship repairs wings are managed by experienced as well as qualified trained staff of 480 officers 984 staff and 1407 workmen.

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ABOUT QUALITY
Quality Control (QC) is a system of routine technical activities, to measure and control the quality of the inventory as it is being developed. The QC system is designed to: (i) (ii) Provide routine and consistent checks to ensure data integrity, correctness, and completeness; Identify and address errors and omissions;

(iii) Document and archive inventory material and record all QC activities. QC activities include general methods such as accuracy checks on data acquisition and calculations and the use of approved standardised procedures for emission calculations, measurements, estimating uncertainties, archiving information and reporting. Higher tier QC activities include technical reviews of source categories, activity and emission factor data, and methods. Quality Assurance (QA) activities include a planned system of review procedures conducted by personnel not directly involved in the inventory compilation/development process. Reviews, preferably by independent third parties, should be performed upon a finalised inventory following the implementation of QC procedures. Reviews verify that data quality objectives were met, ensure that the inventory represents the best possible estimates of emissions and sinks given the current state of scientific knowledge and data available, and support the effectiveness of the QC programme. Quality is a Requirement of product which confirms the specification & customer satisfaction and purpose for intended use.

QUALITY POLICY:
HSL management has adopted a quality policy as per the ISO requirements. To produce consistently quality products to national and International standards in time for customer satisfaction at optimum cost by improving effectiveness of quality management system

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Quality policy : ISO 9001-2000

To produce consistently quality product To maintain national and international standards in time TO produce customer satisfaction at optimum cost By improving efficiencies of quality management system "

OBJECTIVES OF QUALITY: a) b) c) d) e) f) g) h) i) j) To meet quality requirements societies. To ensure safety and reliability of ships during construction as M.M.D rules. To ensure competent work force to carry out assigned activities. To ensure effective usage of measuring and testing instruments during construction. To minimize defects and re-works during production process. To ensure low level defects-free bought out items from approved suppliers. To meet production schedules within reasonable variation. To ensure liquidation of non-moving standard stock items and reduce inventory costs. To ensure prompt and effective response/action on receipt of customer complaints. To ensure good housekeeping by regular cleaning of working areas and disposal of scrap.

k) The surface defects after blasting and priming of plates/ sections at treatmentplants and remarks shall be marked. l) Q.C shall inspect the plate and sections after rectification of pitting/ indentation etc. m) During process, dimensional checks and edge preparation after marking and gas cutting, rolling, and forming. Inspection remarks shall be marked on the job and indicated in the inspection record sheet. The same shall be checked after completion of the remarks and documented.
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QUALITY ASSURANCE DEPARTMENT:

QA involves all activities from design, development, production, installation, servicing and documentation. It includes the regulation of the quality of raw materials, assemblies, products, and components, services related to production and management, and inspection processes. Inspection is a process of sorting well from a lot. Whereas the quality control is an aimed prevention of defects at various sources effective feedback system procedure and corrective action. In quality control program, inspection data are used to take corrective action to check the defects. For this purpose, detail study is conducted to find out that from where the defect is originated and how to prevent, it may be at manufacturing design, purchase of raw material, dispatch or storage stage. So, quality assurance means to provide the necessary confidence to the customer as well as the management that all concerned are carried out their jobs effectively and that the ship quality as per customer(owners)satisfaction at optimum cost. Quality work can be produced only when all the departments fully participate and co-operate.

RESPONSIBILITY OF QUALITY ASSURANCE DEPARTMENT:

a. b. c. d. e. f. Plan, develop and establish quality policy. To assure that products of prescribed specification reaches to the customer Regularly evaluate the effectiveness of the Quality Management System Conduct studies investigation related to quality problems. Liaise with different departments, in and out the organization. Organize training programs on quality

WORKING PROCEDURE FOR QUALITY ASSSURANCE:

1. Quality system and procedure for all departments are prepared and issued to the following departments. 2. Design drawing office, purchase department, production planning department, material inspection department, material stores and production department like
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3. 4. 5. 6. 7.

8. 9.

hull shop, pre-fabrication, Erection department and outfit department the engineering department, carpentry, Black smith and rigging department. All work procedures and standards required to individual department they should follow the established system procedures. During the process of the work of the individual department they should follow the established system procedures. Here quality assurance department plays vital role to over see whether the department are following quality system procedure time to time. Periodically quality assurance conduct s audit for each and every departments and ensures the established system is followed by them. During audit if it is found that any deviations from system procedures the same will be corrected in order to established the quality function as per the ISO90002008 to the concerned departments. By function itself quality assurance establish that the organization is functioning in line with ISO 9001 system. As per the quality system procedures the following documents are issued to all the departments by quality assurance. a. b. c. d. e. Quality manual Quality procedure Quality standards Quality plan Quality formats

Before implementing QA/QC activities, it is necessary to determine which techniques should be used, and where and when they will be applied. There are technical and practical considerations in making these decisions. The technical considerations related to the various QA/QC techniques are discussed in general in this chapter, and specific applications to source categories are described in the source category-specific good practice guidance. The practical considerations involve assessing national circumstances such as available resources and expertise and the particular characteristics of the inventory. The level of QA/QC activities should be compatible with the methods or tiers used to estimate emissions for particular source categories. In addition, resources should be focused on priority areas, such as the key source categories , Methodological Choice and Recalculation, Determining National Key Source Categories and source categories where changes have occurred in methods or data acquisition since the last inventory compilation.
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INSPECTION DEPARTMENT
The purchased and procured material which come to shipyard will be subjected for stringent inspections by material inspection department. All materials viz. steel plates, paint, electrical equipment, plumbing equipment, machinery equipment, like main engine generators, pumps, motor, all ship outfit accommodation equipment, furniture are inspected and inspection reports (IR) are generated and issued to all concern department, design offices, purchase department,(P.P.C.D), Quality control(Q.C) and all yard working departments.

