engineeringDamen shipyarDs gorinchem

march 2013

P. 1 psV 8318 unDer construction at wilson, sonsP. 2 ForeworDP. 2 Dsgo oFFice/yarD closeDP. 3 sea trials on psV4500 at wilson son’s (Brazil)P. 6 DawneFyP. 7 harmonising the BuilDing strategy For the new asD tug 2913P. 8 welcome on BoarD! hungP. 9 mega in a nutshell

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forewordmulticultural multinational

International WatersAll the Dutch employees within Damen have noticed that more and more communication is being done in English. The company we are all working for has grown rapidly from a local Shipyard, to national, then to international, and is currently a well established multinational company. Within this multinational company also Engineering has many colleagues all over the world, mainly in Romania, Ukraine, China and Vietnam. There are well over 200 colleagues working within Engineering outside the Netherlands, all over the world. The goal is to focus on growth abroad therefore it is expected that we will reach a point where there will be more people working for Engineering in other countries than in the Netherlands. To be clear, it is not a goal to reduce the capacity in Gorinchem but to increase the capacity abroad. Therefore it is obvious that this article is in the English language. The same goes for all other important communication in the international projects we do together to operate as one team and to be successful. This development offers a great opportunity for all of us, like working with colleagues from other countries, to be able to visit Yards and experience other countries and cultures. This will contribute not only in teamwork and efficiency in our work but also on personal level; it can enrichen your life by seeing, experiencing and working with people from other cultures. The same goes the other way around, more and more colleagues from other countries are visiting the Netherlands and are working temporarily within Gorinchem, which offers them the same enrichment.

Global TeamHowever, in Gorinchem we do not have to look that far to experience working with people from other countries and cultures. Within Gorinchem Engineering there are currently approximately 15 different nationalities working together. This can sometimes be difficult, especially in the beginning because of language and cultural differences, but at the end a mixture of people with different ideas and backgrounds can be a benefit by combining different experiences and strengths of all these people together. To stimulate this and in order to prevent cultural misunderstanding and miscommunication, a program of traineeships is being organised, named: Cultural Awareness. All Engineering employees inside & outside Gorinchem will learn about the cultural aspects of the colleagues they mostly work with. For Dutch people to understand other cultures and for non-Dutch people to understand the Dutch culture.All of this, cultural awareness and communication in English, is required to be effective and efficient in cooperating and to be able to work in a world wide team. One Global Engineering team which, very much like our Vessels, are operating successfully in international waters. We all can be proud to be part of that.PAUl KiTzEN – MANAGER ENGiNEERiNG TUGS

Dsgo oFFice/yarD closeD

april 2013

may 2013

su mo tu we th Fr sa 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Thursday 9 May Ascension DayFriday 10 May Mandatory day ofMonday 20 May Whit Monday

su mo tu we th Fr sa 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Monday 1 April EasterMonday 29 April Mandatory day ofTuesday 30 April Queen’s Birthday

the country was illegal. First time in Brazil and already illegal activities! After a couple of more hours we finally arrived in the hotel.

Day 1Early arrival at the yard, short briefing in the meeting room and we started a walk around the shipyards and of course on board of the vessel. in the shipyard i had my next surprise. i found out that such a small shipyard with a relatively small number of employees can have such a huge production capacity!The skills off these employees must be very good and they have to work very efficiently! Project 552018 is almost finished, two

Let me introduce myself! I am Elena Anca Stamate, 29 years old, born in Galati Romania. One year ago I started working at Damen as a mechanical engineer. At that point PSV4500 (YN552018) had already started, but there was still a lot of work to be done before the vessel could be delivered.

Gradually i got involved into this project and one of my jobs was to collect the complete FMEA documentation package. Although initially i thought the only thing i would have to do is to gather all the documentation together for this test, but it wasn’t quite as easy as that. i woke up suddenly involved with the electrical part. i had to find out what i had to gather for which system and from which company this information was coming. After quite some time and slaloms among emails and lots of information on the electrical part, we managed to have the FMEA documentation ready and approved by lloyd’s for the upcoming tests.For finalizing the complete FMEA test i got the chance to visit the shipyard of Wilson & Sons in Santos, Brazil. it was a great opportunity to see what the FMEA tests really implies!

