training new building

Classification Survey during Construction (Hull) -1/88-

Surveys for CSR-Applied Ships(for information only)

1 Allowable thickness diminution for hull structure (Sec. 12)

Sec. 2 Thickness measurements and acceptance criteria (Chap. 13)

5.2.6 Thickness measurements(Chap. 5)

Thickness measurement(Ships in service)

5 Testing procedures (Sec. 11)

Sec. 3 Testing of compartments (Chap.11)

2.1.5 Hydrostatic and watertight tests (Chap. 2)

Hydrostatic test

5 Weld design and dimensions (Sec. 6)

Sec. 2 Welding (Chap.11)-Welding

4 Fabrication (Sec. 6)Sec. 1 Construction(Chap.11)-Manufacturing

2 Documentation, plans and data requirements (Sec. 3)

2. Documentation to be submitted(Chap.1, Sec. 2)

2.1.2 Submission of plans and documents for approval (Chap. 2)

Plan Approval

Part CSR-TPart CSR-BPart B

(CSR will not be further explained in this lecture)

Overview of Lecture

Part 1 Hull Survey System

Part 2 Record of Inspection

Part 3 Survey on Site

Classification Surveyduring Construction (Hull)

19~21 August 2008

Training MaterialInternal Use Only


Hull Survey SystemOutline

QC System of Shipyard

General Manager Manager

for Hull Surveyorin Charge

Managers in HLD, EQD and SVD

Project Team

Rules, GuidanceClassNK Instructions

Indirect survey & QC investigation

Directsurvey

InspectionRecord

Hull Survey SystemPrecondition (1/3)

The workmanship is to be of the best quality. During construction, the builder is to supervise and inspect in detail every job performed in shed and yard as well. [Rules Part C 1.1.17-1]The requirements concerning “presence of surveyor” may be modified having regard to the actual status of facilities, technical abilities and quality control at the works, except the case of sea trial. [Rules, Part B, Chapter 2, 2.1.4-4]In case where the works is being in accordance with “Rules for Approval of Manufacturers and Service Suppliers”, the number of times of the surveyor’s attendance to the works may be reduced for the purpose of the requirements 2.1.4-4, Part B of the rules. [Guidance, Part B, B2, B2.1.4-5]

Part 1 Hull Survey System

Outline of hull survey system

Requirements of the rules• Plan approval• Presence of surveyor

Investigation of quality control of shipyard


If the distribution of accuracy is Gaussian, proportion within ±σ, ±2σ, ±3σ is 68.26, 95.44, 99.74% respectively.


The requirements of this Part are applied to the welding where the manufacturer is to adhere to the requirements specified below.(1) To ensure the quality of the welding under the appropriate

facilities and control system, by achieving the process controlthroughout the welding works.

(2) Where deviation from the controls occurs and/or inferior qualityof products is identified, the manufacturer is to investigate thesubstantial cause, to report the result of investigation to thesurveyor and to take corrective measures. [Rules, Part M,Chapter 1, 1.1.1-2]


Even if the presence of surveyor will be exempted, the test should be executed and attended by responsible persons of shipyard. The surveyor in charge should seek for an approval of his GM and Manager before he applies an “indirect survey” and keep the evidence in his inspection record.

limit

standard

“Tolerance” or “limit” in ClassNK Instructions as well as in shipyard’s quality standards are ones which will not usually be reached under well-controlled situation. Therefore, errors bigger than the standard but within the limit are not always and automatically acceptable if they occur frequently.

New Building and Project TeamStage

Plan approval [Rules Part B 2.1.1]

Investigation of QC condition [Rules Part C 1.1.17-1 and Part M 1.1-2(1)]

Meeting with persons concerned (owner, shipyard, etc.) *

Survey during assembly process and block inspection [Rules Part B 2.1.4]

Survey in building berth [Rules Part B 2.1.4]

Survey after launching [Rules Part B 2.1.4, 2.3.1 and 2.3.2]

Managers in charge in HLD, EQD and SVD

GM, Manager (H) and surveyors in charge in service site

Project team

Class entryapplication

Workcommence

Lay down

Launching

Delivery* Meeting shall be held also during survey


(1), (2), (3)

Flow of Plan Approval

Local OfficeHead Office Shipyard

(1) Documents to be approved at Head Office

(2) Documents to be examined at Head Office

(3) Documents for reference at Head Office

(4) Document to be approved at Local Office

(5) Documents for reference at Local Office

(1), (2), (3), (4), (5)

(1), (2), (3) (1), (2), (4)

Note: Regarding plans and document hereafter, ones for application of CSR are excluded)

Presence of Surveyor

Surveyor is to attend to the followings inspection and test in relation to hull and equipment (free quotation from the rules Part B, Chapter 2, 2.1.4-1):

Material test prescribed in Part K, L and MAcceptance inspectionBlock inspectionHydrostatic test, watertight test and non-destructive testFinal inspection of hullPerformance testRudderMeasurement of principal dimensionsLoading computerMarking of Load Lines and ship’s identification numberSea trialStability experimentsEmergency towing arrangementsFire extinguishing arrangement, including its performance test

Patrol Survey

The purpose of “patrol survey” is to grasp the actual circumstance of quality control of the shipyard through an investigation of following points during the fabrication (it may be impossible at block inspection) • Welding procedure (temporary fitting, edge preparation, position, back

gouging, sequence, welder’s qualification, etc.)• Handling of defective work (material, size, accuracy of fitting, record, etc.)Surveyor in charge execute a patrol survey at any time of following occasions, while he follows an application submitted by the shipyard for usual survey• To pass through the work shop on his way to and from the place of usual

survey,• To execute in his spare time of survey, etc.The results of patrol survey should be periodically reported to the General Manager as the monthly report of investigation of QC of the shipyardSurveyor should review his attendance of survey, such as timing and method, according to the results of the investigation of QC of the shipyard


Background of Patrol Survey

The presence of the surveyor is required at the following stages of the work in relation to hull and equipment (extract):(4) When designated by the society during shop work or sub-

assembly.(17) When deemed necessary by the society.[Rules, Part B, Chapter 2, 2.1.4-1]For the effectiveness of the control of the welding works to be carried out by the manufacturer, the society is to confirm the condition during welding works at an appropriate interval accepted by the surveyor, when deemed necessary. In this case, the manufacturer is to give the convenience to the surveyor and to permit the surveyor to enter all relevant areas of the yard.[Rules, Part M, Chapter 1, 1.3.2-1]

Layout of a Shipyard

① Acceptance inspection③ Block inspection④ Block assembling, final, fitting, etc.⑤ Stability experiments, performance testsSeek for opportunity of “patrol survey”

Investigation of Quality Control

Investigation of QC condition of shipyard• Periodical investigation• Annual investigation• Occasional investigation

Investigation of site execution of shipyard• Monthly investigation


Periodical Investigation

Timing(a) When the shipyard builds a ship being classed with NK for the

first time(b) When about 5 years have passed from the previous periodical

investigation(c) When the size of ship being classed with NK breaks through

10,000, 30,000 or 100,000 GT for the first time(d) When the shipyard re-starts building a ship being classed with

NK after a blanc period of more than 2 years

ContentsFacilities and features of construction, number of welders, system and details for quality control, etc. (see Record A)

Annual Investigation

TimingWhen about 1 year has passed from the previous periodical or annual investigation

ContentsAbout 20 % of the items for a periodical investigation

RecordPrepare “Record A”

Occasional Investigation

Timing(a) When there is a change in the organization of the shipyard or in

the layout of shipyard having influence on quality control(b) When the surveyor attending regular survey finds out a serious

deficiency which may affect quality of ships (prepare “Form S”)(c) When the shipyard builds a ship using special production

procedure (e.g. LNG carrier, low temperature LPG carrier, etc.)or special material (e.g. stainless steel, clad steel, etc.)

(d) When the society deems necessary

ContentsThe items that the society deems necessary relating to (a) to (d)


Vertical Inspection of Welding Work

(for each welding work)Material controlEdge preparationFitting accuracy after tack weldingMisalignment between important membersFitting of backing material and run-off-tabConsideration for welding environmentPre-heating etc.Welding sequenceExecution of weldingBack chippingRemoving jigs etc.

(for shipyard)Approval of welding procedureWelder’s qualification

(during welding work)Designated survey [Rules Part B and M]Patrol survey

(for each ship)Approval of welding application plan and NDT plan

(after welding work)Visual inspectionNon-destructive inspection

Investigation of QC condition, etc.Examination of document

Part 2 Record of Inspection

Process control record Form IR

Form IR(H)

Form IR(H-A948)

Form IR(H)Attachment

Deficiency record Form S

QC control record Record A Record B

Monthly Investigation

TimingNotwithstanding its naming, the investigation should be done during daily survey. Report may be done 1 or 2 monthly.

ContentsIdentification of steel, welding procedure, control of welding materials, observance of the quality standard, etc. are to be investigated at each stage such as in-shop fabrication, panel fabrication, block assembly and block loading

RecordPrepare “Record B”


1. Acceptance Inspection

Object of inspectionMaterial and equipment manufactured by subcontractors outside the shipyard, such as rolled steel, steel casting and forging, welding materials, construction materials for fire protection, anchors, anchor chains, ropes, scuttles, hatch tarpaulins, hull blocks (*), steel hatch covers, watertight doors, steering gears, etc.