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HULLSHOP
The process of Hull shop is marking and cutting of elements into various sizes and forming them into required shapes. It consists of 4bays of which 3bays are having cutting machines and last bay consists of marking and bending section. At first the steel plates are lifted from steel storage yard to the captivator by means of overhead cranes, after this the plates are carried to the hydro leveler by means of captivator then the plates are processed in plate treatment line i.e. blasting and painting. The overhead cranes are used to pickup and place the steel elements at different places for different process(CNC cutting and plasma machining and forming press machines).

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WORKING INSTRUCTIONS OF HULL SHOP

SCOPE: To establish work instructions which shall be a guide to all personal in this department for performing Quality related activities.

RESPONSIBILITIES: The quality related activities and personnel responsible or given in the table hereunder Quality related activity Issue and control of drawings Co-ordination of production activities for indenting material ,schedules, and other relevant inputs Documenting results and generation of inspection records of production Work distribution Execution of work Reporting of non-conformance or deviation from drawing Responsibility Nominated person for this purpose Officer-in-charge inE3/E2/E1 cadre in his are of operation. Respective supervisors/assistant supervisors concerned. --do-Respective work force Respective supervisors./assistant supervisors and above.

SYSTEM: 1. Manufacturing documents in the latest version as hereunder shall be referred in the production process. 2. Drawings 3. Material input from other department and stores. 4. HSL quality standards. 5. Quality plan INSTRUCTION: 1. plate blasting and priming: 2. Pick up the required plate issued by steel stores from the pile. Note down the plate size, thickness, IR no. and grade of steel before placing it on the conveyor by the captivator.
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3. Check the thickness of the plate at entry point of hydro leveler 4. If the plate requires mangling, hydro leveler system is to be energized and plate straightens. 5. Ensure that the blasting equipment is in satisfactory working condition that is all rotors, blowers, brushes are functioned. 6. Ensure that compressed air used for blasting is free from moisture and oil and pressure not less than 5kg/cm2. 7. Control the speed such that blasting is maintained long enough to ensure removal of all scale, rust and foreign material should give a surface finish is equal to SA 2 - very through blast cleaning. Mill scale rust and foreign matter shall be removed to the extent that only traces remaining are slightly stains in the form of spots or stripes. Finally the surface is cleaned with the vacuum cleaner or with dry compressed air or with aclean brush, built in the blasting unit itself. 8. Do not leave the plate partially blasted. 9. Do not wet or contaminated shots for blasting. They cause more harm. 10. If after first blasting, the surface finish as required is not achieved, replace the plate and investigate /rectify the cause. 11. Shake and roll the drum containing base few times before opening. Mix hardener to the base(NOT BASE TO HARDNER) and add thinner as recommended by the manufacturer. 12. Allow 15min saturation time after maximizing 13. Ensure compressed air pressure is not less than 5 kg/cm2. 14. Ensure uniform dry film thickness of the premier over the full plate, free from holidays. 15. If holidays are found, apply, premier with a conventional spray or roller/ brush. 16. If DFT is found less than 20microns, stop priming investigate and rectify the defect. the load DFT can be compensated by conventional spray applications of thin coat of the same premier. 17. Pot life of primer is 6 hours. Please ensure that after mixing, primer is consumed within this period clean and flush the system with suitable solvent as recommended by paint manufacturers at the end of each shift. 18. Fill up inspection record sheet no QA-A-01

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CNC MACHINES: 1. Check the control drawing NC format by MLDO and check whether allocated plate dimensions are as per the drawing given. 2. Pick up the correct plate already blasted and primed, and place on the NC skid. Align the plates on the skids depending on the requirement manually and or with the help of the crane. 3. Adjust the torches depending on job requirements i.e. identical or symmetrical. 4. Insert the NC tape in tape reader of computer. 5. Align the torches to the reference point on the plate and start the machine. 6. The machine will do punch marking first, after completion of punching the punch off-set will be off. Observe this point. 7. End of punching is signaled by end of program. 8. Now adjust the gas flow/pressure and ignite the torches. 9. Start the machine and start the cutting. 10. Observe the cutting as to whether it is following 11. The profile described in the control drawing. After cutting are over, check the dimensions with dimensions given in the control drawing wherever applicable. 12. After cutting the burrs slag etc. shall be removed. 13. Panel no. /element no./IR no./Drawing no./Ship no./Tape no. shall be painted on the elements. Grade of steel (for other than GR. A) Also shall be painted on the elements. 14. Ensure that machine is calibrated every month to avoid errors. Date of calibration and due date shall be marked on the machine. 15. Inform maintenance department/MLDO for any malfunctioning of the machine. 16. Fill up inspection record sheet QA-A-02. PMC SHEDULES: MARKING: 1. 2. 3. 4. Check the size of the allocated plate/section is asper drawing. Mark the lines as per dimensions given in PMC with necessary punch marks. Mark the edge preparation required. Punch the element no. drawing, ship no., etc, on the elements.
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GAS CUTTING: 1. Align the portable gas cutting machine correctly on its track. 2. Adjust the gas pressure/flow and start cutting on the marked lines and prepare edge as per the drawing given. 3. If cutting is done on variosec machine ensure proper alignment of plates on the skids and also ensure the squareness of the machine for parallel cutting. 4. After cutting burrs and slag are to be removed. 5. Fill up relevant inspection recd sheet QA-A-03/QA-A-05.

