Hull and Machinery Outfitting Shops -Infrastructure, Layout and Management

Ship Production - 2

Ebin Joseph

Goutham Venkatesh K.

P. Akshay Kumar

Vineesh K

Semester – 7

Department of Ship Technology

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Introduction ..................................................................................................................... 3

Outfitting ......................................................................................................................... 4

Fitting Out Ships.............................................................................................................4

Traditional Practice ........................................................................................................5

Disadvantages with Traditional Practice........................................................................6

Concept of Unitisation: ..................................................................................................6

Block Outfitting Concept:...............................................................................................7

Group Technology / Concept of Workstations / Product-Work-Breakdown-Structure:7

Concept of Zone-Outfitting:...........................................................................................8

Management in Outfit Shops.......................................................................................... 10

Typical Responsibilities for College-Educated Staff People Assigned to an OutfittingFabrication Shop (e.g., for manufacturing pipe pieces) ..................................................10

Special Activities ..............................................................................................10

Routine Activities .............................................................................................11

Typical Responsibilities for College-Educated Staff People Assigned to an OutfittingAssembly Shop (e.g., deck, accommodation, machinery and electrical) ........................11

Special Activities ..........................................................................................................11

Pipe Outfitting................................................................................................................ 13

Pipe Shop: Case Study - Cochin Shipyard Ltd. .....................................................................13

Outfit Warehouse at Cochin Shipyard Ltd. ..............................................................14

Work Flow In A Pipe Shop........................................................................................16

Infrastructure ...........................................................................................................16

Layout Sequence of Machinery ...............................................................................18

Location of piping shop............................................................................................19

Storage of piping......................................................................................................20

Advanced Outfitting Practices in a Shipyard ...........................................................21

Machinery Outfitting ...................................................................................................... 28

Main Engine Installation ......................................................................................................29

Deck and Cargo Space Equipment ................................................................................... 31

Deck Crane Installation ................................................................................................31

Crane Pedestal Installation ..........................................................................................32

Accommodation Outfitting ............................................................................................. 33

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Electrical Outfitting ........................................................................................................ 36

Electrical Repair Shop ..................................................................................................36

Electrical Shop Plan......................................................................................................37

Vote of Thanks ............................................................................................................... 38

References ..................................................................................................................... 38

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Introduction

In conventional shipbuilding, the ship’s hull structure is fabricated and erected on the berthor dock and the outfitting is started only after launching the hull from the berth. As a result,it has been found that the process of first fabricating and completing the hull structurefollowed by outfitting the hull after launching takes longer time. Hence, to reduce the cycletime and improve the productivity of the shipyards, the concept of advanced outfitting hasbeen developed.

All the modern day shipyards across the world have now identified that by adopting theconcept of advance outfitting the vessel building cycle time can be reduced and a substantialsaving of costs, along with other benefits, depending on the availability of infrastructure inthe yards can be achieved. Different concepts have been developed for the completion ofoutfitting in block stage to derive the benefits of this methods. Where previously outfittingwas done entirely after the ship was launched from the slipway or the dry-dock, modernconcept facilitates the outfitting work to be started even before the launch; i.e. within theblock erection stage.

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Outfitting

Outfit includes all non-structural parts of a ship.

Among these items are:

1. Main propulsion systems and auxiliary machinery2. Pumps and piping systems3. Heating, ventilation, and air-conditioning machinery and systems (HVAC)4. Electrical systems5. Accommodations and hotel services6. Deck and cargo space equipment7. Weapons and combat systems for naval vessels

Organization of and responsibility for outfit work may vary from shipyard to shipyard,subject to local traditions, union jurisdictions, subcontractor arrangements, and otherconsiderations.

Fitting Out Ships

This includes a large number of operations of which the main components are hull, machineryand electrical fitting out. Work carried out under these categories includes:

Hull:

Deck equipment WINDLASS/WINCHES/BOATS/DAVITS

Accommodation Spaces JOINERY/ELECTRICAL /PLUMBING/VENTILATION

Piping FUEL/BALLAST/CARGO MAINS

Miscellaneous LADDERS,WALKWAYS, GRATINGS, ETC.