Purpose of inspectionTo confirm that they have been inspected by the society, and that they have not been damaged during transportation

* For hull blocks manufactured by subcontractors, see 4. below

Makers and Acceptance Inspection

Part 3 Survey on Site

1. Acceptance inspection2. Welding3. Shop Work and Sub-Assembly4. Block inspection5. Block joining on building

berth6. Rudder7. Final inspection of hull

compartment8. Tightness/ Hydrostatic test9. NDT of welded joints10. Measurement of principal

dimensions

11. Paint12. Markings13. Piping14. Fire protection15. Closing appliances16. Protection of crew17. Bottom inspection before

Launching18. Stability experiments19. Navigation bridge visibility20. Sea trial21. Documents to be maintained

on board


Rolled Steel

Collation of plate and mill sheet

Verification of control by the shipyard (checking-off of already used plate) should be done at least once before launching

As to checking-up of mill sheet and actual usage of plate, see “4 Block inspection” below

Cast/ Forged Steel

Object of inspection:Stems, stern frames, rudder stocks, rudder fittings, rudder coupling bolts, rudder pintles, rudder horns, shaft brackets and valves required to be made of cast steel by the rules

Manner of inspection:Verification of inspection report by the shipyard, copy of certificate issued by NK (when applicable) and rubbed copy of stamp and marking on the article. Surveyor’s attendance at the inspection is not necessary except for valves.

In principle, “mark shift” during machining of material which has been already inspected is not necessary. When important members such as stern frame, rudder stock, etc. are machined, the report of in-house inspection results should be submitted, and process should be attended if deemed necessary.

Stamps and Certificate

The surveyor should confirm not only the stamp but also if the article is suitable for the intended ship; in this case ship’s Equipment Number.


Steel without NK Certificate

Procedure of material test• Identify the material as NK material, like as “KD36”• Confirm mill sheet or certificate (for chemical composition and

mechanical property)• Carry out visual inspection and measure dimensions for cast steel and

forged steel• Carry out mechanical test by sampling• Put stamp [NK] and issue certificateSampling test• Rolled steel: Tensile test, and impact test if deemed necessary• Cast steel and forged steel: NDT, mechanical test as appropriate to the

material (tensile, hardness, impact, etc.)Testing machine The machine used for mechanical test must be certified by NK or appropriate body

Welding Material

Object of inspection:Welding rods, wire for semi-automatic welding, core wire and flux for automatic welding

Manner of inspection:Verification of brand to confirm that they are of type approved by NK. Reference should be made to the approved welding procedures applicable to the ship in question.

Actual status and control condition of facilities for drying welding materials are to be investigated at the initial stage of construction

Material for Fire Protection

Object of inspection:Non-combustible materials, “A”, “B” and “C” class divisions, flame retardant base materials, materials for primary deck covering, fire retardant veneers, fire retardant coatings, fire retardant surface floorings, fire dampers

Manners of inspectionReferring the list of brand attached to the approved drawings, materials should be confirmed and the results of the inspection should be recorded

The surveyor in charge should attend the site execution at least once in order to confirm the appropriate use of materials, and the results of the inspection should be recorded


Welding procedure qualification and welder qualification approved by other IACS member society may be accepted. In such case, a stamp “for reference” is to be put and copy of the document sent to EQD.

Other Materials and Equipment

Anchors, anchor chains and ropes• Collate NK stamp and certificate• Verify if the type, diameter, length, weight and other particulars are

appropriate as equipment for the ship in question

ScuttlesAfter installing scuttles on the ship, the correct application of the scuttles is to be checked at an appropriate opportunity such as tightness test

Hatch tarpaulinsNK stamp and certificate are to be collated at an appropriate opportunity

Hull blocksInquire the shipyard for any damage during transportation, inspect them if necessary

OthersCollation of rubbed copy of stamp and certificate. If articles are subject to test, the original should be confirmed at such opportunity

2. Welding

Welding procedure qualification (general)Welder qualificationWelding procedure specification (individual application of approved “welding procedure qualification to a ship)• Kind of members within 0.6 L amidships for on-site welding

procedure• The welding procedure applicable to the locations above, and

welding positionExecution of welding and controlControl of welding consumables

A proper welding shall be done by “qualified welder” with “approved materials” in accordance with “approved procedure”.

Kind of Welding Process

MAG welding （CO2）MIG weldingSelf-shielded arc welding

Stick weldingGravity arc weldingTIG welding

Submerged arc weldingElectro-gas welding

Manual welding

Semi-automatic welding

Automatic welding

Statistics in 2001 (Japanese shipbuilders)CO2 semi-automatic 60%Automatic 30%Gravity 5%Manual (stick) 5%


Welding Procedure Qualification

Kind of weld jointsKinds of base metal (grade, maximum thickness)Kinds of welding consumables (grade, shielding gas, backing, etc.)Kind of joints (butt, fillet)Position of weldingShape and size of edge preparation according to the thickness ofthe base metal (including the standards of accuracy for angle, gap, misalignment), number and arrangement of electrode, length or throat thickness, sequence of layer, conditions (current, voltage, speed, etc.)Pre-heating, temperature controlHeat treatment after weldingOther necessary items for the welding procedure

Qualification Test of Welding ProcedureButt Welding -1/2

Finished inspectionWelded surface is to be regular and uniform and is to be free from injurious defects, such as cracks, undercuts, overlaps, etc.

Tensile testThe ultimate tensile strength is not to be less than the minimum ultimate tensile strength specified for the base metal

Bend TestThere is to be no crack nor any other defect greater than 3mm in length in any direction on the surface of bent specimen

Qualification Test of Welding ProcedureButt Welding -2/2

Impact testThe minimum absorbed energy of three specimens are to be in accordance with the Rules (The percent brittle fracture of the specimens is to be measured)Macro-structure inspectionThe etched section is to show no crack, poor penetration, lack of fusion and other injurious defectsNon-destructive testInternal inspection (X-ray, US) and surface inspection (MP, liquid penetrant) are to show no crack and other injurious defects


The test assemblies are not to be

changed their up-and-down or right-and-left position throughout the welding operation. The welding in vertical position is

to be done upward procedure. The welding is to be carried out

only on one side and back welding is not to be carried out unless specified otherwise. In general, the test assemblies for

plates are to be so restrained or prestrained that the warping due to the welding does not exceed an angular distortion of 5 degrees. The test assemblies are not to be

subjected to peening or heat treatment throughout the period before, during and after the welding.

Welder Qualification Certificate(valid for 3 years)

No restriction3

19 or below2

5 or below1

Thickness (mm)Grade

NWithout backing

AWith backingUse of backing

GGas welding

TTIG welding

SSemi-automatic welding

MManual arc welding

Weldingprocedure

9N9% Ni steel

ALAlminium alloy

SUStainless steel

CSMild steel

Materials

SymbolKind of qualification

Each welder intended to engage in the automatic welding operation is to be of a well experienced welder for the specific welding work concerned

PFixed pipePipe

ZAll positions

OOverhead

HHorizontal

VVertical

FFlat

ClassPosition

Plate

Welding Position at Qualification Test

The specimens are to show neither crack nor serious defect greater than 3mm in length in any direction on the outside surface due to the bending

Plate

Pipe

Qualification Test of Welding ProcedureFillet Welding

Finished inspectionFillet welding is to have a regular and uniform surface, and is to be free from cracks, undercuts, overlaps, and other injurious defectsMacro-structure inspectionWelded joint is to be free from excessive difference between upper and lower fillet length, cracks and other injurious defectsFracture testThe remaining test assemblies after the macro-structure specimen has been removed are to be broken by pressing as shown in the sketch. There is to be no cracks, blow holes, poor penetrations and other injurious defects in the fractured surfaceNon-destructive inspectionSurface inspection (MP, liquid penetrant) is to show no crack and other injurious defects.


Qualifications of Welder

A welder of Class Z is regarded to be qualified for all the Classes of F, V, H and O within the same Grade.Any welder who intends to be qualified for Classes V, H, O and P of each Grade and each Kind is to have qualification of Class F of the corresponding Kind and Grade.A welder of any Class of any Grade of Kind N may be regarded as the welder of the same Class of the same Grade of Kind A.If a welder having Class Z of any Grade passes the qualification test on any one welding position of Classes V, H and O (which is specified by the surveyor) and belonging to the same Kind and Grade, his qualifications can be continued.If a welder having Classes other than Class Z passes the qualification test for the Classes (except Class F), he can continue his qualifications including Class F.If a welder having Class P and Classes V, H or O, or Z passes the qualification test for the Class P, he can continue his qualification for plate without test.

Welding of Rolled SteelRestriction

20℃50℃20℃Lowest temperature of pre-heating

0℃5℃-5℃Highest atmosphere temperature requiring pre-heating

Pre-heating(submerged arc welding)

30mmRepair of welding

10mm**50mm30mm

Temporary fitting, repair of scarMinimum length

of short bead

ForbiddenArc strike

TMCP typeConventional

HT*MSObject for control

* For KA40, KD40 and KE40, use the values for conventional HT, even if it is TMCP type.