ROLLING: 1. Check whether punch marks are there for frame lines/roll lines on the elements to be formed. 2. Check the template provided for its correctness by the data provided on the template. a. Mark the lines with the yellow chalk. 3. Handle the plates carefully by hoists of the press and start rolling. 4. Check the rolling with templates provided. HSL standards for rolling are to be ensured. 5. After rolling is over the plates are to be stacked, so that deformation are to be ensured. 6. Fill up the inspection record sheet QA-A-04.

DESPATCH/DELIVERY: 1. Processed elements shall be binned panel/block wise and small components separately. 2. Processed elements shall be dispatched as per the PPCD schedule.

Non-conformity-cum-resolution report (NCRR): If any item is found not conforming to drawing and standard, NCRR is to be raised through QUALITY CONTROL.

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Q.C PROCEDURES AND DOCUMENTATION IN HULL SHOP: 1. Inspection record sheet for plates and sections at treatment plant at hull shop is format QA-A-01 2. For the elements cut on CNC/plasma the inspection record sheet for elements at Hull shop is Format QA-A-02. 3. The elements cut as per plan for manual cutting will be inspected and recorded for all the elements in the format QA-A-03 4. Inspection record sheet for elements cut at hull shop is QA-A-04. 5. Inspection record sheet for sections cut at Hull shop is QA-A-05 6. For dimension check of the template/ rolling set and knuckle set will be recorded in the format QA-A-06.

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PRE-FABRICATION
The cut elements, which are joined together to form a block or panel of the ship as per the structural drawings and designs through different welding processes. To joining these plates as per the grooves and edge preparation which are cut at Hull shop from previous stage the welding will be carried out in the form of grooves as per the required welding process(SAW, MIG,SMAW, MAG) and procedures by qualified welders with suitable selected electrodes and welding equipment.

PRE-FABRICATION:
pre-fabrication shops are existing adjacent to Hull shop at the side which consists of four areas A1, A2, A3 and A4 in two huge buildings consisting all required facilities and infrastructure arrangements to construct and fabricate blocks up to 150 tons in weight.
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WORKING INSTRUCTIONS
Scope: To Establish work instructions shall be a guide to all personnel in this department for performs Quality related activities.
RESPONSIBILITIES:

The Quality related activities and personnel responsibilities are given in the table hereunder..
Quality related activity Issue and control of drawings and material allocation Co-ordination of production activities for intending material schedule and other relevant inputs Documenting results and generation of inspection records or production Work Distribution Responsibility Nominated person for this purpose Officer-in-charge inE1/E2/E3 cadre in his area of operation

Respective supervisors/assistant supervisor of concerned Respective supervisors/assistant supervisor of concerned Execution of work Respective work-force Reporting of non-conformance or deviation from Respective supervisors/assistant supervisors and drawings above

System:
1. Manufacturing documents in the latest version as hereunder shall be referred in the production process 2. Drawings. 3. HSL Quality Standards 4. Quality plan

INSTRUCTION:
MINI SUB -ASSEMBLIES: 1. Identify the mini sub-assemblies in the drawing mark the elements of the subassembly. 2. Align the tack the sub-assembly. Check for correctness as per drawing. 3. Provide the adequate temporary supports to avoid distortion during welding . 4. Complete welding and check for completeness and visual defects. 5. Remove the supports and dress the mini sub-assembly.
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LEVEL SKIN PANELS: 1. Lay the plates on the level skid. Check the identity of the plates and to be done at Hull shop before processing the elements. 2. Mark the reference lines for alignment. 3. Align and tack the assembly. 4. Check the overall dimensions of the skin panel. 5. Complete the welding. 6. Arrange the turning lugs for skin panel. 7. Turn the skin panel. 8. Dress the plate joints as necessary. 9. Complete the sealing weld. SUB-ASSEMBLIES: 1. Mark the skin panel for all the elements of the sub-assembly as per the drawing. Check for the dimensional accuracy as per the drawing. 2. Erect in position elements, and mini sub-assemblies on skin panel with necessary supports. 3. Align the elements, Mini sub-assemblies on the skin panel and tack weld as per the drawing. 4. Check for alignments and then and release for welding. 5. Dress the sub-assembly by removing the supports and check for completeness in all completeness. 6. Remove the weld distortion if any.

