Advanced-Outfitting HYDRAULIC SYSTEM .pptx

FITTING

1. ADVANCED OUTFITTING Presented by:- Adarsh E.K. Akhil Anant Chandan Kumar Harikrishnan

2. Outline Introduction to Outfitting Zonal Design Work Introduction to Advanced Outfitting Types of Advanced Outfits Benefits & Impact of Advanced Outfitting on Shipbuilding Industry Conclusion

3. Overview Outfitting Structural Component Construction Ship Construction Structural Units Assembly Blocks Rings(Grand Blocks) Ship

4. Outfitting Installation of various systems & equipments A llow the ship to operate and perform various missions Occurs during construction of pieces that make the ship or once those pieces are assembled Structural Electrical ( power distribution) ) Joinery Painting & Insulation HVAC Piping Outfitting

5. Outfitting (Stages) Some outfitting must be done during the building of the structural units or blocks since it would be difficult and expensive later in const. process. e.g. Pipe-Work in Double B ottom sections Pre-Outfitting Advanced Outfitting Performing outfitting task early in the ship construction process i.e. at unit, block or grand block stages Conventional Outfitting Occurs at the assembled stage and require works t o move to dry dock, slipway or land-level facility bringing with them materials & equipments

6. Conventional Outfitting Used to be “one job after the other” Main Hull(outer shell) built Equipments & Machinery lowered Connected Piping work laid Cables connected Very slow 10% of piping and other outfit work were done when floated Balanced fitting out in floating condition

7. Drawbacks Did not facilitate optimum layout of various systems 1 Difficulty of the task 2 Excess of Man-hours required 3 Obstructions in outfitting process 4 Reduction in productivity of the shipyard 5

8. Zonal Design Work Outfit design is divided into Engine room, area other than engine room and accommodation. It reduces work by focusing on zones. It forces all departments to pay attention to the planning and interfaces in which they are involved . It forces Production to take an active role early in the product development . Improved scheduling by early involvement of all departments . It promotes the use of multi-skilled teams . Production efficiency is improved by performing all the work, which can be done by the same workers at the same time and same location.

9. Pre-requisites to Advanced Outfitting The development of planning similar to the Shipbuilding Policy and Build Strategy approach Technical documentation format suitable for direct use by Production Highly trained workers Decision making/planning delegated to appropriate level Early involvement of Production in the design process Concurrent development of product and process design to facilitate maximum work in flat position

10. Advanced Outfitting The fitting to ship structure, outfit items at a significantly earlier time in the building sequence than is traditional. Principle Organization of information and materials to a plan that applies labor and facilities to integrate ship’s structure and outfit materials at the earliest and most cost effective stage of the construction process. 1.On-Unit 2.On-Block 3.On-Board Types

11. Goals of Advanced Outfitting Improved quality, productivity and worker safety Improved use of cranes Avoid interference between trades Simplify outfit planning Reduce outfitting time Minimize on board outfitting

12. 1. On-Unit Outfitting Definition On unit refers to a zone which defines an arrangement of fittings to be assembled in-house, independent of hull structure. Assembly of such fittings is called outfitting on-unit. E nhances safety R educes both required man-hours and durations which would otherwise be allocated on outfitting on-block and on-board 20% of the items are fitted in this stage Features

13. An Example Seawater Service Pump And An Air-conditioning Water Pump

14. Steps S hown in previous slide is a machinery unit which will contain both a Seawater Service Pump and an Air-Conditioning Water Pump. Vertical Seawater Service Pump is fitted to the subcontractor-furnished painted foundation which was built according to a shipyard-provided detail drawing. A pipe support, to be subsequently fitted, is included. The horizontal Air-Conditioning Water Pump is on the platen alongside are scheduled to be fitted on block.

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

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

17. A second worker temporarily assists by guiding a strainer to its final position while the gasket and a few bolts are secured

18. Pipe piece supports are being fitted

19. The completed unit is being transported for fitting on-block

20. 2. On-Block Outfitting Definition The assembly of any fittings on any structural subassembly (e.g. semi-blocks , blocks and grand blocks) is referred to as an outfitting on-block. On-Block outfitting purposes refer to a rather flexible relationship between block and zone. The zone applies to a region being out fitted. Following block turnover, the fitting arrangement on deck is another zone 50% of the items are fitted in this stage Features

21. On Block Advanced Outfitting Advanced Outfitted Grand Block Modular Engine Room Outfitting

22. Examples forecastle upside down forecastle deck right upside up side shell and engine room flat upside down aside shell and engine room flat right side up

23. Outfitting components , units, and grand units are sometimes fitted in a block zone defined for hull construction. However , when they are to be fitted to ceilings, blocks should be inverted because fitting down-hand enhances safety and efficiency. Following block turnover, the outfit zone encompasses the components, units, and/or grand units fitted to the floor.