** It is recommendable to be 30mm or more for KE32 and KE36

Welding ConsumablesDrying Control

300~350℃, 30~60 min.64HTLow-hydrogen

70~150℃, 30~60 min.248MSNon low-hydrogen

Allowablelimit

Control target

Standard drying conditions

Maximum period for weathering (hours)

Type of steelType of welding rods

Welding work outdoors is forbidden when it rains. When such a situation is unavoidable, a rain shelter or covering should be arranged, and special care must be taken to ensure the dryness of the groove of joints and other welding materials

Shielded arc weldingCO2 gas arc weldingSubmerged arc welding

Molded flux 200~350℃,60 min.105

Submerged arc welding

MS & HT

Bonded flux

Allowable limit

Control target

Standard drying conditions

Maximum period for weathering (hours)

Welding methodType of steel

Welding material


Patrol Surveyduring Shop Work and Sub-Assembly

Identification of steelsConfirmation of proper use of steels according to the approved drawingsAccuracy of edge preparationProper fitting of strong back, temporary tack-welding, run-off tab, etc.Accurate fitting of members and corrective measures for defectsProper welding sequenceAdequate welding method (including back gouging conditions)

conforming to approved “welding procedure specification”Strict enforcement of rules for arc striking and short bead especially for high tensile steel and Grade E mild steelQualification of welders

Agreed Rules and Quality Standard

For the allowable criteria of accuracy, refer to the shipyard’s standard recognized by the society, if available. In principle, such standard should be equivalent or superior to JSQS or SRQSIf such standard is not available, refer to JSQS or SRQSJSQS: Japanese Shipbuilding Quality StandardSRQS: IACS “Shipbuilding and Repair Quality Standard” SRQSJSQS

Ship’s owner

Rules etc.: Rules, quality standard (JSQS, SRQS, etc.)

Specification: Conformance to NK Rules, quality standard of the ship builder

ClassNK Ship builderRules etc.: Rules, quality standard (see below)

3. Shop Work and Sub-Assembly

Patrol survey (investigation of quality control)

Quality standard


Appropriate Arrangement of Material

(1) Are the steel plates per approved plan ?(2) Are the material and size reasonable comparing to mill sheets ? (3) Is the actual block per this plan ?

Cutting

Allowable depth of gas notch in edge preparation is:• For a butt welding within 0.6L amidships→2mm or less• Elsewhere →3mm or less

Accuracy for gas cutting

Gas Notch at Free Edge

• No notch is allowed at those locations. The notch shall be welded up avoiding a short bead, and ground smoothly.

• Allowable depth of notch at other locations of free edge, is 1mm.


Size of Bracket

11012.5-1,150

10512.5-1,100

10012.0-1,050

9511.5-1,000

----

306.58.0250

306.57.0200

--6.5150

FlangedPlaneBreadthof flange

ThicknessDepth oflonger arm

Mechanical Flanging

Accuracy of Processing


Joint with Cast / Forged Steel

Lap Joint

Edge Preparation for Butt Welding

Part C 1.2.3-2 requires this tapering not more than 1/3 when there is the difference in the thickness over 4mm

Same thickness

Different thickness


Kinds and Sizes of Fillet Weld

1. The size f for Tee joints is in general to be determined according to the web thickness of stiffener to deck plate, inner bottom plate, bulkhead plate, shell plate and face plate, and the thickness of the thinner plate in case of connection of other members

2. Lap joint is to have the fillet size of F1according to the thickness of the thinner plate

3. Intermittent fillet weld is to be staggered and w at ends is to be welded on both sides

1181126~40101022~269

7918~21

86815~1775712~14669~115

457~8

35020075

446250150603

33Up to 5

F4F3F2F1Pitch pLength of

fillet wSize offillet f

Size of fillet fIntermittent fillet weldContinuous fillet weldThickness

of members

Lap joint

Tee joint

Intermittent weld

F4

F3 (F2 for two frame spaces at the end of floor)

F2 (F1 for water/ oil tight boundary)

F3F4

F2

F4F3 (F2 for two frame spaces at the end of floor)

F3

Application of Fillet WeldExample (Double Bottom Construction)

Deep / Full Penetration

Usually, edge preparation is not required for fillet weld, except at intersection of important members. Instead, size of fillet shall be increased according to the thickness of the member.


Slot Weld

Precaution before Welding

Cleanliness in groove

Jig for positioning

Tack Weld

• Tack weld should be shifted from the ends of welding• Avoid “short bead”

Butt joint

Fillet joint


Positioning of Important Members

Securing jig (strong back, bridge) should be used for important members in place of tack weld

Appropriate Gap for One-side Welding

If the gap is too small, penetration may be insufficient

Run-Off Tab

Tabs should be provided at both ends of butt welding, because defects are likely to occur here.Tabs are cut after completion of welding, to inspect for defects.


Welding Sequence (2/8)T-Shaped Joint

If seam is not withheld, (1) Butt joint will be deformed due to heat(2) End of butt joint overlaps on the seam, and defect is likely to occur

Welding Procedure (3/8)Joint of Internal Members

(1) A scallop is provided to pass the weld of face plate (a scallop in high-stress zone should be closed later)(2) Usually, thicker plate shall be welded first (to avoid deformation due to the heat)

Welding Sequence (1/8)Both-Sides Welding

V groove X groove + cross welding

Finish both sides first

Then connect two strips

Plates are relatively thicker, and cracks are likely to occur at the intersection of welding


Welding Procedure (4/8)Shell Plate with Internal Member

Shell plate, Face plate of internal member, Web plate of internal member, Fillet welding between shell plate and web plate

Welding Procedure (5/8)Collar Plate

Welding Procedure (6/8)Closing Round Hole

Thickness ≤ 25mm

Thickness > 25mm


Welding Procedure (7/8)Closing Access Hole

Welding Procedure (8/8)Partial Renewal of Plate

Diameter of stop hole is 20~30 mm, depending on the thickness

CO2 Semi-Automatic WeldingDefect in the First Pass

Caused by inappropriate groove, gap, current, speed, etc.


Defects at Butt Joint (1/3)




Defects at Fillet Joint (1/2)

Defects at Fillet Joint (2/2)

In downward pass of welding in the vertical direction, the throat thickness of the bead tends to become too small, if welding rod motion is incorrect.

Foul Welding

Not only too broad bead, but also too narrow bead is doubtful


Treatment of Mal-FabricationShortage of Size at Fillet Joint

only at compression part

Treatment of Mal-FabricationShortage of Size at Butt Joint

Damage Due to Misalignment

Bending rigidity « Axial rigidity

Allowable limit of misalignment is, according to JSQS, 1/3 (important members) or 1/2 (others) of the thickness.


Reconditioning of Misalignment

Cross joint (fillet joint)

Butt joint

Scope of Survey

The scope of the survey covers blocks below the uppermost continuous deck, blocks for superstructures and deckhouses on the first tier above the uppermost continuous deck, and other blocks deemed necessary by the surveyor. [ClassNK Instructions A20, 0144-5)

The requirements are prescribed for the superstructures/ deckhouses up to the third tier above the freeboard deck. [free quotation from Rules, Part C, Chapter 18 & 19]

4. Block Inspection

Scope of survey

Block plan

Confirmation of steel (see 3. above)

Confirmation of structure, accuracy and welding

Others


Structure, Accuracy and Welding (1/2)

Confirmation of shape, scantling and missing members:• Shape and scantling, including thickness, of membersEspecially primary members such as web frames and girders

• Missing membersCollar plates, carlings, stiffeners, small brackets, etc.

• If abnormality such as imbalance of structure and discontinuity of strengthare found, even if they are per drawings, surveyor is to discuss with theshipyard and have them corrected

• If the plate thickness is smaller beyond the negative tolerance, it should beregarded as an error, and countermeasures including replacement is necessary

Confirmation of assembly accuracy:• Misalignment at cross joint (fillet welding)Especially counter members to primary members

• Misalignment at butt joint• Distortion of members

Structure, Accuracy and Welding (2/2)

Confirmation of welding and remaining works:• Missing welding and back gouging of critical points• Defects such as under cut, blow hole, lack of leg length (90 % specified inthe drawings), distortion at welding joint, etc.

Inspection around blocks :• Finished surface of edge preparation and treatment of craters• Sufficient penetration of automatic welding• Scallops on internal members at welding line of plates

Others:• Penetration of internal members through water-/ oil tight bulkheadProperly arranged “cut water weld”

• Blocks forming deep tankAir holes and drain holes

Quality standard:See 3. above

Sub-Blocks of Side Shell Construction

Tightness of welding joints on the boundary may be locally tested in this stage (explained in Chapter 11), to start painting


Continuity of Structure (1/3)

It is not so easy to find such problem, when different blocks or compartments are involved

Block Joining

Inspection of this joint only is enough at this stage, because each block has been already inspected


Members should be extended and lapped each other because a steep knuckle can not transfer the load (maximum angle is about 30º for practice)


Usually, lug and bracket connection are adopted for stiffeners of tank boundary that bears big lateral load, while snip connection for wall of accommodation, etc.


If surveyor is not well about the construction, he may overlook this inconvenience

Accuracy of Processing

Deformation of face plate a :a = 2 (5)+ b/100 mm

( ): limitmm000,1/2)6(3

mm000,1wheremm)8(5

mm000,1where:stiffenerofnDeformatio

λλ

λ

+=δ>•

=δ≤•

δ

End Connection of Stiffener

Lug

Clip

Snip

Bracket (lap)

Bracket (butt)

Distribution of bending moment will be significantly affected by the end connection


Edge of Block Joint (1/2)

Edge of Block Joint (2/2)

Girder under Main Engine

Normally, such important girder shall be designed as continuous member.


Continuous Welding

High stress zone

Cut-Water Weld

Water or oil penetrates from an accidental defect and travels through the gap to other compartments

Air Holes and Drain Holes

If those holes are not provided, air/water cannot go out during charging/discharging.