MAIN ASSEMBLY: 1. Main assembly skin panel is identified for each panel/block in the drawing. 2. The level skin panels and sub-assembly shall be fabricated as at 2 and 3 3. In case of panels/blocks having curvature,and panels being manufactured in natural position. 4. Skid shall be prepared as per the data given in the drawing. 5. Plates shall be laid on the skid prepared. 6. Mark the plate reference lines for alignment. 7. Align the plates and tack weld. 8. Check for the dimensional accuracy of the skin panel 9. Temporary clamps provided to skin panel and skid. 10.Release for welding.
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11.Complete the welding of the skin panel 12.Mark the skin panel for the accuracy of the skid panel after welding and marking. 13.Check for the dimensional accuracy of the skin panel after welding and marking. 14.Erect in position the elements and sub-assembly providing with temporary supports. 15.Align and tack the elements and sub-assemblies. 16.Check for fit-up, alignment completeness of all elements and sub-assemblies. 17.Offer for inspection. 18.Upon satisfactory fit up,complete the welding. 19.Turn the panel by providing lift and turning arrangement. 20.Complete the scaling and welding. 21.Inspect the weld joints for torsion. 22.Rectify defects if any noticed. 23.Dress the panel /block assembly 24.Remove welding distortion 25.Record the dimensional check sheet 26.Inform QA NDT the completion of the welding of the panel. 27.Rectify the defects if any reported in the radiography and inform(action by PFS welding). 28. Offer for inspection for dry survey

FABRICATION OF ASSEMBLIES OTHER THAN PANELS:

1. 2. 3. 4. 5. 6. 7. Mark the elements of the assembly for alignment Align and tack the assembly as per drawing Provide adequate temporary supports to avoid distortion Check for fit up and alignment Complete the welding Dress the sub-assembly. Rectify the defects Fill in the conformation report

PRESERVATION: Press ve the panel/blocks/assemblies by touching up the area paint is damaged. DISPATCH OF ASSEMBLIES: Dispatch the assemblies by appropriate handling available to other departments as per the internal works order
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ERECTION
Hull berth department consists of three slipways each consisting of 19526.6mts and 14022.7mts respectively and a covered building dock with intermediate gate facility of size 240531.25mts depth for a capacity of building ships up to 50,000 DWT. The building dock has two over head cranes, of which one is of 150 tons capacity and the other is 100tons capacity. Adjacent to building dock there is a wet basin of size 22.5167.514mts depth where ships can be repaired and outfit works can be carried out while a floating vessels. There is a dry dock with a size of 244381.6mts depth for the repairs of the ships up to 50,000DWT. There are cranes of capacities 45tons, 60 tons, and 100tons in between the building dock and berth and in between berths respectively.

WORK INSTRUCTIONS FOR ERECTION: SCOPE: To establish work instructions which shall be a guide to all personal in this department for performing Quality related activities.
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RESPONSIBILITIES: The quality related activities and personal responsible or given in the table hereunder Quality related activity Issue and control of drawings Co-ordination of production activities for indenting material ,schedules, and other relevant inputs Documenting results and generation of inspection records of production Work distribution Execution of work Reporting of non-conformance or deviation from drawing SYSTEM: 1. Manufacturing documents in the latest version as hereunder shall be referred in the production process. 2. Drawings 3. Material input from other department and stores. 4. HSL quality standards. 5. Quality plan INSTRUCTIONS: PREPARATION OF BERTH/BUILDING DOCK: The following reference lines are marked or grooved for total length of the ship to be built on the dock by berth shall be ensured: 1. Centre line of berth/dock. 2. Buttock lines one at the board and other at outboard to be grooved or marked parallel to central line 3. Transverse line perpendicular to center line at least one in F.E. or in A.E. of each panel or at every tenth frame or as required 4. These lines are the reference datum line for alignments 5. Establish sighting line by sighting by theodolite on the stands provided at every tenth frame covering W.T. BHDS. On berth /building dock floor at convenient buttock line Nearest to centre line below 200 mm from the base line throughout the length of the ship.
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Responsibility Nominated person for this purpose Officer-in-charge inE3/E2/E1 cadre in his are of operation. Respective supervisors/assistant supervisors concerned. --do-Respective work force Respective supervisors./assistant supervisors and above.