So, there i was, flying together with project manager mechanical engineering Paul de Jong, to Brazil. i have to admit my only knowledge about Brazil was the nice weather, Copacabana beach and football.After 11 hours of flying i had experienced my first surprise regarding this country. Namely at landing in Sao Paulo there was a tropical rain. At that point i had told Paul i would take first plane back home because i have plenty of rain in Holland too. it changed quickly and in the end it was not bad at all!Next step was to pass customs. We carried two suitcases full of parts which were needed for the vessel. The value of the parts were not so high so we decided to take the “nothing to declare” lane. Unfortunately the customs wanted to scan our suitcases and we had to explain that these parts were needed on the shipyard. We were given a hard time persuading them but at the end we had to leave both suitcases over there because bringing them in The dry dock with RSV 8318(YN 556064) under construction

psv4500

sea trials on psV4500 at wilson, sons (Brazil)

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project news

psV4500

Section of dry bulk tank

With the help of Jorge Mroz from Wilson&Sons shipyard, Paul de Jong and Bram Verwijs (Production Manager) from Damen, i discovered engineering and purchase departments, warehouse, complete production side with their way of working from strategy to assembly, welding and mounting for all parts of the vessel.

Day 2, 3 and 4Again, early arrival at the yard and the first sailing of the PSV was about to start. We did a quick walk around on the second PSV which was in progress on the slipway. it was very nice to see how these vessels are being built together. After 11.00h we went on board because the trials were about to start. All commission teams involved in this project were on board: Sotreq (Cat)-Rolls Royce, Brunvoll, Kongsberg, Van der leun, Praxis, Van Aalst and of course Wilson&Sons (workers and crew). They were preparing the vessel for the FMEA tests of which i didn’t have the chance to see, because they were being postponed till after my scheduled departure from there. But i had plenty of time to walk along the vessel to observe and ask questions regarding: n Navigation equipmentn DP-power& controln Operator stationsn Cargo system (dry bulk, FO, FW, Brine)n Engine room arrangementn Cargo room arrangementsn Thruster installationsn Galleyn Accommodationn Feedback from Wilson Son’s

it was a premiere for me! Being on board of a fully equipped vessel for the first time. Once i stepped in, everything was much bigger than the 3D E-browser model that we normally observe at the engineering department. Of course you have an imagination of all these parts during the engineering phase but in reality, everything from equipment in relation to the pipes and the heights of the decks seems to be very different. i’ve become aware of the sizes and the weights of all these parts now. The real model, vessel itself doesn’t have so many shiny colors and totally lack of

other sister vessel are under construction together with our Fugro project and some ASD Tugs.Among all these they manage to open the second shipyard at a few minutes walking distance from the previous one. A completely new and ready for use dry dock is the masterpiece of this second shipyard!

Cargo rail section from one of the PSV’s

Bow thruster room section from PSV

YN 556064 under construction

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psV4500

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dust like my 3D E-browser and when you need to go on different decks you can’t do it with a click of the mouse. i noticed with surprise that everybody was open, friendly and ready to share in their knowledge with me. To all of my questions i got answers and detailed explanations for almost every system and used technology.

looking back to the last four days on the yard/sea trials i realized how much i had learned in a few days only. i managed to accumulate much more than i could do in a couple of months in my cozy office back at Damen.

i don’t know if it was because of the weather, the food or the friendly people that i have met there but for almost four days i felt like being at home in there… and when i think i wanted to go back immediately after landing due to some ordinary tropical rain!ElENA STAMATE MECHANiCAl ENGiNEER - DEPARTMENT ENGiNEERiNG O&T/ P&B

Integrated bridge system (Radar; Conning; Ecdis; Ams/Ias; Radar) Inside dry bulk tank

Engine room upper –Auxiliary sea water cooling system

Propulsion room-Rudder propeller& Lubrication unit

Main switchboard 690V panels

At the beginning of last year and the end of the year before we began with engineering the first two vessels in IFS. The first version of the integration between Acad and IFS was just released and briefly tested, so we felt we could start. “Proof of the pudding is in the eating”, as some say.

