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General Procedure of Shipbuilding
Soo-Kwan OhTechnical/ Marketing Manager
For the benefit of business and people
2
1 FROM CONTRACT TO DELIVERY
2 CLASSIFICATION SOCIETY
3 LARGE CONTAINER VESSEL
SUMMARY
3
> From Contract to Delivery
1
4GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
CONCEPTCONCEPTFrom Contract to Delivery1
Contract/ Business Dept.Ship Sales Engineering Dept.
Basic/ ProductionPurchasing of Material Purchasing Dept.Owner/ Class Approval
HullHull OutfittingMachinery OutfittingElectric OutfittingPaintingQuality AssuranceProduction Control
A/S
Owner ProjectOwner Project Shipyard
CONTRACT
DESIGN
PRODUCTION
DELIVERY
5GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
BRIEF SPEC’
1 INITIAL STAGEINITIAL STAGEFrom Contract to Delivery
Owner Project Planning
Contract/ Business Dept.Ship Sales Engineering Dept.
NegotiationTechnical Meeting
Full Spec’/ ClassCost Balance
Letter of IntentTotal Quantity
OptionDelivery Date
Contract SpecificationContract G/A, Midship, Piping DiagramAccommodation Plan
CONTRACT
PurposeRouteEconomic
Broker* Owner
* ShipyardShipyard
OFFER
6GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 INITIAL STAGEINITIAL STAGEFrom Contract to Delivery
GENERAL ARRANGEMENT
7GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 INITIAL STAGEINITIAL STAGEFrom Contract to Delivery
75K MIDSHIP
8GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 From Contract to Delivery
75K MIDSHIP
INITIAL STAGEINITIAL STAGE
9GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 From Contract to Delivery
DIAGRAM OUTFIT
INITIAL STAGEINITIAL STAGE
10GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 From Contract to Delivery INITIAL STAGEINITIAL STAGE
DIAGRAM OUTFIT
11GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 From Contract to Delivery INITIAL STAGEINITIAL STAGE
DIAGRAM OUTFIT
12GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 From Contract to Delivery
DIAGRAM-MACHINERY
INITIAL STAGEINITIAL STAGE
13GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 From Contract to Delivery
DIAGRAM-MACHINERY
INITIAL STAGEINITIAL STAGE
14GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 From Contract to Delivery
DIAGRAM-MACHINERY
INITIAL STAGEINITIAL STAGE
15GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 From Contract to Delivery
ACCOMMODATION PLAN
INITIAL STAGEINITIAL STAGE
16GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 From Contract to Delivery
ACCOMMODATION PLAN
INITIAL STAGEINITIAL STAGE
17GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 From Contract to Delivery
ACCOMMODATION PLAN
INITIAL STAGEINITIAL STAGE
18GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
DESIGN STAGEDESIGN STAGE1 From Contract to Delivery
Key DesignProduction Design
Lines, PropellerGeneral ArrangementTrim & StabilityLoading, etc.
Hull Key Plan : Midship Section Construction Profile & Deck Plan Shell Expansion
Structure Drawing : Cargo Hold Engine Room/ Fore Body/ Aft Body Stern Frame/ Accommodation
Production Drawing : Shop Drawing/ Cutting Plan
Structural Analysis : Static Analysis –Coarse Mesh/ Fine Mesh Fatigue Analysis Sloshing Analysis Bow Impact & Slamming Analysis Vibration Analysis
PaintingPurchasing Order : Steel Plate, Angle etc, Paint
DESIGN STAGE
Hull Design
Basic Design
19GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 DESIGN STAGEDESIGN STAGEFrom Contract to Delivery
Key Design : Piping Diagram, Ventilation Mooring, Anchoring, Steering Life Saving, Fire Fighting Traffic Arrangement
Production Design : Pipe Piece, Traffic Piece, etc Small Equipment
Accommodation Design : Interior, Piping, Outfitting
Purchasing Order : Pipe, Valve, Equipment
Key Design : E/R Piping Diagram, Machinery Arrangement, M/E, Generator, Boiler, Compressor
Production Design : Pipe Piece, Vent Piece, etc. Small Equipment
Purchasing Order : Equipment, Valve, etc.