ANCHORING POINTS: The anchoring points minimum 4 nos in athwart and 4 nos in longitudinal direction for datum panel shall be arranged in two nos in athwart direction for other panels. ERECTION OF PANELS: 1. Ensure that the panel is cleared by class/owners from pre-fabrication department. 2. Adequate lifting or turning arrangement as per the concerned drawing before erecting the panel shall be ensured 3. If any chain blocks are used the capacity and the distribution of load shall be ensured 4. The area or space is to be ensured for clear of all cables etc. before erection of units. 5. Any staging required for erection of the panel shall be arranged prior to erection of the panel for locking purpose 6. The reference line such as buttock lines /frame/water lines before lifting shall be marked on the panel ALIGNMENT OF DATUM PANELS: 1. Datum panel is defined as the panel from which the growth of the vessel progresses both ford aft and upward direction 2. Datum panel immediately after erection on the keel or bilge blocks laid earlier as per drawing shall be tied with 8 rigging wires to the anchoring points firmly to the berth/dock by means of turn buckles. 3. Datum panel centre line at tank top/ bottom shell be aligned and fixed with reference to centre line and frame line of berth or dock by means of plumb and rigging wires tied upon both FE and AE sides cross check with other buttock lines and frame lines the frame lines at FE/AE shall be aligned and fixed transverse lines marked on berth/dock (if it is berth declivity is to be considered while checking with plumb) by means of plumb and longitudinal rigging wires. 4. The water level shall be checked at centre line longitudinally 5. Athwart at AE middle and FE hydraulic jacks shall be used, Hydraulic jacks if any twist is found necessary concrete blocks are equivalent weights shall be used for a creep in case of loose decks
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6. After ensuring all the requirements the data regarding frame line/buttock lines/water lines documented in the alignment check sheet. 7. All the 8 rigging wires shall be tightened to prevent any further deviation. it shall be ensured that there is no deviation on the centre line of the unit a constant vigil of the datum unit is to be made by regular inspection. 8. The lengths of panel shall be measured and recorded from AE frame of panel to AE frame of the next panel two contain the total length as per the HSL quality standards. HST PANELS: 1. datum panel shall be selected so as to have maintained preferably within the panel shall be supported by 2 nos of shores on FE/AE sides outside and two nos of wire ropes on AE and FE inside 2. The panel shall be kept to correct buttock space from DB unit by means by turn buckles on tank top through the corresponding frame line of DB on inboard side outboard point shall be plumbed to berth/dock and fixed in correlation to the plumb point 3. The half bredth of panel is to be checked by dropping a plumb on outboard to dock floor and corrected 4. Panels on P and S shall be preferably aligned simultaneously 5. Panel shall be conformed only after the final check of the breadth 6. Water line at fore and after athwart direction shall be checked the same is counter checked by measuring the height of HST (top) from base line. 7. Ensure 3 mm gap between floors quarters in way of seam to allow welding contraction of tank top and bottom shell seam. To allow welding contraction of tank top/bottom shell seam 8. Panel shall be locked and dimensional data be documented on alignment check format
HOLD BULK HEADS:

1. The bhd shall be fitted with rigging wires of FE/AE sights before erection the eyes of rigging wire holding point sj=hall be fixed in such a way that the bhd can be adjusted to declivity or vertically as the case may be . 2. Ensure adequate ribbons are provided to prevent any buckling while lifting & erection of Bhd ensure the working staging provided before erection of the panel
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3. Bhd. shall be checked with the marking of centre a water level before erection height and breadth shall be checked with etc before erection at the top of the bhd remove the slings etc. 4. Guiding flat bars of adequate scantling shall be provided on the ship so that the bhd. Shall be erected in the exactly right positions on the right frame line. 5. The temporary stay wires shall be tied and tightened by means of turn buckle and vertically of the bhd to be checked by means of the plumb. 6. The bulk head shall be aligned to buttock line or centre line. Frame line with reference to the buttock lines/center lines and frame lines of the DB below. 7. The bhd. shall be aligned and water line shall be checked by water tube. 8. The extrashall be marked to suit that water line adjustment on the athwart direction any error in DB panel shall be nullified here. 9. BHD shall be lowered by cutting the extra as marked BHD shall be checked finally for frame line buttock line and waterLine with reference to DB and side shell panels. 10. Bhd. Shall be locked at side before tacking and all rigging wires are to be kept tight. T.S.T panels: 1. The location and scantling of temporary pillars are to be designed for each panel. 2. The temporary pillars are fitted as per drawing before lifting the panel 3. Water line reference shall be marked on the part to TST unit 4. Guiding members/flat bars shall be fitted on to the ship for the panel in order to erect the panel in correct position. The projecting lugs of main bhd.shall be cut off before lifting the TST panel. 5. Panel shall be erected to correct frame line and plumb to correct buttock lines. 6. Alignment of panels shall be started from the datum panels to be chosen coming in way of vertical bhd. And their succeeding intermediate panels(2 nos) and DB panel at the centre shall be erected. 7. The intermediate panels shall be aligned for frame line and buttock line with reference to tank to lines. 8. The TST datum panel on Bhd. Shall be aligned holing to the integrated intermediate panels/UD. 9. The panel shall be set to correct buttock line by dropping a plumb to the tank top at FE and AE positions. Adjustments shall be made by means of turn buckles to
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a) Integrated FE and TST panels and b) UD panel. 10. The panel shall be set to frame line by dropping a plumb to tank top. 11. Water line of panel at shell shall be set to bhd. FE and AE ends. 12. After setting for frame line. Btk. Line and water line the panel shall be checked in positions. 13. If any error in DB panel or HST regarding the water level the same shall be adjusted at the seam joint of shell and HST. 14. The alignment shall be confirmed only when the other side (P&S) panel is also set and half breadth shall be checked for both the panels. 15. All TST units in way of hatch opening are aligned. 16. The hatch measurements and the diagonals shall be checked. Any adjustments and the diagonals shall be checked. Any adjustment shall be made if necessary.