Special Block (1/3)Stern Frame

Stern frame for “A” type rudder

Check point:• Welding between steel

plate and cast/ forged steel

• Slot welding• Tightness test• Centering

Special Block (2/3)Shoe Piece

Slot welding

Tightness test

Special BlockHatch Cover

Check point:• Dimensions L & B ±5mm, Height ±3mm (standard)• Distortion 5mm (standard)• Gasket and equipment• Tightness (if applicable)Note: The standard is for pontoon hatch covers for container carrier

≤− 21 λλ


Blocks Manufactured by Subcontractors

Shipyard Subcontractor

NK Office A NK Office B

Application/Notification

Request of survey

- /Application

- /Report

Delivery of block

Report on results

In , and , offices A and B are in same/different country

Upon delivery of the block, the surveyor in office A is to ask the shipyard for report on any damage during transportation and inspect it, if any

Positioning of Block

Reference markingA line just on the correct location will be hidden by the block

5. Block Joining on Building Berth

Patrol survey:Correct sequence of block loadingAppropriate fitting accuracy of members in adjacent blocks and appropriate measures for defects (including marking of reference line)Condition and accuracy of joints just before welding (including back gouging condition)Proper fitting of strong back, temporary tack welding, run-off-tab, etc.Proper welding sequenceAdequate welding method (including back gouging condition) conforming to approved “welding procedure specification”Strict enforcement of rules for arc striking and short bead especially for high tensile steel and Grade E mild steelQualification of welders


6. Rudder

Confirmation of material and welding procedure

Internal/ External inspection

Fitting of sleeve, pintle, bush, etc.

Coupling (rudder plate and rudder stock)

Alignment (centering of rudder and stern frame)

Installation of rudder

Measurement of clearance

Swing test

Material and Construction of Rudder

Confirmation of material and welding procedure• Material of rudder stock, pintles, rudder plates, frames, coupling

bolts, etc.• Material of sleeve and bush• Adoption of welding procedure

Internal inspection• Scantling and arrangement of rudder plates, frames, main pieces, etc.• Welding condition• No gap between rudder plate and strap for slot welding• Dimension and pitch of slots• Confirmation of internal coating• Drain plug on the bottom

External inspection• Slot welding• Pressure of tightness test (see 8. above)

Serious Accident Originated in Field Joint

A crack generated at poor penetration of one-side welding of hatch side box girder, and propagated into the Second Deck


Alignment of Stern Frame and Rudder

Rudder carrier• Material of rudder carrier and bearing• Completion of all the construction works in the vicinity of deck• Finished surface, dimension and install angle of rudder carrier and liner

plate• Arrangement and dimension of reamer bolts or stoppers

Alignment of rudder• Fore/ aft direction, athwart ship direction

Alignment of stern frame• Completion of construction works and hydrostatic test in the vicinity• Measurement of pre-alignment prior to boring• Fixing of rudder carrier• Final boring

Installation of Rudder

Coupling of rudder plate and rudder stock• Fitting condition of coupling bolts• Locking of nut

Portable box

Jumping stopper

Measurement of clearance

Lubrication of rudder carrier bearing

Swing test (only for confirmation that the rudder does not come into contact with any part of the hull)

Kind of RudderRules Part C

Type A Type B

Type C Type D Type E


Construction of Type A Rudder

Fore and Aft Edge of Rudder

Shift the joint from the center

Fitting of Rudder Plate by Slot Weld

The stud bolts are not necessary if the rudder plate is well formed


Colour Check of Pintle

① Put red lead on the tapered part

② Insert the pintle into the gudgeon

③ Confirm the contact by the color remained on the gudgeon

Standard is 65%, and the contact must be uniform

Pintle and Sleeve

Confirmation of contact by hammeringHydrostatic test of sleeve

Shrinkage fitting

Crack at Slot Weld


Water Seal and Nut Stopper

If water soaks…

① Rust of pintle② Rust of pintle and

slackness of sleeve

Centering of Rudder

Allowable error is 0.5mm(standard is 0.3mm)

Centering of Stern Frame

Allowable error is also 0.5mm (standard is 0.3mm)

Centering shall be carried out after hydrostatic test of aft construction is finished (to avoid its effect).


Sequence of Rudder Fitting

Various Coupling of Rudder

Horizontal coupling Vertical (scarf) coupling

Cone coupling Sleeve coupling

Locking of Nut


Stuffing Box

Jumping Stopper

Bush Retainer


Portable Box

(Note) This slide illustrates the procedure to lift the rudder

Rudder Carrier

Inside

Rudder lifted

Accident Due to Poor Weld

Even if the portable box only is missing, the reduction of area affects the performance of rudder, and generates unbalanced force


7. Final Inspection of Hull Compartment

Structure and members:• Missing members• Balance of structure and continuity of strengthAssembly accuracy:• Misalignment • Distortion of membersWelding works (after block joining)• Missing work• DefectsOthers• Arrangement of various pipes and equipment• Reinforcement of the deck under the seat/ bed of auxiliary machineryand equipment

• Finishing of free edge of important members• Disposition of jig • Treatment of fault

Measurement of Clearance

Note: Clearances at shoe piece, rudder horn, packing gland of stuffing box and jumping stopper are also to be measured as applicable

)mm(0.25.1bearingmetalicNonbushtheofdiameterinnerisdwhere

)mm(0.1000,1d

clearancebearingMetalic

bu

bu

−−∗

+≥∗

To be measured at top, middle and bottom, and averaged.

Misalignment at Various Locations


Prevention of Misalignment (1/2)

Avoid “lap joint”, or provide the same joint at both sides

Prevention of Misalignment (2/2)

Fit a part of members of adjacent block

Re-conditioning of Misalignment

Increase fillet size by 10 %


Finish of Free Edge

Deformation at Various Locations

Absence of Work at Various Locations


Local Reinforcement

(1) Compensation for cutting-off to pass other members

(2) Reinforcement for big load

Serious Accident Originated in Secondary Member (1/2)

A crack generated at poor welding of half-round-bar of hatch coaming propagated into Upper Deck

Drawing

Actual work

Disposition of Jig Piece


Partial Renewal of PlateDue to Mal-fabrication, Defect, etc.

Breadth of replacement• Shell plate, strength deck, decks of refrigerating cargo hold

High stress zone 1,600 mm or moreElsewhere 800 mm or more

• Other members 300 mm or moreWhere the new welding line is not on the existing butt or seam, sufficient radius (more than 300mm for important members) should be providedEdge preparation should be inspected for full lengthRolling direction of the new plate should be arranged to ship’s longitudinal direction

Closing Hole by Insert/ Doubler/ Spigot

Insert Doubler Spigot

Longitudinal member:• Enlarge the hole to 75 mm (if applicable) and close it by spigot, or• Enlarge the hole to 300 mm (if applicable) and close it by insert

Other members:Enlarge the hole to 200 mm (if applicable) and close it by insert or doubler

RemarksWelding sequence, grinding of bead, NDT

Serious Accident Originated in Secondary Member (2/2)

Other possible triggers


Block Inspection vs Final Inspection

• Absence of members• Balance of structure• Discontinuity of strength• Some parts are impossible to inspect

at earlier stage

• Easy inspection (staging, position, physical strength, safety, etc.)

• Small unit fits to elaborate inspection• Some parts are impossible to inspect

at the final inspection• Easy repair, when necessary

Final InspectionBlock Inspection

This table lists up the advantages of one, and they are disadvantages for another. Therefore, both inspections complement each other.

Kinds of Tightness Test

Hose test Internal pressure Hydrostatic test External pressure Whole

Vacuum test Air hose test Airtight test

Local Air injection test

Hydropneumatic test

Tightness test

Other test

Note: Weathertight and WatertightWeathertight means that in any sea condition water will not penetrate into

the shipWatertight means capable of preventing the passage of water through the

structure under a head of water for which the surrounding structure is designed

8. Tightness / Hydrostatic Test

Approval of test procedureHydrostatic testHead, deformation, leakageAirtight testDetector, pressure, leakageHose testPressure, sequence, leakage


Deep tank is a tank designed for carriage of water, fuel oil and other liquids, forming a part of the hull, regardless of shape and location.

Double Bottom Tank

Hydrostatic test with a head of water to the top of air pipe

Deep Tank

Hydrostatic test with a head of water to ;(a) load water line,(b) top of overflow pipe,(c) level of 2.45m above the tank top, or,(d) level of 2/3H above the tank top, where H is

the distance between the tank top and upper end of D

Whichever is the greatest

(Note) Alternative method of hydrostatic test for a big deep tank

LWL

2.45m

H H2/3

COT and Cofferdam of Tanker

Hydrostatic test with a head of water to;(a) level of 2.45m above the deck at side, or(b) level of 0.6m above the top of hatch,Whichever is the greater

2.45m

0.6m

(Note) Alternative method of hydrostatic test for a big tank


Double Plate Rudder

(a) hydrostatic test with head of 1.5D or 2d whichever is the smaller, or(b) airtight test with pressure of 0.05MPa

1.5D or 2d, whicheveris the smaller

Hose Test

Pressure (in nozzle): 0.2MPaDiameter of nozzle: 12mm or moreMaximum distance: 1.5m

Hose test is applicable to shell plating, water-tight deck, water-tight bulkhead, shaft tunnel, hatchway, etc.