During these first projects many issues were raised and solutions to problems were created. The integration between Acad and iFS was made more reliable and more user friendly. The first start was made to make a planning tool for Engineering: the Workbench. A procedure was made to be able to handle material lists from Cadmatic.Part Catalog procedures were made to create and maintain parts. Many examples of PDM structures and how they are made were collected and the first rules of engagement on how to create structures were derived from that. We also started with the Handbooks, specifically HB03 Piping, in order to line up Acad, iFS and Cadmatic.The first Work instructions and Trainings were made.

After those projects were started up and well on their way to be the first vessels ever to be built using iFS throughout the whole project, we started making plans to put all projects in iFS. Because Engineering has about 300 employees, about 150 projects at any given time and just a few people with any knowledge of iFS, it was clear that this is going to be a challenge. We decided to start first with the conversion (Dawnefy) of fast running Standard ship types as we have the most to benefit of those.Then we decided to start with every new one-off or new Standard

ship type in iFS, because otherwise we would have to convert those ship types to iFS later as well. Only two of the fastest running ship types were selected, such that we would be able to do several things in a reasonably controlled manner. One is that we only have the first set up of the training material and we need these two projects to be able to fine-tune the Work instructions and training material. Two is that some of the problems that we encountered during the Engineering of the first two Projects are not completely solved yet. The solutions are known, but it requires some time to work everything out and to test the solutions. Three is that we need these projects to train more experienced users such they can help out the next teams. Four is that we are only just now learning what it means to do PDM and we are now determining rules and instructions for creating PDM structures.

At the time of writing this update we are testing the complete flow of building a vessel in iFS. So not just testing the engineering part, but the whole project. it starts at D&P/Sales, goes through Engineering, Material Coordination, Purchase etc. up to Services and all managed by Project Management. The goals of these tests is to see if all solutions are ready and well implemented, whether we need any additional solutions and to see if all sub-processes (engineering, purchase etc.) all add up to one total integral process. These first tests show clearly how the various processes in the supply chain depend on each other on one hand. And on the other hand it also makes clear that teamwork becomes more and more important to handle our projects efficiently.THEO PEElEN – TECHNiCAl MANAGER ENGiNEERiNG HSC/FE`

Currently the status of ‘Engineering going live in iFS’ looks like this picture. it shows the %-ready of the subgroup and of the project/standard ship type:

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DawneFy/iFs-upDates

mission anD amBition

ENGINEERING GOING LIVE IN IFS

new asD tug 2913

Why harmonise?What one can see is that the lowest level of assembly is the same for all shipyards. Yards which have more hoisting capacity will assemble sections and if possible blocks.Engineering will provide information to the shipyards on section level. However during the detail engineering phase, engineers will incorporate the lowest level in the 3D model. This means; one 3D model for all yards! in this way yards with fewer capabilities can easily change to the smaller level of assembly. On the other hand yards with more capabilities can do the same but then upgrade to bigger blocks. Both ways are possible without needing different info from engineering!

Final result for ASD Tug 2913The final result for the ASD Tug 2913 are drawings defining; sub-assemblies, sections and blocks as schematically presented in the figure below. Engineering has started up the basic engineering at this moment with these drawings as input. in the mean-time these plans are also presented at NDSQ and we received positive feedback from the yard. Damen Song Cam Shipyard will be informed soon and we are confident that the yard will be positive as well regarding the presented building strategy.JACK TEUBEN – PROJECT MANAGER DEPARTMENT YARD SUPPORT

What is a building strategyDefining a building strategy is anyway the first step in making a production planning for a ship; what has to be done in which order. A building strategy is represented by three items:1 Section plan;2 Assembly plan of sections, in which order sections are to be

assembled;3 Feed-in plan of big and/or heavy components during the

assembly of the hull.

Until now the engineering department requested advice from shipyards involved to define the building strategy/section plan. Because shipyard facilities & standards can differ tremendously, building strategies will be different as well. This results in different section plans, 3D models and delivered production information (e.g. nine different 3D models for ASD 2810). For engineering this is very labour intensive. Also it becomes very difficult to keep all 3D models updated at all-times. When there is an update from the Product Group, which 3D model must be updated?