Machinery:

STERN TUBE, MAIN AND TAIL SHAFTS, PROPELLER

RUDDER/STOCK

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MAIN ENGINES

AUXILIARY MACHINERY/EQUIPMENT

PIPING

Electrical:

Engine Room

Hull main services.

Traditional Practice

In the past, the tendency has been to separate various trades and to commence outfittingonly after a significant proportion has been erected. The principal features is this mode ofwork where the ship spending a relatively short time at the assembly/fabrication stage andcomparatively long periods on the building berth and in the basin.

Typical steps for accommodation work following approximate completion of steelwork aslisted below:

1. Make pipe/trunk/electrical penetrations2. Fair buckled plate3. Install airports/windows4. Perform hose testing5. Paint steelwork6. Fit insulation/wiring/ducts pipes7. Fit joiner partitions/bulkheads8. Install plumping fixtures9. Lay floor covering10. Install built-in furniture/doors/fixtures11. Complete painting12. Fit carpets/curtains13. Install portable furniture.

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Traditional sequence of Production Event

Disadvantages with Traditional PracticeAlthough it appears simple, this manner of work has a number of disadvantages associatedwith it:

(1) Longer build time

(2) Uneven labour requirement

(3) Larger space requirements

(4) Extensive re-work

(5) Uncomfortable work environment

(6) Difficult to plan

(7) Access problems

Concept of Unitisation:

Even before the hull block is made, the outfit components (machinery, piping, seatingstructures, etc.) which are supposed to be located in a particular small area in the ship arefully assembled into a small unit and when the hull block is made, this unit is then directlyinstalled at the required position in the block. Hence you see, in this process, the steelstructure and the machinery outfit units are developed simultaneously instead of a traditionalprocess wherein the machinery and outfit are installed only after complete erection of the

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ship’s hull. This process actually helps in reducing the cycle time required to build the ship.Remember, in ship-building too, time is money.

Block Outfitting Concept:

Block outfitting involves erection of units of assembled components (a component may be aunit of a pump with its seating and associated piping) and also heavy machinery (for example:boilers) on large blocks of the hull before the blocks are erected and welded to each other.However, consideration is always given to the limitation of the total weight that can behandled by the carnage facilities of the yard. The size of the hull blocks are accordingly pre-decided by the design department of the yard, keeping this factor in mind.

By this process, the yards have managed to prefer down-hand welding because, the hullblocks can be inverted and the outfit can be installed before erection of the blocks. As a result,the components requiring overhead welding (for example: exhaust lines, ventilation trunks,etc.) can be welded by down-hand welding. This is actually very fruitful because down-handwelding is not only easier than overhead welding but also a safer option for the welders inthe shipyard.

Also, open-sky access for erection of machinery, makes it easier for the productiondepartment to erect larger machinery.

Group Technology / Concept of Workstations / Product-Work-Breakdown-Structure:

The basic principle of Group Technology is that it involves identifying the subdivisions of aproduct, which although may not be necessarily identical are produced by the same processand set of operations. For example; in the engine room area of a ship, a unit can be consideredas a machinery component along with its seat and connected piping. The kind of workrequired to erect such a unit, will be similar to that required to erect many similar units in theengine room area. Therefore, Group Technology involves identification of the interimproducts or so called units, which can be handled by the same type of processes.

The application of Group Technology to ship-building results in dividing entire ship into sub-divisions based on the kind of work required to build and erect each division. Each divisioncan now be assigned to different manufacturing groups who are specialised to build thoseparticular units effectively. Such categorisation of the components required to build the shipis known as Product Work Breakdown Structure (PWBS). Now, each type of component is tobe manufactured in separate and specialised locations in the shipyard called workstations.