For shell plating of fully welded construction being inspected from both sides visually, the hose test may be omitted at the discretion of the surveyor.

APT and FPT

APT(a) below LWL: hydrostatic

test with a head of water to LWL

(b) above LWL: hose test with pressure of 0.2MPa

LWL

LWL2/3D

FPT(a) below LWL: hydrostatic test

with a head of water to LWL or to the draught of 2/3D whichever is the greater

(b) above LWL: hose test with pressure of 0.2MPa


Ballast Hold of Bulk Carrier

Notwithstanding the requirements for deep tanks, ballast hold ofbulk carrier may be tested as follows:

• Hydrostatic test is to be carried out with a head of water to thelevel of the top of the hatch coaming

• Hose test for “weathertight steel hatch cover” is to be carried out

Procedure of Hose Test

(1) Dry-up the surface before the test(2) Apply water jet from lower part to upper(3) The speed must be restrained

Hydrostatic Test and Airtight Test

Structural test is indispensable when following data are insufficient;① Reliable direct calculation or model test,② Experience of sister ships

As the ratio of compression of air is very high, special attention should be paid during its release (leakage, over pressure, exhaust)


Airtight Test in Place of Hydrostatic Test

ConditionsWatertight test may be replaced by airtight test at the discretion of the society, providedthat certain tanks designated by the society are to be subjected to hydrostatic test afloatTiming of airtight test• Airtight test is to be carried out, prior to the application of a protective coating, on allfillet welds, penetration welds and erection welds on tank boundaries

• Regarding other welds on tank boundaries, airtight test after coating is acceptable,provided that visual inspection on the welds was carefully done before coating to thesatisfaction of the surveyor (up to the quality control operations in the shipyard)

Execution of airtight test• An air pressure of 0.015MPa is to be applied during the test• Prior to examination, air pressure in the tank is to be raised to 0.02MPa and kept at thislevel for about 1 hour to reach stabilized state and then lowered to the test pressure

• Welds are to be coated with an efficient indicating liquid• A U-tube, having cross section larger than that of pipe supplying air, and filled withwater up to a height corresponding to the test pressure is to be fitted to verify the testpressure

• The test pressure is also to be verified by means of one master pressure gauge or otherequivalent means

Hydrostatic Test at Sea

Where it is impracticable to carry out the hydrostatic test on the berth with the specified test head, the test may be carried out in such a manner;

Hydrostatic test for each compartment on berth under the water head tothe level of ballast water lineAfter that, hydrostatic test for each compartment under the water headspecified above, when ship is afloat

When hydrostatic test for certain compartments is replaced by air test on berth;

Some of them including FPT, APT, all COT adjacent to cofferdam andpump room and ones selected by the surveyor are to be subject tohydrostatic test in afloat condition under the water head as specifiedaboveAll ballast tanks other than the above selected ones are to be subject tothe hydrostatic test during sea trial with the head of water to the top ofthe air pipe

Test Plan

Hydrostatic Testwith Full Head

Hydrostatic Testwith Partial Head Airtight Test

Start

End

Hydrostatic Testto Air Pipe Top

Hydrostatic Testwith Full Head

Specified tanks Ballasttanks

Others

Buildingberth

Afloat


Check Point for Possible Leakage

Vacuum Test

The speed to shift the box should be restrained

Test is meaningless when the gauge doesn’t go down due to leakage of the box

Air Injection Test

• This test may be done during “in-shop fabrication” or “block inspection”, in accordance with the approved procedure

• If the gauge doesn’t go up, the tunnel is stuffed by any reason. The test becomes meaningless in such case.


NDTMembers and Number

* One-third thereof is to be the intersections of weld lines

3L/40Frames

2L/40Girders L/40

L/403L/40 (*)Plates

Other member

2L/102L/106L/10 (*)PlatesStrength deckSide shell platingBottom shell plating

Butt or seam jointsSeam jointsButt joints

Hull without 0.6L amidships

Hull within0.6L amidships

Number of inspection foreach member subject to inspection

Members subject to inspection

In addition, parts of start/ interrupted/ end points of automatic welded joint, welded joints of hatch corner, connection of stern frame or rudder horn made of casting steel to rolled steels for hull, welded joints of insert plate for working holes and welded joints in the vicinity of parts where stress is concentrated shall be tested.

9. NDT of Welded Joints

Radiographic (X-ray) test and ultrasonic test

Members and spots to be tested (approval of NDT plan)

Examination of X-ray films

Condition for Adopting Ultrasonic Test

The Society has approved the consistence of results of manufacturer’s ultrasonic test for at least 3 ships at 1/10 points to be subjected to radiographic testFor strength deck, side shell plating and bottom shell plating, the number of inspection replaced by ultrasonic test is to be not more than 1/2. Furthermore, the intersections of butt welds are to beexcluded.For internal members, all spots may be replaced by ultrasonic test, except the intersections of weld lines of plate members.The surveyor is to attend during ultrasonic test, in principle


X-Ray Photos of Defect (1/3)

Blow hole Pipe


Slag inclusion Incomplete infusion


Incomplete penetration Longitudinal crack


Incomplete “Infusion” and “Penetration”

“Incomplete fusion”: boundary of welds do not melt each other

“Incomplete penetration”: empty part in a full penetrate welding

(Note) A fillet welding is not always a full penetrate welding

NDTClassification of Defects

Any defect of Type 3 is to be judged unacceptable regardless of the size

Cracks and similar defectsType 3Incomplete penetrationB

Incomplete fusion, elongated slag inclusion, pipe and similar defectsA

Type 2

Round blow holes and similar defectsType 1Kind of defectsClassification of defects

NDTAllowable Limit (Radiography)

Allowable limit of defect of Type 1

25t/2t/25Sum of size of defect (mm)

10t/555Maximum size of defect (mm)Size of defect

10mm x 20mm10mm x 10mmTest field of vision

50 < t ≤ 10025 < t ≤ 5010 < t ≤ 25t ≤ 10Thickness of base metal t (mm)

50t1002tSum of size of defect (mm)

25t/225t/2Maximum size of defect (mm)Size of defect

Defect of Type 2-BDefect of Type 2-AClassification of defect

50 < t ≤ 100t ≤ 5050 < t ≤ 100t ≤ 50Thickness of base metal t (mm)

Allowable limit of defect of Type 2


NDTExpansion of Scope

The first test

• Plate: 2 parts within the weld lines where the faulty welds are found• Girder or frame: 2 welding joints for each member, where the same welding procedure with the faulty welds is applied to the same block joints• Automatic welding: Full length or all number of the welded joints

Plate: Full lengthGirder or frame: All number

Rejected

Passed

Accepted

Failed

Accepted

Accepted

Rejected

Rejected

10. Measurement of Principal Dimensions

Flatness of keelLengthBreadthDepthTools and accuracyPosition of measurementRecord of weather, temperature and time during the measurement

Treatment after Rejection

Repair is to be carried out after the surveyor’s judgementAll length or all number of welded joints may be repairedThe rejected welds (at the first and second test) are to be repairedRepair process and additional NDT in other welded joints are to be carried out according to the surveyor’s direction taking account of the condition of faulty welds (kind, size and distribution of defects, etc.)Where the rejected welds are more than 10% of the number of inspection, the results of investigation on the substantial cause and measures to improve the quality are to be submitted to the surveyorSurveyor in charge prepares Form S (Deficiency Record)


Standard for Error (JSQS)

Flatness of keel:

Length: ±50 mm (per 100 m)

Length between aft edge of boss and main engine: ±25 mm

Breadth and Depth:

Measurement of L, Flatness of Keel

Slit gauge

The base line is defined at first

Point of FP

Measurement of Breadth and Depth

① Erect a pole at middle of L along the side shell

② Shift the height of the lower face of keel to the pole using a water level

③ Measure the height from the deck line to the lower face of keel using a mould

④ Measure the breadth at upper deck or bottom

①

②

③

④


Specification of Coating

Surface preparationRemove mill scale, rust, other foreign object on the surface of steel plate, as well as apply certain roughness for better adhesiveness with coating

Various paint• Below water line: Corrosion by sea water, stain by marine creature • Above water line: Impact of waves, alternation of dry/wetness due to

wave splash and sunshineShop primer Paint for accommodationAnti corrosive paint Paint for E/R, work shopAnti fouling paint Paint for cargo holdBoot top paint Paint for fresh water tankTop side paint Paint for ballast tankPaint for exposed deck etc.

Shop Primer

Wash primerShort/Long period of exposure. Long one is usually applied. Good for 3 months.Zinc-epoxy primerWeak points are noxious smoke during gas cutting and low weldabilitydue to zinc. Good for 6 months. (Non-zinc) epoxy primerPigment other than zinc is used. Durability is between wash primer and zinc epoxy primer.Non-organic zinc shop primerChemical adhesion to steel plate is excellent and good for 8 months. But same problem as zincky primers.

Temporary protection of the surface between surface preparation and coating, as well as improvement of adhesiveness with coating

11. Paint

Approved “corrosion prevention scheme”Ballast tank (full coating)Cargo hold/ tank• Exemption from coating for bulk carriers• Restriction of kind of paint for COT of tankersOil tank (no need of coating)Cathodic protectionPaint for fire protection (see 14. below)


Timing of Coating

Hydrostatic/watertight tests are to be carried out after all work in connection with water-tightness are completed but before painting except shop primer.