INTERMEDIATE PANELS: 1. The growth of DB shall be on both and aft direction from the datum panel. 2. Before erection of the unit, the keel blocks and bilge blocks shall be ensured with correct height as per drawing and kept to water level on dock floor and ship declivity on berth by SWB dept. 3. The unit shall be held outside to the panel that has already been aligned and locked by means of 3 nos turn buckles on longitudinal and 1 or 2 nos cross wise. 4. The free end of the unit to be aligned shall be fitted with 2 nos of wire on athwart direction to the anchor point on the dock or berth. 5. The centre line of the intermediate panel shall be coincided with the center line of the panel which was already aligned on one side. 6. The centre line of the panel at the free end shall be plumbed to the centre line of berth/dock and coincide by means of rigging wire and turn buckles anchored to dock or berth. 7. The panel shall be set to correct frame space as per drawing at the centre line and OBD buttocks on p/s by means of longitudinal turn buckles. Fitted to the panel which was already aligned. 8. The overall length of panels shall be checked to the designed length and diagonals shall be checked for squareness.
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9. The water line of panel at longitudinal direction at the centre line from the frame line of previous panel at the panel joint to the extreme frame line of the panel shall be ensured 10. The water line at athwart direction at the frame end shall also be checked from centre line on a frame line. The water levels shall be ensured at the solid floors only. 11. Variation in frame space/overall length. Buttock space and water levels referred thro NCRR and corrected according to the resolution. The overall length between the frame lines of main bhds . Shall be checked in order to have overall length of the ship to be within tolerance limits. ENGINE ROOM DOUBLE BOTTOMS: 1. Special care shall be taken while aligning the ER area as any deviation in frame space of individual units may result for correction in accommodation area. 2. The overall length of the engine room forward bulkheads to aft bhd shall be ensured for dimensional accuracies care shall be taken on this aspect for every panel joint in ER area as any deviation in frame space of individual unit s may result for correction in accommodation areas. 3. The water line at free end of the panel shall be cocked down to take care of the lift at free end while welding the panel joint. The lift in the free end shall be monitored. 4. The centre line deviation of ER DBs to berth/dock or ship centre line may effect the shaft alignment. Cross wires provided to bottom shell on athwart direction to the anchoring points shall be kept Tight while welding and shall not be removed till all the welding works of joints are completed. 5. Frequent monitoring shall be carried out. 6. The line shall be sighted once in a month and any corrections shall be attended. 7. The panel adjacent to A.P. unit shall be secured by means of rigging wires. a) 2no s on athwart direction b) 2 nos vertically downward. PEAK PANELS: aft peak panels; 1. Before the erection of A.P. panel the following shall be ensured. 2. Keel sighting shall be confirmed and the reference imaginary line shall be extended to A.P. point for further reference.
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3. The centre line of berth /dock shall be rechecked to centre line and extended to A.P. pointOn berths centre line shall be transferred to a rigid temporary platform ease of working in water front area. 4. Any deviation of the adjoining free end of double bottom panel shall be corrected. 5. The geometric centre point of stern tube casting shall be marked and punched at the ford &aft sides. 6. The actual measurement of C.L of shaft from base line. Shall be taken at site from the keel sighting board at AE and FE of engine room. 7. The guiding flat bars of adequate size shall be welded to bottom side of free end adjoining DB unit to enable erection of AP unit In right position at ford and matching to the bottom shell. 8. Keel blocks shall be kept 15 mm lower than the designed height for easy erection. ERECTION OF AP PANELS: 1. AP1 panel shall be lifted to correct declivity at berth or spirit level at dock. 2. Panel shall be held by turn buckles on tank top and deck. 3. After pulling to frame space equality on port & stbd. The gap for keel block to bottom of panel shall be filled up by SWB dept. 4. Shores on the water front side or aft side shall be provided by SWB dept. 5. After erection the shores shall be tied with ropes to shoring lug. 6. The panel shall be tied by means of 2 nos .rigging wires on athwart direction to the anchoring points. ALIGNMENT FOR FRAME SPACE: 1. The frame space at the panel joint shall be ensured as per HSL quality standards and shall be made uniform at bottom shell level to IV deck(nearest deck) any angular deviation in frame space may lead to considerable error in super structure. 2. Overall measurement of engine room shall be ensured along the shaft line. ALIGNMENT FOR CENTRE LINE: 1. The centre line of the F.E. shall be coincided with tank top centre line by means of cross turn buckle. 2. A geometric centre point at A.E. shall be plumbed to dock or berth (temp. platform) and coincided by means of athwart rigging wires. 3. As a final check the centre line of shaft be sighted by theodolite and checked.
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ALIGNMENT OF WATER LINE: 1. Initially the panel shall be aligned to water line by means of water tube on deck &shores below. 2. The height of geometric centre point of at AE shall be checked from sighting line and the designed height from base line shall be ensured. 3. Final conformation shall be done by means of theodolite fitted ford of ME through ford & aft stern tube by keeping the seam at correct designed height at ford of ME & aft of stern tube. 4. After alignment. The radial measurements of the theodolite to centering shall be documented for constant vigil while welding. 5. The panel shall be held vertically downward at AE for following the unit to rise up at free end while welding the ford panel joint.

CONCLUSION: 1. Preparation of panel joint for full welding. 2. Level and lock the joint with strong backs in way of stiffening members (without distributing the panel alignment). 3. Edge preparation shall be done as per drawing/ HSL quality standards 4. Root- gap to be maintained as per HSL quality standards 5. Level and lock the plating and stiffening members of the panel joint. 6. Proper size scallops are to be cut in the internal members coming in way of panel joint as well as in strong backs and locking pieces and ensure panel joint is free from rust, dust etc,, 7. Fit up of the joint shall be offered to inspection authorities as per quality plan. 8. Remarks If any, Shall be completed as recommended and release for full welding

THE TEST PROCEDURE FOR THE ERECTION OR HULL BERTH DEPARTMENT: a. b. c. d. Leak test Hose test Pressure test Pressure test with air