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The question arises as to why do we need such a grouping? The answer lies in the fact thatthis method of grouping offers considerable potential for the improvement of themanufacturing efficiency of the shipyard. Because each workstation is now specialized inefficiently manufacturing its designated units, since it is equipped with the suitable tools,machinery and workforce required for the same. This not only allows easier planning of workbut also maintains a steady work load with increased performance of operators.

One very notable aspect that we must take note of is that this method can now be applicableto develop and manufacture the interim products of units for all types of ships that the yardwill be building in the future. Thus, the advantage of repeated work can be obtained inutilising the workstation concept in shipbuilding industry.

Concept of Zone-Outfitting:Before we start understanding this concept of advanced outfitting, it is necessary tounderstand what a “Zone” is when we are speaking in terms of shipbuilding. A zone maycorrespond to a compartment or even any integral part of a compartment of a ship, such asa cargo hold or a machinery space and its sub-divisions. It completely depends on the yard asto how they define the zones in a ship to be built. Even an entire superstructure or just onelevel (deck) of a superstructure could be considered to be a zone. Hence, in a nutshell, a zoneis a sub-division of a ship that is selected for the convenience of outfitting either on units ofhull block or on larger hull blocks or directly on-board the whole ship after all the blocks arejoined.

There are three types of zone outfitting practices, mainly dependent on the scale on which itis applied.

1. On-Unit2. On-Block Installation:3. On board (either on berth or afloat):

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Advanced Outfitting - Sequence of Production Events

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Management in Outfit Shops

Typical Responsibilities for College-Educated Staff People Assigned toan Outfitting Fabrication Shop (e.g., for manufacturing pipe pieces)

Special Activities1. For each building contract, budget man-hours and materials allocated to the shop to

the various flow lanes based on records of efficiency achieved and also based on

planned improvements in work methods, e.g., automatic welding, and better jigs and

tools.

2. Maintain a long-term (1 year) shop loading plan and revise it in response to every

change in the shipyard’s master schedule.

3. Manage the use of subcontractors and the use of overtime to offset work-load

fluctuations.

4. Negotiate with subcontractors and settle on volumes of work and unit prices that are

to apply for a one-year period.

5. Estimate work associated with drawings, material lists and other information provided

by designers.

6. Develop intermediate-term (3 months) schedules to meet pallet required dates using

feedback, i.e., man-hours per unit weight, per-piece, per electric-cable lengths, etc.

7. Maintain man-hour control graphs per ship by the parameters used for feedback.

8. Maintain the data bank for computer processing of information.

e.g., lot number and serial number for control during fabrication vs. ship

number, part number and pallet number needed for control during assembly

on-unit, on-block and on-board.

9. Plan facilities improvements.

10. Implement special projects, e.g., how to make the shop more vivid.

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Routine Activities

1. Preside over weekly meetings attended by the shop manager, flow lane foremen and

their assistants and other staff assistants to:

a. ascertain the number of components completed per week relative to planned

output per flow lane,

b. establish the amounts of work to be accomplished next week, including

overtime work and work to be subcontracted, and

c. Establish a manning plan per flow lane for next week’s work.

2. Once each month, prepare the shop manager’s report to the department manager

presenting the actual trend of production (difference between what was planned and

scheduled and final results) and presenting recommendations for improvement.

3. Maintain the accuracy control system.

4. Attend safety control meetings which are held twice per month.

Typical Responsibilities for College-Educated Staff PeopleAssigned to an Outfitting Assembly Shop (e.g., deck,

accommodation, machinery and electrical)

Special Activities

1. Participate in the study of each preliminary design, before contract design starts, andcontribute to a basic build strategy

2. Participate in meetings for hull block definition.3. Prepare the strategy for zone outfitting by designating zones and stages for outfitting

unit , on block, on grand block and on board and when necessary advising designersof changes in arrangements that would improve productivity without inhibiting ownerrequirements.

