MAR2012 Engineering applications

Paul Stott Hossein Enshaei February 2011

Agenda
Statement of the coursework Product breakdown and shipyard layout: Paul Stott Process analysis: Hossein Enshaei Questions

Block breakdown
Modern shipbuilding divides the ship into blocks.

Block breakdown
This is a typical block, leaving fabrication ready for erection on the building berth.

Ship construction processes

Dont forget that some means is necessary to get the block to the erection site

Ship construction process

This is what the erection of blocks in a building dock looks like when it is very well done.

Block breakdown
How is the block breakdown decided on?

Shipyards strive for the largest practical block at the erection stage.

Why?........

Block breakdown
12
12 10 8 6 4 2 0

8 4 1 2

Relative cost of work (manhours) by stage of construction

Block breakdown
Fewer manhours are needed at earlier stages of production because: Supply routes are short Access is open and easy Crane accessibility is good Work can be done down-hand Staging is unlikely to be required Conflict with other work will be minimum

Block definition in shipbuilding

How is the block breakdown for a ship determined?

Constraints and considerations:

Blocks should as far as possible be self-supporting Where possible temporary bracing should be avoided Unit breaks should be away from major elements of structure Blocks should take account of functional zones Maximise the final lift (maximum weight including outfit) Capacity of transport from steel shop to blocking area Door dimensions from steel shop Workstation dimensions within steel shop Blocking area workstation dimensions Crane heights Other constraints?

Block definition in shipbuilding

How is the block breakdown for a ship determined?

Further considerations:
Blocks will have a leading edge and a trailing edge The leading edge should be relatively rigid for example close to a bulkhead: this will ensure maximum stability (i.e. Maintaining the shape) of the steel until the next block is added The trailing edge should be relatively flexible to allow for fairing If green material is used it should be on the trailing edge

Block definition in shipbuilding

Block definition in shipbuilding

Block definition in shipbuilding

Outfit Block Breakdown Considering the equipment functional arrangements define the block breakdown for both steel and outfit.
As far as possible keep block breaks clear of equipment

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Lower zone configuration

Outfit Block Breakdown Define the outfit units installed on steel blocks prior to erection
As far as possible keep block breaks clear of outfit unit boundaries

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Lower zone configuration

Outfit Block Breakdown Define the outfit units to be installed blue sky after block erection
Ensure that the erection sequence enables straight-lift unit installation

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Lower zone configuration

Outfit Block Breakdown Define accessway and services route assemblies installed on steelwork blocks
Ensure that services routes are contained within steel block boundaries

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Lower zone configuration

Steel production
Blocks are the ultimate product of the steel shops.

How are the blocks built up?

Steel manufacture processes

Assembly: the hierarchy of stages

The following diagrams are by kind permission of Malcolm Bell Associates (Malta)

3D solid model

2 Blocks (P&S)

CAD model exploded at second level Block assembly analysis

1 Blocks = 4 units + 4 sub assemblies

CAD model Block Breakdown Unit definition

1 Unit = 5 sub assemblies

Steelwork processes

OUTFT INSTALLATION

Treatment (shotblasting & priming) Cutting / marking Forming / shaping Welding Painting Storage, transport and marshalling

Outfit installation
It is essential to productivity and competitiveness that outfit work and steelwork are integrated as far as possible and that outfit items are fitted at the earliest possible stage

Piece parts
OUTFIT INSTALLATION

Minor assembly Sub assembly

Unit assembly

Block assembly Ship

Outfit installation
Outfit installation stages by increasing cost
Cost increases because of more difficult access and more difficult working conditions

On sub-assembly On Unit On Block: open sky

On Block: closed
On Berth: open sky On Berth: closed Post-launch

Outfit installation
It is essential to productivity and competitiveness that outfit items are installed in units or assemblies wherever possible, rather than piece by piece.

Optimum ease of access and least cost in a workshop environment

Outfit manufacture workshops

Pipe shop Machine shop Sheet metal shop Electrical shop Stores

Dont forget painting

Shipyard layouts

A layout is on Blackboard for you to look at Yanbu al Bahr (note this is a large yard and includes repair as well as newbuild)

Contact details: Office: email: On mezanine floor behind LT1 paul.stott@newcastle.ac.uk