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Leak testing: It is determination of the rate at which a liquid or gas will penetrate from inside a TIGHT component or assembly to the outside, or vice versa as a result of a pressure difference between the two regions, or of permeation of a somewhat extended barrier it has become conventional to use the term LEAK to refer to an actual discontinuity or passage through which a fluid flowed through a leak. LEAK RATE refers to the rate of fluid flow per unit of time under a given set of conditions and is properly expressed in units of mass per unit of time. The term Minimum detectable leak refers to the smallest hole or discrete passage that can be detected and minimum detectable leak rate refers to the smallest detectable fluid flow rate. There are two basic types of leaksReal leaks and virtual leaks. A real leaks is an eccentrically localized leak that is a discrete passage through which fluid may flow. Such a leak may take the form of a tube a crack and orifice. A system may leak through permeation of a somewhat extend barrier, this type of a real leakage called a distributed leak. Virtual leaks are leaks that involve the gradual description of gauges from surfaces are components within a vacuum system a vacuumed system may have both real leaks and virtual leaks simultaneously.

HOSE TESTING: With help of fire tender water jet will be applied on weld joints with a pressure of 2.5 kg/cm2 keeping the water delivery nozzle tip 1.5m away from the testing job and simultaneously inspects other side of the job for any leakage of water, if leaks are found the same will be repaired .

PRESSURE TEST: With hydraulically carried out by filling the water in the tank, space, voids, and keeping a water head in the top of the tank as required by the testing rules and inspects the for any leakage and soundness of the welds, as well as total integrity of the hull structure of the tankers space whether it is with standing the load or not for a specific time.

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PRESSURE TEST WITH AIR: In this test process compressed air will be filled in the tank space void etc, and keeping a manometer other end of the tank and see that the pressure of the filled air comes to 0.145 bar head and observe the pressed tank for hours time after that outside of the tank joints will be inspected for leaks by applying soap water thus gives bubbles in case of any leakages, same will be repaired after releasing the air .

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NON DESTRUCTIVE TESTING (NDT) METHODS

Non destructive testing is a wide group of analysis techniques used in science and industry to evaluate the properties of a material component or system without causing damage. Because NDT does not permanently alter the article being inspected, it is a highly valuable technique that can save both money and time in product evaluation, trouble shooting, and research. Common NDT methods include, ultra sonic, magnetic, liquid penetrant, radiographic and Eddy current testing NDT is a commonly used tool in forensic engineering, mechanical engineering. Electrical engineering , civil engineering, medicine and art. NDT methods ma y relay upon use of electromagnetic radiation, sound, and inherent properties of materials to examine samples. This includes some kinds of microscopy to examine external surfaces in detail, although sample preparation techniques for metallographic, optical microscopy and electro microscopy are generally destructive as the surfaces must be made smooth through polishing of the sample must be transparent in thickness. The inside of a sample can be examined with penetrating electromagnetic radiation, such as X-rays or with sound waves in case of the ultrasonic testing contrast between a defect and the sample may be enhanced for visual examination by a unaided eye by using liquids to penetrate fatigue cracks one method LPT involves using dyce, florescent or non florescent, in fluids for magnetic materials usually metals. Another commonly used method for magnetic materials involves a liquid suspension of fine iron particles applied to a part while it is in an externally applied magnetic field.

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RADIOGRAPHIC TESTING
PURPOSE: To ensure identity the internal welded joints defects on plating and section, pipe joints etc. SCOPE: This procedure shall be used for the detection of internal defects in welds SYSTEM: RADIATION SOURCE: Radiography will be performed with Ir-192gamma ray source. FILM IDENTIFICATION: Each radiograph shall be properly identified with nos and letters attached to the component during radiography. FILM DENSITY: The density of the radiography shall be between 2.0 t0 4.0 opt. densities TECHNIQUE: Single wall single image where possible. Double wall double image for jobs of OD up to maximum 89 mm Double wall, single image for jobs of OD more than 89mm and where single wall image is not possible. TYPE OF FILM: AGFA, Kodak, INDU or equivalent films with lead intensifying shall be used to achieve required quality radiograph. SENSITIVITY: Radiography shall be performed with a technique of radio sensitivity (2t) to display the essential wire of a wire type to QI. PROCESSING: Manual processing at controlled temperature

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ACCEPTANCE STANDARDS: DEFECT TYPE Under cut PERMITTED MAXIMUM Slight intermittent under cut is permitted, provided the depth does not exceed 0.5mm Shrinkage grooves/root concavities Slight Intermittent shrinkage grooves and concavities permitted to a maximum depth of 1.2mm Mis-alignment T/5 (up to 3mm max.) Cracks Not permitted Lack of root fusion --do-Lack of side wall fusion --do-Lack of inter run fusion --do-Lack of root penetration --do-Uniformly distributed porosity 2% by area of the weld. Slag individual and parallel weld axis L=T but not more than 25mm W=1.5mm max Slag linear group Aggregate length not exceed T in a length of 12T. T=plate thickness, L=length of defect, W=width of the defect

ULTRASONIC TESTING
Purpose: To ensure the materials/welded joints, sections etc. Are free from laminations &other discontinuities etc. in the sub surfaces. Scope: The procedure shall be used for the detection of laminations and discontinuities in welded joints, plates, sections etc. SYSTEM: SURFACE CONDITION: The surface shall be smooth and free from weld spatter , surface irregularities, for the free movement of the probe. Equipment:Pulse echo (Kraut Krammer Usk-7)