Hull Outfitting Design
Machinery Outfitting
20GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 DESIGN STAGEDESIGN STAGEFrom Contract to Delivery
Key Design : Automation Electrical System Navigation Equipment
Production Design : Cable Piece Light Equipment
Purchasing Order : Switch Board Equipment, Cable, Sensor
Electric Outfitting
21GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 PRODUCTION STAGEPRODUCTION STAGEFrom Contract to Delivery
Yard FacilityProduction Control
Material Control
Production ControlProduction – Hull, Hull Outfitting,
Machinery Outfitting, PaintQuality Assurance
Grand P.E
P.E Block Painting
InspectionOwner/ Class
Pre-Outfitting
Each BlockAssemblySub-Assembly
Dock Erection
CONDITION
HULL PRODUCTION
Cutting
22GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
1 PRODUCTION STAGEPRODUCTION STAGEFrom Contract to Delivery
Pre-OutfittingIn Block
OutfittingIn Dock
OutfittingIn Quay
Block Painting Dock PaintingCosmeticPainting
OUTFITTING PRODUCTION
PAINTING
23GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Shipyard Ship owner
1 DELIVERY & A/SDELIVERY & A/SFrom Contract to Delivery
Official Sea TrialShipyard, Owner, Class
SpeedEnduranceTank TestAnchoring/ MooringRudder, SteeringVibration, NoiseEquipment OperationNavigation
CorrectionIf Any
DeliverySign
Departure A/S
(1 YEAR)
READY TO SEA TRIAL
24
> Classification
2
25GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
2 MAJOR WORKMAJOR WORKClassification
DRAWING APPROVAL
INSPECTION DURING BUILDING
CERTIFICATION
INSPECTION AFTER DELIVERY
Yard Design
Maker Design
Intermediate
Periodical
SHIP’S SAFETY DURING LIFE TIME
26GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
CLASS PROCESS
T0
Contract
RFC Signed
T0 + C
Deliveryto Owner
Ad 523 signed by
LPO
Commercial Design review Follow-up in service
SHIP NEW CONSTRUCTION :
27GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
CLASS PROCESS
Design review : basically 4 BV actors
Field surveyor
LPO
Marine Center
BVN surveyors
DTM support
28GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
CLASS PROCESS
T0
Contract
RFC Signed
T0 + C
Deliveryto Owner
Ad 523 signed by
LPO
Design review
LPO core activity : Design review
• Design review can start before RFC signed ( TAKE CARE - CONTRACT DEFINITION )
•Completed when Ad 523 + annexes are examined and signed ( technical green light given to CM for Class certificate )
29GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
CLASS PROCESS
T0
Contract
RFC Signed
T0 + C
Deliveryto Owner
Ad 523 signed by
LPO
Design review
LPO core business : Design review against Referential
• Referential : BV Rules / IMO Reg.
• LPO Interpretations : - allowed with BV Rules ( within general conditions) - not allowed for IMO Reg.
• Rules : technical interpretations / protect interest of Owner ( final CLIENT )
• High technical knowledge frequently requested as Clients may be less educated / powerfull than BV
• Great risk of uncontrolled move from design review activity to Consultancy activity
30GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
CLASS PROCESS
T0 + C
Deliveryto Owner
Ad 523 signed by
LPO
Follow-up in service
LPO activity :
• Design review at any time in case of conversion
• Rules : technical interpretations / protect interest of Owner
• Technical support of CMs / Station surveys
• Several LPOs may be concerned
• Technical documentation processing ( drawings + calculation sheets )
Scrap
or
Changeof
Class
31GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
TECHNICAL ASSISTANCE TECHNICAL ASSISTANCE
Different from Class design review : BV acts as designer in scope of Consultancy
Technical expertise and knowledge is ( must be ) sold to Client
Highly profitable
HIGH RISK OF : - transfer of Yard know-how - confusion on status of conclusions - pressure from management
ALWAYS BE CLEAR ABOUT THE CAP YOU WEAR / THE FORMAT OF COMMENTS YOU ARE ALLOWED TO GIVE
32GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
2 IACS MEMBERSIACS MEMBERSClassification
MEMBER
ABS : American Bureau of Shipping
BV : Bureau Veritas
CCS : China Classification Society
DNV : Det Norske Veritas
GL : Germanischer Lloyd
KR : Korean Register of Shipping
LR : Lloyd Register
NK : Nippon Kaiji Kyokai
RINA : Registro Italiano Navale
RS : Russian Maritime Register of Shipping
33GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
2 Classification IACS MEMBERSIACS MEMBERS
ASSOCIATES
IRS : Indian Register of Shipping
REQUIREMENTS
- Procedural Requirement
- Unified Requirements
- Unified Interpretations
- Guide Line & Recommendations, etc.