How can we harmonise?Yard Support’s point of view is that this situation improves dramatically when building strategies are harmonised. This can be realized when Yard Support coordinates the process of defining building strategies and represents all shipyards within the group. Of course Yard Support has the responsibility to keep in contact with the yards to be sure that the developed building strategies will be accepted.Engineering tugs has asked Yard Support to assist in this matter for the ASD 2913. Together with Damen Shipyard Galati a building strategy is developed which can be used on different shipyards.When we started developing the building strategy of the ASD 2913, the only information available was a general arrangement plan and some cross sections – nothing else!

The first step is to divide the ship construction into smaller parts and see what the impact is on the following items:n Sections – building position and maximum weight of section n Pre-outfitting/outfitting – locate the surfaces/area’s with high

density of outfitting partsn Preferred way of assembly of ship hull – stacking of sectionsn Feed-in plan

Defining a building strategy is an iterative process. Normally yards and engineering distinguish “a section” as the smallest unit. However one can identify also smaller sub-assemblies within a section. These “subs” are following the main structural panels which can be used as “primary building beds”. This is represented in the next figure where the sub-assemblies (grey in the figure) are forming the smallest structures which can be assembled as one unit. Starting with sub-assemblies is a new way of thinking!Bigger yards are thinking more in blocks (being an assembly of two or more sections). So if we manage to identify the smallest units and group them to sections and then to blocks and finally to a ship, every shipyard can work with the defined building strategy. This is shown below for two different ways of grouping subs, sections and blocks into a ship.

harmonising the BuilDing strategy For the new asD tug 2913

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n sub assemblyn sectionn block

Sub-ASSEmbLIES

SEcTIONS <50t

n My name is Hung Anh Phamn i work for Damen Song Cam (DSCS) Vietnamn My function is iCT Engineern i am quite interested in iCT Orientation & Vision such as:

global organization/system, global standard, centralized datacenter, worldwide engineering

n What i liked in Holland the Head Office (Gorinchem), snow, the flat landscape, wind mills, museums, cheese, Super Yacht (AMElS, Vlissingen) and above all the beautiful Dutch girls.

n Back in Vietnam i continue contributing on the further success of the new shipyard

n i’d like to say this Thank you so much: my friends and Management Board in DSGo & DSNS, you are all nice and always smile. i hope this is not the last time i’m here. See you soon…

This picture says a lot about me, because: i Amsterdam

hungAt this moment only eighty percent of Engineering DSGo is Dutch. Romanians, belgians, Poles, Turks, Slovaks, Surinamese, Portuguese etc. make it fun and interesting to work at Engineering DSGo.

At the beginning of March the CAD support and iCT department had a visitor from Vietnam. He introduces himself:

welcome on BoarD!

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2004 2005 2006 2007 2008 2009 2010 2011 2012

megamega in a nutshell

n Ship design company, belonging to the Damen Group; n Company Policy: Quality first!n Settled up in 2004 under Schelde Naval Shipbuilding, within

the Damen Shipyard Galati area;n Matrix Organization: two departments (Hull and Machinery &

Arrangement) and Projects Coordination; n Detail design project oriented, all disciplines (Hull, Machinery &

Piping, HVAC, Electrical) and the future goal is to do basic design;

n input data: the basic design received from our partners Damen Schelde Naval Shipbuilding and Damen Shipyards Gorinchem, VFi and building standards

n Navy & navy support vessel, Offshore supply/patrol vessel, tugs, hoper dredger, commercial (heavy lift, containers, tanks)

HistoryThe story starts in April 2004 when due to the necessity of supplementary engineering capacity, Schelde Naval Shipbuilding took the decision to set up a new engineering company in Galati within the Damen Shipyard Galati area, named Marine Engineering Galati, well known as MEGA.The first team had only six (6) hull and piping engineers and in the next four years the MEGA team grows up to 37-38 employees – in the summer of 2008 – but also in performance.Following the Damen Group Top Management decision, in July 2008 MEGA took over almost half of the engineers of the Engineering Department of Damen Galati Shipyard and MEGA grows (suddenly) in size – up to 67 employees.