However, the tests may be carried out after the protective coating has been applied, provided that following conditions are satisfied prior to the application of the protective coating:• All the welds are completed and carefully examined visually to the

satisfaction of the surveyor • An airtight test is carried out

Exemption from Coating (1/3)Cargo Hold of Bulk Carrier

If thickness is increased in accordance with the Rules

Exemption from Coating (2/3)Cargo Hold of Chip Carrier

• Resin contained in the chip prevents corrosion• Inside of deck does not touch the chip, therefore coating

should not be omitted

Coating may be exempted


Exemption from Coating (3/3)Oil Tank

(Note) Inside of oil tanks need not be coated as “exception”, but coating of ballast tanks adjacent to oil tank with heating facility is likely to deteriorate

Cathodic Protection

Anodic protection systemZinc, aluminum, magnesium, etc. are used as sacrificial anode that has lower electric potential than the metal to be protected. This system is adopted as a back-up for protective coating for shell plate and ballast tank. Duration is usually designed as 2~4 years.Impressed current cathodic protection systemThe electric potential of the target is maintained by direct current supplied by the system

-1.03VZinc

-0.61VLow carbon steel

-0.36VCopper

Electric potential in sea waterMetal

12. Markings

Load lines• Position of each mark and line• Accuracy (±0.5 mm)• Permanent marking (welding of thin steel plate or punching• Color (in contrast with the color of the shell)Draught scaleShip’s identification number (SOLAS XI/3.4)CC mark (TM69)


Load Line Mark and Lines

Load line mark(ring and horizontal line)

Deck lineLoad lines

Note: This marking is one on the starboard side

Measurement of Load Lines

Allowable error is 0.5mm

Draught Scale

• Marked at fore, aft and midship on both port/ starboard side, every 20 cm. The height the letter is 10 cm.

• The lower edge of the letter coincides with the draught line represented by it. (standard ±1 mm, limit ±2 mm)


Ship’s Identification Number(SOLAS XI/3.4)

Stern, both sides of hull at midship, both sides or front of superstructure

Aftermost bulkhead or hatchway in the machinery space

13. Piping

Pipes and valvesPressure test Air pipeSounding pipeScupper and sanitary pipeBilge and ballast line

CC (Cargo Compartment) Mark

Characters “CC” should be permanently marked at the compartments included in the calculation of net tonnage. Location of the marking is in principle as follows:

Cargo ship: Outside of hatch coamingTanker: Outside of cargo hatchPCC: Outside of entrance to the holdLPG carrier: Coaming of tank on upper deck


Material of Pipe

Steel pipeCarbon steel pipe for pressure piping (STPG) is the most commonly used for ship

Cast steel pipeCorrosion-resistant. Large scale and thick ones are used for cargo oil line and ballast line of tankers

Stainless steel pipeFor piping, where less-maintenance and corrosion-resistance are required

Copper and copper alloy pipeEasy for bending and corrosion-resistant. For deck steam line

Other materialSynthetic resin, PVC, etc.

Pressure Test

Object of test• Pipes in Group I and II• Steam pipes, feed water pipes, compressed air pipes and fuel oil pipes withthe design pressure exceeding 0.35MPa (e.g. F.O. pipes and heating pipes)

• Cargo oil pipes, crude oil washing pipes for oil tankerCheck point• Hydrostatic test with pressure of 1.5 time (1.25 time for cargo oil pipes) thedesign pressure. The test may be replaced by airtight test by priorconsultation.

• Test pressure is to be checked by JIS/ISO pressure gauge properlycalibrated

• Welding of pipe is to be executed by qualified welders. Joints of pipes inGroup I & II with a diameter of 50A or more is to be of butt welding type

Others• Penetration of air pipes, sounding pipes, etc. is to be confirmed at the timeof pressure test of tanks

• Not applicable to the pipes with opening end

Insufficient Pipe Support


Protective Arrangement of Pipes

Kind of Air Pipe Head

Gooseneck type Mushroom type

Disc float type

Ball float type

Manual closing type Self closing type

(Note) Head of air pipe located on the exposed deck of a ship, whose keel is laid on or after 1/1/2005, should be of self closing type

Hinged Steel Cover of Air Pipe Head

Direct clamping may hider sometimes sufficient passage of air during ballast operation

To prevent negative pressure of tank, air passage hole of about 10 mm in diameter may be drilled in the cover plate


Number and Sectional Area of Air Pipe

1. Tanks having top plates not less than 7m either in length or in width are to be provided with two or more pipes arranged with a suitable distance

2. However, tanks having inclined top plate may be provided with one air pipe located at the highest part of the top plate

Height of Air Pipe

On Freeboard DeckOn Superstructure Deck

(1) Air pipes for water tank should open above Bulkhead Deck

(2) Air pipes for oil tank should open at weather part (with wire gauze)

Note: The height is specified by ILLC, not for positions I and II but for kind of deck

Check Point of Air Pipe

Drain free under any trim condition of the ship (see the slide just before)

Name plate at upper end

Protection for mechanical damage

Thermal insulation in refrigerated compartments

Closing appliance• The openings should be provided with a permanently attached effective

closing appliance (wooden plug and canvas are not regarded as effectiveat Position I and II)

• For ships intended to carry timber deck cargo, the closing appliance is tobe of an automatic type

Detachable and corrosion-resistant gauze wire net at the open end of air pipe to fuel oil tank, cargo oil tank and adjacent cofferdam (If gauze wire net is found to air pipe to ballast tank, it should be removed)


Kind and Position of Sounding Pipe

In principle, the pipes are to be led to positions above the bulkhead deck which at all times readily accessible, and are to be provided with effective closing appliance at their upper endsRequirements for air pipes concerning name plate, protection and insulation are applicable to sounding pipesSelf-closing device is required for sounding pipes which open in E/R

Construction of Sounding Pipe

Additional holes are drilled on the pipe for viscous liquid

Striking plate

Cap of Sounding Pipe

Head of short sounding pipe in E/R (With self-closing cock for confirmation of absence of oil before opening the cap)Cap should be permanently attached by

chains or other means, to prevent loss


Other Scupper Pipes

Refrigerated compartmentWater seal is arranged to prevent a back flow of the atmosphere

Car carrier• Scupper line from car space to E/R bilge well → automatic closing valves• Bilge from living quarters should not be led to car space• Scupper line from car space to bilge well of another car space (different

fire protection compartment) → automatic closing valves of vertical non-return valves

Scupper from Living Quarters

The scupper piping within superstructure is not to be connected to the scupper piping on the weather deck

In general, different systems of overboard discharge are not to be connected each other, unless specially approved by the society.

In general, scupper piping should not pass through fresh water or potable water tank

Example of bad piping

Arrangement of Deck Scupper

Square gunwale Round gunwale

“Standard” of is 25m (20m, when B exceeds 48m)λ


Discharge from Enclosed Spaces (1/3)

(9) If pipe penetrates shell plating at either more than 450mm below the freeboard deck or below 600mm above the load line, one ANRV is to be provided at the shell plating

Penetration of shell plating

(8) One stop valveInboard end is always closed, except when discharging, during navigation

(7) One ANRV (*)Height between inboard end and tropical LWL exceeds 0.02Lf

(6) Two ANRV below tropical load line, and one stop valve between the two ANRV (*)

(5) Each one ANRV above/below tropical load lineHeight between inboard end and tropical LWL exceeds 0.01Lf

(4) One ANRV, and one positive closing valve operated in manned engine room (*)

(3) One ANRV, one stop valve controlled from above the freeboard deck, and one open/close indicator

(2) One ANRV with positive means of closing it from a position above the freeboard deck, and one open/close indicator

General

Overboard discharge

(1) To be led directly to inboard bilge wellsPrincipleInboard discharge

* Not applicable to scupper pipes from spaces below the freeboard deck

Discharge from Enclosed Spaces (2/3)Cases (1)～(4)

(1) (2)

(3) (4)

Discharge from Enclosed Spaces (3/3)Cases (5)～(8)

(5) (6)

(7)(8)


Reinforcement of Distance Piece

Bilge Line System (1/2)Manifold System or Independent System

If the pipes pass in cargo holds, they must be protected against cargo damage

Bilge Line System (2/2)Main Line System or Xmas Tree System


Bilge Suction for Long Hold

In ships having only one hold exceeding 33 m in length, bilge suctions are to be provided in suitable positions in the after half-length and in the forward half-length of the hold

Slip-on joints are not to be used in pipe lines in cargo holds deep tanks, and other spaces which are not easily accessible, unless approved by the society.

(Bend type)

Bilge Well

• In either case, a should be less than d0/2, and b more than 460 mm• Capacity of the “well” should be 0.17 m3 or more (reasonable

capacity, in case of “hat”)

“Bilge hat” for small compartment

Non-Return Valve for Bilge Line

The same is applicable for bilge line in side tanks and bilge hopper tanks


Cargo / Ballast Hold

This slide shows the arrangement for cargo mode. For ballast mode, a blank flange should be fitted to the hold bilge line

Fire Protection Materials

Non-combustible material“A” and “B” class divisionFire retardant base material (for divisions, groundsills)Fire retardant veneersFire retardant surface flooringsPrimary deck coveringFire retardant coatingDoor (“A” and “B” class)Side scuttle (“B” class)

In addition to confirmation of the certificate including its validity and label on the articles, proper use of the articles should be confirmed according to the approved drawings

Classes A and B mean equivalent performance as the division where they are installed. (Class B of side scuttle is a category of strength)

14. Fire Protection

Fire protection materials

Inspection at intermediate stage

Inspection of fire protection, detection and extinction and means of escape


Inspection at Intermediate Stage

Following parts are to be inspected before ceiling, paneling and lining.