Web Site
www.iacs.org.uk
34
> Large Container Vessel
3
35
1 General : Large Container Vessels
2 Bureau Veritas References in Large Container Vessels
3 BV Hull Expertise
- Steps of review process
- Torsion analysis
- Fatigue analysis
- Bow flare analysis
4 BV Lashing Expertise
5 BV Shaft Alignment Expertise
6 Parametric Roll Calculation
SUMMARY
36GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
The size range for the largest containerships is expected to increase significantly in the near future as economies of scale remains the dominant operational factor driving efficient transport.
The Largest containerships currently in service are in the 7000-8000 TEU range. Many leading shipyard have developed designs for vessels with additional containers rows, tiers and holds. Increase main dimension and capacity up to 9000/10000 TEU.
In the future the carrying capacity of containerships is expected to increase to 12000 TEU and above
1 GENERAL LARGE CONTAINER VESSELSLARGE CONTAINER VESSELS
37GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Fleet development for container ships
1
Fleet development in '000 teu
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004
GENERAL LARGE CONTAINER VESSELSLARGE CONTAINER VESSELS
38GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Order Books for container ships
1
Order book Feb 2005, number of ships
0
50
100
150
200
250
<1000 1000-2000
2000-3000
3000-4000
4000-5000
5000-6000
6000-7000
7000-8000
8000+
GENERAL LARGE CONTAINER VESSELSLARGE CONTAINER VESSELS
39GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Challenges with the increase of size of containerships
• Torsion/Warping stress
• Fatigue
• Acceleration forces on lashing
• Engine power
• Shaft alignment
• Parametric roll
• Slamming/Bow impact
1 GENERAL LARGE CONTAINER VESSELSLARGE CONTAINER VESSELS
40GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
LAST MAIN REFERENCES
• HHI
» 1x5,500 TEU containerships for YANG MING LINE
» 1x7,800 TEU containership for CMA CGM
» 10x5,100 TEU containerships for CMA CGM (under building)
» 2x5,100 TEU containerships for CMA CGM (under building at HSHI)
» 2x9,200 TEU containerships for CMA CGM (under building)
» 2x9,200 TEU containerships for CMA CGM (under building at HSHI)
» 2x8,200 TEU containerships for CMA CGM (under building)
» 2x8,200 TEU containerships for CMA CGM (under building at HSHI)
» 1x8,200 TEU containership for YANG MING LINE (under building)
• DSME
» 1x6,500 TEU containership for CGM CMA
2 BV REFERENCES CONTAINER SHIPS BUILDINGCONTAINER SHIPS BUILDING
41GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
LAST MAIN REFERENCES
• HHIC
» 2x1,600 TEU containerships for DELMAS
» 4x1,600 TEU containerships for VROON
» 2x4,300 TEU containerships for CMA CGM
» 3x6,500 TEU containerships for CMA CGM
• SHI
» 8 x 5,770 TEU containerships for CMA CGM
• CSBC
» 18x2,200 TEU containerships for WAN HAI LINES, DELMAS, CMA CGM, YANG MING LINE
• IMABARI
» 3x5,500 TEU containerships for COSCO
2 BV REFERENCES CONTAINER SHIPS BUILDINGCONTAINER SHIPS BUILDING
42GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
< 9,200 TEU CONTAINERSHIP >
Main Dimensions:
• Length btw. PP 333,44 m
• Breadth 42,8 m
• Depth, to upper deck 27,3 m
• Draught, summer 14,5 m
• Speed 24,25 kn
• Power 68656 kW
Key elements: Between half December and the end of March the complete structure has been reviewed. This was only possible in close cooperation with the Shipyard. Several meetings at the shipyard site, exchanging information and calculation results and discussing the findings, have taken place. Two offices of Bureau Veritas, Korea and Paris, have been working around the clock in order to make the deadlines of the shipyard.
2 BV REFERENCES PROJECT MANAGEMENTPROJECT MANAGEMENT
43GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Hatch coamings / Superstructures connection
Bottom Slamming
Transverse Bulkheadconnections
Bow Flare impact
Hatch corners
Longitudinal Hatch Coamings
Cross-deck structures
3 BV HULL EXPERTISECRITIAL AREA OF LARGE
CONTAINER SHIPSCRITIAL AREA OF LARGE
CONTAINER SHIPS
44GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
DESIGN REVIEW PROCESS
» General and subdivision arrangement
» Mid-ship section : Longitudinal strength and local rule scantlings
» All sections : Longitudinal strength and local rules scantlings
» Torsion model : Warping stress estimation all along the vessel (to be included in the global stress)
» Key drawings: primary members calculation (local + global stress)
» Detail drawings / reinforcement : bracket reinforcement under stack...
» Bow impact and flat forward bottom area
» Other calculations: Loading manual strength analysis, Lashing...