4. Designate special material required dates such as for a main engine and check for suchmaterial availability.

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5. Prepare 3-months and l-month schedules using the design outputs per pallet and man-hour rates associated with fitting specific materials.

6. Continue to contribute to further definition of a build strategy as subsequent designphases evolve and eventually inputting information needed to facilitate work, e.g.,check points, reference lines, means for air testing welds , so that the output of detaildesign is, literally, work instructions.

7. Document the outfitting strategy and establish targets taking into account new ideasfor reducing costs.

8. Prepare the zone-outfitting schedule insuring that it is compatible with the designschedule for preparation of work instructions corresponding to pallets (MLF).

9. Prepare a staging plan.10. Specify access and routes from a safety point of view.11. For each building contract, budget man-hours and materials allocated to the shop to

the various flow lanes based on records of efficiency achieved and also based onplanned improvements in work methods, e.g., automatic welding, and better jigs andtools.

12. Plan relocations of on-board cranes to anticipate erection progress.13. Prepare plans such as for main engine installation, propulsion system alignment,

flushing completed pipe systems, etc.

Routine Activities

1. Attend the brief meeting of electric shop foremen each morning.2. Preside over the weekly meeting for finalizing next week’s work load specifically by:

a. Checking monthly schedules proposed by foremen and weekly schedulesproposed by assistant foremen,

b. Conveying policy conceived by the shop staff for how work is to proceed.c. Discussing and adjusting the distribution of workers with the foremen, and

3. Resolve owner’s and surveyor’s reports of unsatisfactory items and process feedbackreports.

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Pipe Outfitting

Pipe Shop: Case Study - Cochin Shipyard Ltd.

At the Cochin Shipyard Ltd., the Outfit department takes over the ship from the Hull Erectiondepartment. The hull erection department assembles the blocks and the basic structure islaid. Now the ship needs to be stuffed with all the equipment, machinery and comfort. This isdone in the outfit department. There is outfitting of machineries, piping, electrical outfittingand accommodation outfitting.

Software used in Cochin Shipyard Ltd. for Pipe modelling

Ship Constructor FORAN TRIBON

Pipe Layout example in AVEVA TRIBON

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Outfit Warehouse at Cochin Shipyard Ltd.

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Piping is divided into:

1. Engine Room Piping

Compressed Air pipe Fuel oil pipe Lube oil pipe Cooling water pipe Exhaust Gas Piping Bilge piping

2. Piping used by crew and passengers

Fresh water pipe Grey water pipe Black water pipe Scupper

3. Machinery support and safety

Steam piping Ballast piping system Ventilation pipes Refrigeration pipe Sounding pipe Air pipe

4. Ship specific piping system

Cargo Handling piping Firefighting pipes Inert Gas Pipes

1. Engine Room Piping

2. Piping used by crew and passengers

3. Piping for machinery support and safety

4. Ship specific piping system

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Work Flow In A Pipe Shop

1. Pipe Design Process

2. CAD Drafting

3. Cutting Process

4. Edge Preparation

5. Hole And Contour cutting FlangeFitting and welding

9. Bending

8. Hole Punching

7. Stress Relieving

6. Testing

10.Surface Preparation

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Infrastructure

Machinery Items in Pipe Shop:

MACHINE SPECIFICATION

Pipe Coaster 350NB

CNC Pipe Coaster 80NB to 1200 OD pipe

2” Pipe Bending Machine 10NB – 50NB (2D & 3D)

6” Pipe Bending Machine 65NB – 150NB (2D & 3D)

2” Yogi Pipe Bending Machine 10NB – 50NB

Wallace Coast Bending Machine 50Nb – 150NB (2D & 3D)

Portable Pipe Bender 15NB – 25NB

Threading Machine Rems Uni upto 2”

Threading Machine Rems 773 upto 4”

Winch 5T

High Speed Cutting Machine upto 80NB

High Speed Cutting Machine (Roller Type) upto 175NB

Sand Filling Machine

Manual Metal arc Welding (AC & DC)

CO2 Welding 15V – 50V (Megatronic)

TIG Welding Machine (AC & DC)

Radial Drilling Machine RM62

Centre Lathe HMT – H26

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Pedestal Grinder Heavy Duty

Tool Grinder Light Duty

Hyd. Pressure Testing Equipment 250Kg/cm2

Plasma Cutting Machine plates upto 2” thick

Power Hack Saw upto 250NB

EOT Crane 5T & 2T

Post Crane 1T

Layout Sequence of Machinery

.