Treatment at intersection of bulkhead or deck, and extension of insulation

Construction of bulkhead or deck at penetration of pipe, duct orelectric cable

Arrangement and construction of ventilation duct including damper

Arrangement and construction of draught stop behind ceiling, paneling and lining

Non-combustible materials (especially for Method IC)

Inspection of Fire ProtectionCargo Ships Other than Tankers

For cargo ships applying Method IIC or Method III, arrangement of automatic sprinkler system (Method II only), fire detecting and fire alarming equipmentIn ro/ro cargo spaces• Mechanical ventilation systems and their closing appliances • Materials and arrangement of ventilation ducts• Arrangement of scupper pipes• Means of escapeIn Cargo spaces of ships carrying dangerous goods• Exclusion of source of ignition• Installation of mechanical ventilation systems• Installation of explosion-proof mechanical ventilation systems• Prevention of ingress of bilge into engine room (from cargo spaces)• Insulation of boundaries between cargo spaces and machinery space of

Category A

Inspection of Fire ProtectionTankers

Arrangement of machinery spaces of Category AArrangement and separation of accommodation spaces, main cargo control stations, control and service spaces including insulationConstruction and arrangement of coaming to prevent oil from flowing into accommodation spaceInsulation of exterior boundaries of superstructures and deckhouses enclosing accommodation spaces and service spacesArrangement of entrances, air inlets and openings of superstructures and deckhousesConstruction and arrangement of scuttle on the sides of superstructures and deckhousesSkylights of cargo pump roomsProtection of cargo tanks


Class of Division

--• Constructed of approved non-combustible materialsC

Prevent the passage of flame for 30 minutes

• Average: 140℃• Any point: 225℃• Time: 0, 15

minutes

• Formed by bulkheads, decks, ceiling or linings• Constructed of approved non-combustible

materials and all materials entering into the construction and erection of “B” class divisions shall be non-combustible

B

Prevent the passage of smoke and flame for 1 hour

• Average: 140℃• Any point: 180℃• Time: 0, 15, 30, 60

minutes

• Formed by bulkheads and decks• Constructed of steel or equivalent material• Suitably stiffened• Insulated with approved non-combustible

material

A

Passage of smoke and flame

Rise of temperature of unexposed sideConstructionClass

Non-combustible material is a material which neither burns nor gives off flammable vapours in sufficient quantity for self-ignition when heated to approximately 750℃

Fire Integrity of Bulkheads(Cargo Ships other than Tankers)

Spaces (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)(1) Control stations A-0 A-0 A-60 A-0 A-15 A-60 A-15 A-60 A-60 * A-60(2) Corridors C B-0 B-0

A-0B-0 A-60 A-0 A-0 A-0 * A-30

(3) Accommodation spaces C B-0A-0

B-0 A-60 A-0 A-0 A-0 * A-30

(4) Stairways B-0A-0

B-0A-0

A-60 A-0 A-0 A-0 * A-30

(5) Service spaces (low risk) C A-60 A-0 A-0 A-0 * A-0(6) Machinery spaces of category A * A-0 A-0 A-60 * A-60(7) Other machinery spaces A-0 A-0 A-0 * A-0(8) Cargo spaces * A-0 * A-0(9) Service spaces (high risk) A-0 * A-30(10) Open decks - A-0(11) Ro-ro cargo spaces *

* Where an asterisk appears in the table, the division is required to be of steel or other equivalent material but is not required to be of “A” class standard

Fire Integrity of Decks(Cargo Ships other than Tankers)

Space above (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

(1) Control stations A-0 A-0 A-0 A-0 A-0 A-60 A-0 A-0 A-0 * A-60(2) Corridor A-0 * * A-0 * A-60 A-0 A-0 A-0 * A-30(3) Accommodation spaces A-60 A-0 * A-0 * A-60 A-0 A-0 A-0 * A-30(4) Stairways A-0 A-0 A-0 * A-0 A-60 A-0 A-0 A-0 * A-30(5) Service spaces (low risk) A-15 A-0 A-0 A-0 * A-60 A-0 A-0 A-0 * A-0(6) Machinery spaces of category A A-60 A-60 A-60 A-60 A-60 * A-60 A-30 A-60 * A-60(7) Other machinery spaces A-15 A-0 A-0 A-0 A-0 A-0 * A-0 A-0 * A-0(8) Cargo spaces A-60 A-0 A-0 A-0 A-0 A-0 A-0 * A-0 * A-0(9) Service spaces (high risk) A-60 A-0 A-0 A-0 A-0 A-60 A-0 A-0 A-0 * A-30(10) Open decks * * * * * * * * * - *

Spac

e be

low

(11) Ro-ro cargo spaces A-60 A-30 A-30 A-30 A-0 A-60 A-0 A-0 A-30 * *

* Where an asterisk appears in the table, the division is required to be of steel or other equivalent material but is not required to be of “A” class standard


For tankers, only this method is applicable.

Protection in Accommodation Area (1/3)Method IC (Cargo Ships including Tankers)

•All the internal divisions are of class B or C

• Without automatic sprinkler, fire detection and fire alarm system in accommodation and service spaces

Protection in Accommodation Area (2/3)Method IIC (Cargo Ships other than Tankers)

• Automatic sprinkler, fire detection and fire alarm system is required in all spaces in which fire might be expected to originate

• No restriction on the type of internal divisions unless otherwise required

Protection in Accommodation Area (3/3)Method IIIC (Cargo Ships other than Tankers)

• Automatic sprinkler is exempted from Method IIC

• Area of any accommodation spaces bounded by class A or B division shall not exceed 50 m2


Space for Emergency Fire Pump

※ to be extended by 450 mm

• No direct access is permitted between machinery space of category A and the space for emergency fire pump

• When this is impracticable, the access may be by means of an airlock with the door of the machinery space being of A-60 class standard

Materials of Overboard Fittings

Materials readily rendered ineffective by heat, such as PVC, FRP, aluminium alloys, lead, copper and copper alloys, should not be used for overboard scuppers and sanitary discharges at following parts:

(1) The parts below the freeboard deck(2) The parts in the space having the open end(3) The parts in the spaces directly above the freeboard deck

Prevention of Heat Transmission

Extend the insulation at least 450mm (principle)

If the pipe is made of material having low-heat conductivity character and a diameter of less than 150mm, the insulation may be terminated at the end of penetration piece or sleeve


Penetration of Electric Cables

Class A division

Class B division

Working DrawingType approval of Fire Protection Material

The on-site survey is to confirm that the execution of works is in accordance with the approved drawing

Inspection at Intermediate Stage


Route of Escape in Machinery Space

Division and Penetration

“A-60” Class “A-0” Class

Cables penetrating “A-0” Class Division

15. & 16 ILLC Matters

Refer to a separate topic “Load Lines and Stability” for following topics:

15. Closing appliances

16. Protection of crew


18. Stability Experiments

General stability requirements

Stability requirements in wind and waves

Inclining test:to locate the center of gravity of the ship

Oscillation test:to determine rolling period of the ship

Rolling angleT

s

Rules Part U assume that rolling angle θ1 is proportionate to the root of s, which is functional to T (rolling period)

17. Bottom Inspection before Launching

Shell plating:Any deformation (damage occurred after block inspection etc.) especially

around block joints and blocks of building berthAny notches around the openings of shell plate, such as sea chest (including

air holes and drain holes), rudder trunk, etc.Welding and shapes of penetration part of distant pieceAny discharge pipe around lifeboat launching area (if any, cover and

stopping device of discharge water should be provided)Any undercut or notch after removal of jigs and eye pieces for lifting or

stagingClosing of bottom plugs, fitting of zinc anodes (only for reference)

Rudder and sea chestBush retainers for rudder, grating for sea chest

Results of NDTThe results of NDT for welds below the water line

Construction and arrangement for in-water survey, if applicable(see next slide)

Construction and Arrangementfor In-Water SurveyApproval of the documents and plans for in-water survey

Marking of the position of bulkheads and the name of space on bottom shell plate

Following items are to be arranged for measuring at afloat condition• Clearance of each rudder pintle• Clearance between propeller shafts and their bearings (in case of waterlubricating type stern tube bearings)

• Reading of ware down gauge (in case of oil lubricating type stern tubebearings)

• Confirmation of the position and identification of each propeller blade• Open and close of hinged gratings on all sea chests


Inclining Test

Prior to the measurement, the surveyor is to confirm that the ship’s condition, test circumstances and test devices conform to the requirements in “Annex B2.3.2-2 Guidance for Inclining Test” of the guidanceDuring the measurement, the surveyor is to confirm that sufficient data is gathered to determine the particulars of stability information of the shipIf the ship has not completed construction work, the weights and positions of items which are to be added, removed or relocated should be recorded by the shipyard and confirmed by the surveyor (within ±2% of final lightweight)When the test report incorporating the data is submitted, the surveyor is to ensure that the data given in the report is consistent with that gathered during the test

Note:1. Small heel angle may result in deviation over tolerance limit (expected heel 1º

to 4º)2. Mooring lines are to be free of transverse tension

Document and Tool Concerning Loading

Stability information• ILLC Annex I, II/10 (2): Stability information and loading information shall be carriedon board all times together with evidence that the information has been approved bythe Administration• SOLAS II-1/22: The master shall be supplied with such information satisfactory to the Administration as is necessary to enable him by rapid and simple processes to obtain accurate guidance as to the stability of the ship under varying conditions of service

Loading manual• ILLC Annex I, II/10 (1): The master of every ship shall be supplied with sufficientinformation, in approved form, to enable him to arrange for the loading and ballastingof his ship in such a way as to avoid the creation of any unacceptable stresses in theship’s structure.• SOLAS VI/7.2: To enable the master to prevent excessive stresses in the ship’sstructure, the ship shall be provided with a booklet, which shall be written in alanguage with which the ship’s officers responsible for cargo operations are familiar.