ship design;n Ships engineered by MEGA built by shipyards located in:

Romania, The Netherlands, Brazil, China, Vietnam;n The engineering process is principally done by using the

shipbuilding specialized 3D software systems – NUPAS and CadMatic. Also used are AutoCAD, MicroStation, AutoNesting, Shell Plates and Siemens NX (NASTRAN);

n Main design facilities: three rooms accommodating abt 46 separate/individual offices, three meeting rooms and one videoconference room, pantry rooms and canteen;

n Started with six engineers in 2004 and has grown every year up to 94 employees in early 2013.

n loaded rate (2012 and prediction for first half of 2013): 72-100%.n Clients: DSNS, DSGo (O&T) and (T&W), China, Qatar, others

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n hull n piping n total

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60

40

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EmPLOYEES EVOLuTION SINcE 2004

Extension of MEGA offices spaces

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introDuction

b Participation at the displacement tests and inclining tests, preparing of the input data (weights estimation and distribution, inspection of the vessels) but also of tests reports to be done specially for the vessels to be build in DSGalati.

Couples of other steps, for shifting scope to basic engineering, are planned for the next year as following:a Purchase licenses for performing local structure calculation

and train couple of engineers on this design field. b Purchase licenses for light weight distribution and preliminary

stability calculation and train couple of engineers on this design field.

MEGA should support the DSNS and the Damen Group policy and extension by opening Engineering Offices (for technical assistance and production support) next to the production facilities where the navy vessels will be build.

Now is the right time to take important steps to the next stage in the development of MEGA, ref. to the organization, efficiency, productivity, production engineering friendly, but also extension of the design activities to basic design.This is a very important action/development and should be treated like a big project.

We should go in this direction, but it is necessary to have the understanding and the fully support from all the parties – internal and external – involved in the engineering processes.FlORiN RASCANU - GENERAl MANAGER MEGA

This article is only part of a more extensive presentation on Mega, written by Florin. The complete article can be found at the Engineering portal (https://damenplaza.dsgo.nl/Organisation/Operations/EngineeringPortal/Pages/Engineering-portal-Home.aspx) category "Reading stuff”

megaAn old building was completely up-graded and the entire team of MEGA was moved in the same location in April 2009.Till the summer of 2011 the MEGA team was growing up to 74 direct engineers and it became necessary to arrange another room with abt. 46 workplaces.The investment for the extension of the office spaces was approved in May 2011 and the “project” starts in the same month.The new room, with a surface of abt. 432m² which accommodate 46 new workplaces and two separate/individual offices, was finalized at the end of September 2011.The entire office extension project is almost finalized, including a new lunch room having abt. 126m², a new meeting room, the main hall and main entrance.

medium and long term FuTuREThe level of knowledge of the employees and the quality level of the documentation delivered in the last years shows that the MEGA team is prepared to expand the area of the design activities and gradually shift the SOW to the BASiC DESiGN works in the next 2-3 years. The Basic Design activities are the real/core engineering works and one way for MEGA to continue the development process – the next big step – is to go in this direction. it will be a loss – wasting of the qualified resources – if we will stop here or if team MEGA will be directed/ involved too much on the Job Preparation and Production Support activities.

The first steps for expanding the area of the design activities to basic design were already done this year, as following:a Participate with small teams at the Basic Design stage on

the projects performed at DSGo and DSNS together with experienced Dutch engineers.

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PSWe hope you enjoyed our newsletter and stay informed about the news of the Engineering department. We kindly invite you to contribute. Do you have information that is interesting for our other colleagues? Please send your input by e-mail. Do you know other persons who would like to receive this Newsletter? Please contact us (contact details below).

The next edition will be launched in May 2013Kind regards, The EditorsEllA DEKKERS (EDE@DAMEN.Nl)

MARiSKA liBRETTO (MJl@DAMEN.Nl)

liSETTE VAN WERSHOVEN (lVW@DAMEN.Nl)