24. Double Bottom On-block Outfitting Outfit items should be fitted in the zone of a double bottom block before its tank top panel is installed. At a later stage, a different outfit zone encompasses everything to be fitted to the tank top. The primary goals of this manufacturing level are to outfit ceilings and double bottoms when blocks can be manipulated to provide ideal access.

25. Outfit Units Engine room tank top unit Engine room tank top components fitted on-block

26. When a large quantity is planned, the completed block should be transferred to an indoor or outdoor region designated for out fitting in accordance with an on-flow concept. On-flow means work packages start and complete in unison Separation by stage is in accordance with the following sequence which reflects block turnover : on-ceiling fitting on-ceiling welding or nil on-floor fitting on-floor welding or nil When the items to be fitted compose a small quantity per block, outfit work can be performed at the site where the block was assembled

27. Divisions By Problem Area It addresses problems which are inherently different. Each work package for outfitting on-block can be assigned to the appropriate team of assembly specialists. These classifications are further subdivided by the quantities of items to be fitted, resulting in the following problem area divisions: Hull large quantity / small quantity 1 Machinery large quantity / small quantity Superstructure large quantity/ small quantity 2 3

28. Erection Outfitted blocks can be erected in combination with outfit units. On-block outfitting work is often greatly facilitated by block turnover for down-hand on-ceiling outfitting and painting. Complex blocks may be outfitted together to ensure accurate fits at erection.

29. 3. On-Board Outfitting Definition It can be defined as all the outfitting work that is done after the hull blocks are completed and erected in the slipway or docks. Conventional method of outfitting Only those heavy equipments which cannot be erected at the general stage are left to be done at this stage. 30% of the items are fitted in this stage Features

30. On-Board Outfitting( contd ) Ideally, assembly and painting work are left for accomplishment on-board . These works are limited to: Fitting of components that are too large to fit on block like main engine, diesel generators etc Connecting distributive systems at block butts and seams Pulling only the ends of electric cables that were fitted on block

31. On-Board Outfitting( contd ) Pulling electric cables that could not be pulled on block Connecting electric cables Clean up Painting touch up Installation of the main drive line Finish painting

32. Problems Faced

33. A worker is performing fitting work of a certain problem classification, on board. The worker had to carry tools from the shop to the relatively inaccessible and dark workplace. In addition, the welding-cable leads had to be pulled into position and thereafter the worker had to commute from the shop, up the gangway, and down into the machinery space. The same work could have been performed in a shop on-unit.

34. Fitting work of the identical problem classification shown in is being performed on unit in a shop the smart way.

35. When traditional system-by-system work is performed on board relatively out of sight of supervision, workers pressed to meet a schedule are prone to improvise and risk damage and accidents. Sometimes just the access to a work site is dangerous in traditional system-by-system outfitting of machinery spaces.

36. Some shipyards have another type called Blue Sky (Landing outfit on the ship under construction on the berth before the compartment is decked over), but this is really a subset of On Board. On-board outfitting in the main machinery space of a large vessel is facilitated by providing temporary access through the shell. Otherwise, workers expend significant energy ascending a gangway and climbing down machinery-space ladders and vice versa.

37. Advanced Outfitting Practices-A Comparison Current use of advanced outfit by UK,US and EU shipbuilders UK shipbuilders lag behind US and EU shipyards in levels of advanced outfitting in pipe work, electrical, and HVAC functions.

38. Benefits of Advanced Outfitting Reduced/eliminated overhead work Improved access, (workers and material) ventilation and lighting Reduced/eliminated scaffolding Improved tool/equipment availability Reduction in time cycle and cost

39. 20% Advanced Outfitting 80% conventional Outfitting 80% Advanced Outfitting 20 % conventional Outfitting 50 % Advanced Outfitting 50 % conventional Outfitting

40. Recommendations* Encourage shipyards to develop manufacturing plans that strive to produce super blocks that are at least 80 percent outfitted before they are sent to the assembly shipyard. Involve all shipyards in the design process and encourage the sharing of information on advanced outfitting practices. Ensure production designs are nearly complete before construction begins and that the necessary equipment and materials are available in a timely fashion to facilitate advanced outfitting. * By RAND Cooperation Europe

41. Impact on Shipbuilding Industry Has modernized shipbuilding and its approach to facing problems head on. More and more computer applications are being resorted. Exclusive softwares are being developed. Modular construction is getting popular esp. accommodation area. The outfitting time after a ship has been floated out has been reduced from 12 months to 2 months in countries like Japan.

42. Conclusion The introduction of new and appropriate technology makes a big difference. In fact it is in going for difference that will make a difference. Without training there can be no technology upgradation, and without technology upgradation ,there can be no competitive edge. In absence of focus on technology we will be working hard and not smart. Are we going to work hard or work smart to be present in this decade and coming ones?

43. Thank You !!