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TECHNIQUE: PLATES/SECTIONS:Back-wall echo technique with straight beam transducer. Welds: longitudinal and shear wave modes with straight and angle beam transducers. COUPLANT: Machine oil, glycerin, water, grease etc. shall be used as couplant SCANNING: PLATES/SECTIONS: scanning shall be continuous along the 225mm grid lines and on 50mm path line from the edges. WELDS: scanning shall be performed on base metal adjacent to weld with straight beam probe. Scanning shall be performed with angle beam probe, directing the beam toward the weld with a swivel of 5-10 degrees and with 108 overlap between successive scannings. ACCEPTANCE STANDARDS: WELDS: For examination of welds using a distance amplitude correction curve(DAC) any reflector which cause an indication in excess of DAC shall be investigated to the extent that it can be evaluated in terms of the acceptance standards of the reffering code sections. PLATES& SECTIONS: Any discontinuity indication causing a total loss of back reflection which cannot be contained with in a circle the diameter of which is 3 inches(75mm) or one half of the plate thickness whichever is greater is unacceptable shall be repaired and re-examined.

MAGNETIC PARTICLE TESTING

PURPOSE: To ensure the materials/welded joints/sections etc. are free from surface and sub-surface defects. SCOPE: This procedure shall be used for the detection of surface and sub-surface discontinuities in welds, plates, casting etc. of ferromagnetic materials.
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SYSTEM: DESCRIPTION OF METHOD: This magnetic particle test method shall be applied to detect discontinuities on or sub surface ferromagnetic materials. This method involves magnetize the area to be examined and magnetic particles shall be applied on the area under the tests. SURFACE CONDITION:surface shall be clean dry and free from all dirt, scales, weelding flux, weld spatter, oil grease etc. MAGNETIZING APPRATUS: EQUIPMENT:PROD/YOKE Type Current: Half way DC/AC

EXAMINATION MEDIUM: Magnetic particles black/red. EXAMINATION TYPE: dry or wet. For wet method: a suspension of 2t-2.5tsolid material by volume in kerosene or water. FIELD ADEQUECY: The field adequacy or the magnetic direction shall be checked by the field indicator. FIELD STRENGTH: For prod type ammeter reading shall be verified for yoke type by lifting the weight. EXAMINATION TECHNIQUE: The examination shall be conducted with over-laps and mutually perpendicular directions for full coverage. The test shall be carried out by the qualified persons and the results shall be evaluated by the level-II qualified persons. ACCEPATNCE STANDARDS: The surface to be examined shall be free from: Relevant linear indications. Relevant rounded indications greater than 5mm. Four or more relevant rounded indications in a line separated by 1.5mm or less(edge to edge)

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LIQUID PENETRANT TEST

PURPOSE: To ensure welded surface of plates , sections, pipes etc. is free from defects. SCOPE: This procedure shall be used for the detection of discontinuities opened to the surface in welds, plates, castings etc.

SYSTEM: SURFACE CONDITION: Surface preparation by grinding, machining or other methods may be necessary where surface irregularities could mark the indications of the discontinuities. Prior to L.P testing, the surface of the plates has to be examined and all the adjacent areas within 25mm shall be dry and free from dust, dirt, grease, oil etc. Cleaning agents such as detergents, de scaling solutions and paint removers may be used. DRYING: After cleaning the surface to be examined visually and shall be allowed for drying. TECHNIQUE REQUIREMENT: As a standard technique, the temperature of the penetrant and surface of the part are to be examined & shall not below 50 0F and above 1250F. PENTRANT APPLICATION: The pentrant may be applied by brush or by spraying. The minimum penetrations time shall be 5minitues. EXCESS PENETRANT REMOVAL: After the penetration time the excess penetrant remaining on the surface shall be removed with a cloth the surface shall be cleaned by wiping with solvent moistened cloth care shall be taken to avoid the removal of penetrant from discontinuities. WORKING PRINICIPLE:LPT inspection depends mainly on a penetrants effectively wetting the surface of solid work piece or specimen, flowing over that surface to form a continuous band reasonably uniform coating and then migrating in to cavity that is open to the surface.
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The ability of a given liquid to flow over a surface and enter surface cavities depends principally on the following factors. Cleanliness of surface- dirt, oil, grease, covers openings of flaws Cleanliness of the cavity-m improves surface tension properties, increases wetting effect Size of surface opening of the cavity Ability of the liquid to wet the surface which is closely related to phenomenon of capillary raise or depression.

ACCEPATNCE STANDARDS: The test shall be carried out by qualified persons and the results shall be evaluated by level-II & Level-III qualified persons only. The surface examined shall be free from: Relevant linier indications Relevant rounded indications greater than 5mm.

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CONCLUSION
This is a great opportunity for us to undergo in Shipyard for the project work . During the project work we have come across various technical and engineering aspects and we are enlightened due to the dissemination of the knowledge and information about the ship construction by various technical aspects. We have observed the mission and values of Hindustan Ship Yard executives in an hierarchical way are highly innovated standard of the organization which is the quite draining force of the yard functioning We proposed to add to this colossal organization as a drop in an ocean that the systems and procedures that working in each area should be exposed to lower level for exposition of employees involved in every area in order to shift the responsibilities of the top executives to middle management as well as down level in the staff and workmen. .

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