1. CUTTING

2. BENDING

3. SPOT WELDING

4. WELDING

5. GRINDING

6. BLASTING

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Location of piping shop

1. Closely related to outfitting bay

Largest outfit tasks in shipbuilding Easy handling, saving time as well as cheap cost makes it near to the outfitting

bay

2. Readily accessible to the ware house

The pipe piece fabrication is very important to connect all the pipes by smallpieces.

Easy handling, saving time as well as cheap cost makes it near to the outfittingbay

3. Flow of work not interrupted

No interrupt of flow of work Separated from hull, block assembly, block storage, the building berth and the

steel stockyard.

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Storage of pipingIn the storage of pipes in shop before fabrication or after fabrication one shouldconsider the following

• Space occupation

• Retrieval of the material

• Flow of work

• Minimum apparatus

• Least time should be spend

• Recommended should be obeyed

• In pipe shop pipes are kept in racks with recommended height and properaccessibility with minimum space available for the handling of pipes

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Advanced Outfitting Practices in a Shipyard

On-Unit Outfitting

Outfitting on unit is the assembly of a unit of machinery or component or an alreadymanufactured product (which can also be purchased by the shipyard). But this unit is not apart of the steel structure of the hull. For example: a unit can be a boiler mounted on its seat,along with its connected piping, flanges, valves. This unit is first completely assembled, andthen transported to the site where the hull block is previously erected. The unit is thenerected on the hull block as a single unit. This is again similar to the application of theUnitisation Concept that we discussed previously. But the point to be noted is that in zoneoutfitting, we are focussing on the zone of the ship where the unit is erected.

Step: 1

Seawater Service Pump and an Air-conditioning Water Pump

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• Shown in previous image is a machinery unit which will contain both a SeawaterService Pump and an Air-Conditioning Water Pump.

• Vertical Seawater Service Pump is fitted to the subcontractor-furnished paintedfoundation which was built according to a shipyard-provided detail drawing.

• A pipe support, to be subsequently fitted, is included. The horizontal Air-ConditioningWater Pump is on the platen alongside are scheduled to be fitted on block.

Step: 2

A strainer has been fitted to the Seawater Service Pump, the Air-Conditioning Water Pumphas been fitted and a valve is being lifted into position

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Step: 3

A pipe piece is being lifted by the shop's bridge crane for bolting to the Seawater Service Pump

Step: 4

A second worker temporarily assists by guiding a strainer to its final position while thegasket and a few bolts are secured

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Step: 5

Pipe piece supports are being fitted

Step: 6

The completed unit is being transported for fitting on-block

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On-Block OutfittingOutfitting on block is the installation of outfit components (machinery with seats, piping,electrical cables, ventilation trunks, etc.) after an entire hull block is completed. The units areinstalled either as separate components or after unitising them (similar to what is describedabove)

On Block Advanced Outfitting

Advanced Outfitted Grand Block

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• Outfitting components, units, and grand units are sometimes fitted in a block zonedefined for hull construction.

• However, when they are to be fitted to ceilings, blocks should be inverted becausefitting down-hand enhances safety and efficiency.

• Following block turnover, the outfit zone encompasses the components, units, and/orgrand units fitted to the floor.

Forecastle Upside Down

Forecastle Deck Right Upside Up

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Double Bottom On-block Outfitting

• Outfit items should be fitted in the zone of a double bottom block before its tank toppanel is installed.