Loading instrument (SOLAS XII/11): Bulk carriers of 150 m in length and upwards shall be fitted with a loading instrument capable of providing information on hull girder shear forces and bending moments.

Omission of Stability Experiments

The stability experiments of an individual ship may be dispensed with, provided that available stability data are obtained from stability experiments of a sister ship or other adequate means and special approval is given by the society.Where the stability experiment is dispensed with, light weight measurement is to be carried out, and it is to be confirmed that the deviation of light weight as well as of lightship longitudinal centre of gravity between the ship in question and a lead sister ship (to be modified, if necessary) do not exceed following values.

⎟⎟⎠

⎞⎜⎜⎝

⎛−+=

100L

043.0dB023.0373.0

MGB2T wl

m0

When the society gives a special approval, oscillation test may be dispensed with and rolling period may be determined by an approximate calculation

0.5% of LsLongitudinal centre of gravity1%By linear interpolation2%Light weight

Lf < 160m50m ≤ Lf ≤ 160mLf < 50mLength for freeboard


Hydrostatic Curves

Measured draughtKMW

Draught and Specific Gravity

Measured at fore, aft and midship on both port/starboard sides

Measured around the depth of center of buoyancy

Calculation of KG

GMKMKGtanW

awGM

GMWawtan

p/rtan

−=θ⋅

⋅=∴

⋅⋅

=θ

=θ

This value, obtained as for light weight condition, is the basis of calculation for all the loading conditions

The length of the pendulum should be so arranged to obtain a swing of about 100 mm, in order to improve the accuracy (This requires the length of 5.7 m to detect an angle of 1°. It may be almost impracticable for big ships.)


View of Sea Surface

2L or 500m, whichever is less

10º

10º

It must be satisfied even in trimmed condition

19. Navigation Bridge VisibilitySOLAS V/22

View of sea surfaceBlind sectorsHorizontal field of vision

Terminology

Bridge wingsWheel house

Main steering position Conning position (5m to each side)

Bridge


Blind Sectors

θ1

θ2

θ3

φ1

φ2

θ1, θ2, θ3... < 10°θ1+θ2+θ3+... < 20°φ1, φ2,…> 5°

Horizontal Field of Vision

22.5°

At “conning position”

45°

45°

At each “bridge wing”(The ship’s side is to be visible from the bridge wing.)

At “main steering position”

60°

60°

Bridge Front Window

Horizontal forward must be seen even the ship makes pitching.

The height of eye may be reduced up to 1600mm when approved by the administration


One Day of a Sea Trial

Progressive speed trialContinuous running test

Boiler accumulation testMain steering gear test

Crash astern & ahead test (engine side)

Ship inertia test (different from stopping test)

Windlass performance test

Aux. steering gear test

Crash astern & ahead test (bridge side)

Zigzag test

Turning test

Speed Test

To confirm “speed of ship” defined in 2.1.8 of Part A of the Rules• where test is carried out in full load condition → speed at MCO(maximum continuous output) of the main engine• where test is carried out in other condition → speed at MCR(maximum continuous revolution, corresponding to MCO) of themain engine

In addition, speed at 25%, 50%, 75%, normal continuous cruise power run (85%) and 100% of the engine is also to be confirmed

The speed against ground is measured by running between two mileposts erected ashore, or by GPS (accuracy is 10m) or DGPS (accuracy is 5m)

Measurement is taken on going and returning, in order to cancel the effect of current

20. Sea Trial

Speed testAstern testSteering test, main/auxiliary steering gears change-over testTurning testPerformance test of windlassConfirmation of no abnormality for the operating condition of machinery and behaviors of the ship during the trialPerformance test of automatic and remote control systems for main propulsion machinery or CPP, boilers and electric generating setsThe accumulation test of boilersMeasurement of the torsional vibration for the shafting systemOther tests deemed necessary by the Society. (e.g. initial turning test, zigzag test, etc. for hull part)

Regarded as belonging to hull part


Astern TestAn order for full astern* is issued while the ship is running ahead at the maximum speed. The test is continued until the speed against the water reaches 0** (Rudder is to be kept at the mid position during the test)Speed, heading angle and trace of running are to be measured at a constant interval (it is to be confirmed that machinery installations have normal functions while the ship is running astern)Track reach, Stopping distance and lateral deviation are to be measured

Note:

* The rate of main engine is to be kept more than 70% of MCR

** Continuous running of engine in astern is required for more than 30 minutes for machinery part

Steering Test

Main steering gear: While ship is running ahead at maximum speed,• put the rudder over from 35° on one side to 35° on the other side• put the rudder from 35° on either side to 30° on the other side in not more than 28seconds

Aux. steering gear: While ship is running ahead at max (half of maximum speed, 7kt)• put the rudder over from 15° on one side to 15° on the other side in not more than 60seconds• Change-over test

During those, the power units, hydraulic fluid recharging system, emergency power supply, operation of controls, means of communication between bridge and engine room/ steering gear compartment, indicators for the alarm, rudder angle indicator, etc. are to be also tested.

Rudder stockConnecting rod

Hydraulic cylinder

Cross head

Pump

Plunger

Turning Test

The ship is steered to 35° while running ahead at the maximum speed, and the rudder angle is to be kept until the ship turns to 360° (turn to right and left)Ship’s speed and/or turning rate are measured at the heading angle reached at 0°, 5°, 15°, 30°, 60°, 90°, 120°, 150°, 180°, 210°, 240°, 270°, 300°, 330°, 360° and the elapsed time reached to each heading angle is also to be measured


Performance Test of Windlass

Loading test: Hoist up anchor chains from the state in which 82.5 m (3 lengths) of chain are submerged and freely suspended at commencement of lifting, in accordance with the manner specified below• hoisting up 2 lengths of chain by one side (average speed not less than 0.15m/sec)• hoisting up 2 lengths of chain by the other side (ditto)• hoisting up one length of chain together by both sides regardless of the timeCable lifter braking test: The brake is to be tested with the anchor dropping at every about ½ length of chain to confirm safe paying out and holding of the anchor chain by the brake

Chain wheel

Brake

Driving lever Clutch handle

Zigzag Test, Initial Turning TestThe initial turning test: The ship is steered to the 10º rudder angle, while running ahead at the maximum speed, and this rudder angle is to be kept until the ship turns to 10° from the original course. This test may be conducted at the 10/10° zigzag test.The zigzag test: While the ship is running ahead at the test speed• steered to θ to p (s) side• when the ship’s heading reaches toθ, the ship is steered to θ to s (p)side• when the ship’s heading reaches to θ, the ship is steered again to θ tothe p (s) side• The test is continued until theship’s heading reaches to theoriginal course

θ shall be taken as 10° and 20°

21. Documents to Be Maintained on Board

Finished plansGeneral arrangementMidship section, scantling plans (construction profile), deck plans, shellexpansion, transverse bulkheads, plans for rudder and rudder stock, andplans for cargo hatch coversBilge, ballast and cargo piping diagramsFire protection plansFire extinguishing applications arrangementPlans and data showing the navigation bridge visibility

Manuals and lists (see following slide)Ship construction file (see following slide)

Note 1: Other than those required by Parts CSR-B, CSR-T, N, S, PNote 2: Certificates shall be also confirmed

At the completion of a classification survey, the surveyor confirms the following drawings, plans, manuals, lists, etc., as applicable, of finished version are on board.


Ship Construction File

“Ship Construction File” required to be maintained on board for ships engaged in international voyage, contains the necessary documents from the following drawings, plans, manuals and documents (duplicate documents to previous slides are not necessary)

Finished plans of hull structural drawingsOperating and maintenance manuals for the door and inner doorDamage control plansLoading manualsStability information bookletsShip structure access manualsCopies of certificates of forgings and castings welded into the hull structuresPlans showing locations, sizes and details of equipment forming part of the watertightand weather-tight integrity of the ship including pipingCorrosion prevention schemePlans and documents for in-water surveyDocking plan including locations and other necessary information of all penetrationsTest plans, test records , measurement records, etc.

Manuals and Lists

Documents approved by the SocietyOperating and maintenance manuals for the door and inner doorDamage control plansLoading manualsShip structure access manualsStability information bookletsCargo securing manuals (Japanese ships only)Coating technical filePlans and documents for in-water survey

Other documentsTowing and mooring fitting arrangement plansOperation manuals for the emergency towing arrangementBooklets for the damage control

Operation manuals for the loading computerPlans for means of accessOperation manuals for stability computerOperating and maintenance instructions for ship machinery and equipmentManuals for water level detection and alarm systemsMaintenance records of batteriesInstruction manuals for the cargo tank venting systemsFire control plans, fire safety operational booklets, training manuals and maintenance plansOperation manuals for the helicopter facilitiesInstruction manuals for the inert gas systems