• At a later stage, a different outfit zone encompasses everything to be fitted to thetank top.

• The primary goals of this manufacturing level are to outfit ceilings and doublebottoms when blocks can be manipulated to provide ideal access.

Engine room tank top unit

Engine room tank top components fitted on-block

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Machinery Outfitting

On-Board OutfittingConventional method of outfitting - It can be defined as all the outfitting work that is doneafter the hull blocks are completed and erected in the slipway or docks.

Ideally, assembly and painting work are left for accomplishment on-board.

These works are limited to:

1. Fitting of components that are too large to fit on block like main engine,diesel generators etc.

2. Connecting distributive systems at block butts and seams

3. Pulling only the ends of electric cables that were fitted on block

4. Pulling electric cables that could not be pulled on block

5. Connecting electric cables

6. Clean up

7. Painting touch up

8. Installation of the main drive line

9. Finish painting

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Main Engine Installation

STEP 1:

Preparing the engine for installation,attaching it to the lifting equipment

STEP 2:

Lifting the engineusing the crane

safely and moving ittowards the engine

room’s position

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STEP 3:

Lowering the engineinto the engine room

STEP 4:

Checking for properalignment and finallysetting the engine onthe engine mountfoundation

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Deck and Cargo Space Equipment

Deck Crane Installation

This is a highly precise and skilled activity taking place post erection of a vessel

Mainly done by specialized set of workers specially skilled at handling such heavy and

large system on a confined deck space.

Usually for large cranes, the various components are erected one by one

Thus alignment of the units becomes an important consideration in this operation.

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Crane Pedestal Installation

Post erection deck crane installation

Figure showing unit-wise erection of the deck crane structure

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Accommodation Outfitting

Accommodation spaces are available as pre-outfitted modules. These are installed on the shipas On-block installations. Depending on the space availability in the unit of installation,modularised accommodation units are ordered.

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Modules lifted into ship using Cranes

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Accommodation Units – Before, During and After Installation

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Electrical OutfittingElectrical equipment installations in ships:

1. D.C. Generators2. D.C. Switchgear3. A.C. Generators4. Automatic Voltage Regulators5. A.C. Switchgear6. Distribution Box – Main Switch Board, Sub-Switch Boards.7. Electric Cables8. Insulation and Temperature rating of Machinery9. Motors10. Motor Control Gear

Electrical Repair Shop

The electrical shop in a ship repair yard should be equipped and capable of undertakingrepairs and rewinding of full range of motors and generators of ships and overhaul ofelectrical apparatus and switch gears. List of major equipment’s here are:-

1. Electric Coil Winding machines2. Industrial Furnaces3. Dimmer stats4. Quick way Armature winding machine with counter5. Coil winding machinery with counter6. Testing panel with dimmer status

The potential for electrical shock hazards is greater in shipbuilding and repair than in otherindustries, because workers stand on metal decks and often work in a wet environment. Workon or around energized electrical equipment can expose workers to electrocution, burns, orelectrical shock. Before work is performed, energized equipment must be guarded, de-energized, or appropriate PPE used to prevent worker exposure.

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Electrical Shop Plan

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Vote of ThanksWe would like to take this opportunity to express our sincere thanks to the following personswho have helped us in completing this assignment.

Mr. Arjun Jacob (Oshima Shipyard Ltd.)

Mr. Akhil Augustine (Cochin Shipyard Ltd.)

Mr. Tomy Joseph Praful (Goa Shipyard Ltd.)

References

Ship Production Technology Part-I and Part-II, Prof. R.A. Shenoi, University ofSouthampton

i.T.Ü. Faculty of Naval Architecture and Ocean Engineering Shipyard Organization –GEM 412-E

Shipyard Management - Design, Planning & Operations: Event Brochureo BC Asia website@ibcasia.com.sg

Ship Production – Storch Lee Marine Insight Website www.marineinsight.com