IN PARALLEL TO DESIGN REVIEW PROCESS
» FEM (VeriSTAR) calculations: double check for design review
» Fatigue Analysis with Mars/VeriSTAR
3 BV HULL EXPERTISE STEP OF REVIEW PROCESSSTEP OF REVIEW PROCESS
45GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
» TORCIS calculation
3
MARS - TORCIS ANALYSIS
Estimation of warping stress
in side shell , upper-deck
all along the vessel N/mm2
Modelisation of
all cargo holds
Estimation of shear force
in cross deck beams
2 calculations:
wave 60 degree
wave 120 degree
BV HULL EXPERTISE TORSION ANALYSISTORSION ANALYSIS
46GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
3
Fatigue due to warping
(L27) 16 years
(L28) 17 years
(L29) 13 years
(L30) 15 years
(L31) 17 years
Buckling due to warping
MARS - TORCIS ANALYSIS
BV HULL EXPERTISE TORSION ANALYSISTORSION ANALYSIS
47GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Analyses based on complete ship model
3
Full model of 9200 TEU containership
VeriSTAR is use for
- Buckling analysis (coarse mesh)
- Yielding analysis (fine mesh)
- Fatigue analysis (very fine mesh)
BV HULL EXPERTISE TORSION ANALYSISTORSION ANALYSIS
48GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Methodology and steps of a VeriSTAR CSM calculations
»σX1 = γs1σs1 + γw1(Cfvσwv1+Cfhσwh1 + CfΏσΩ )
3
Maximum Torsion at fore part50% Vertical Bending moment
Quartering sea: Maximize static , vertical bending (50%), horizontal bending (100%) and torsion (100%)
BV HULL EXPERTISE TORSION ANALYSISTORSION ANALYSIS
49GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Methodology and steps of a VeriSTAR CSM calculations
» Coarse mesh modelling : full ship
» Definition of ballast areas and container loading points
» Static calculation with lightship weight: loading conditions
– lightship (checking case)
– ballast (maximum Bending moment)
– full load (maximum draft)
– compare data with loading manual (draft,displacement,still water bending moment…)
» Wave Load calculations: load cases
– based on selection of design waves (table 5)
– Head Sea (longitudinal strength)
– Beam Sea (transverse strength)
– Quartering sea (torsion strength)
» Fine mesh analyses
– based on areas to be analysed (Table 1)
– Hatch corners, cross deck, connection superstructure,connection girders...
6 3D FEM CALCULATIONS VERISTAR
COMPLETE SHIP MODELCOMPLETE SHIP MODEL
50GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Principle Design wave load (see also Table 5)
» Maximum Vertical Wave Bending Moment in Hogging condition
» Maximum Wave Torque at vicinity of 0.25L (aft part)
» Maximum Wave Torque at mid-ship
» Maximum Wave Torque at vicinity of 0.75L (fore part)
» Maximum vertical acceleration in inclined conditions
» Maximum vertical acceleration in upright conditions
» Maximum transverse acceleration
Wave design load to be associate with loading conditions
» Ballast, full load
» Load cases
3
Sea keeping calculation
Iterative process
BV HULL EXPERTISE COMPLETE SHIP MODELCOMPLETE SHIP MODEL
51GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Stresses and Deformation
3
Head Sea Condition Quartering sea condition
Stress in Hatch coaming
Connection superstructure
Stress Hatch corners
Stress Cross deck
Stress Girders
Buckling in bulkhead and bilge areaBuckling in bottom area
BV HULL EXPERTISE TORSION ANALYSISTORSION ANALYSIS
52GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Areas to be analysed through fine Mesh models
3
- Hatch Corners
- Connection of hatch coaming
with superstructure
- Transverse Bulkhead
- Support Bulkhead
- Transverse Frame
- Bottom Girders
Examples:
BV HULL EXPERTISE TORSION ANALYSISTORSION ANALYSIS
53GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Typical stress range in head sea Typical stress range in oblique sea
HATCH CORNERS
3 BV HULL EXPERTISE TORSION ANALYSISTORSION ANALYSIS
54GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Support Bulkhead
3
Shear stress
at maximum draft
Maximum pressure
in alternate condition
one bay empty
BV HULL EXPERTISE TORSION ANALYSISTORSION ANALYSIS
55GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Connection with superstructure
3
Stress concentrations
BV HULL EXPERTISE TORSION ANALYSISTORSION ANALYSIS
56GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Steps for Fatigue calculation of side shell longitudinals:
» 1st step : 2D Fatigue Analysis
» 2nd Step: 3D Fatigue Analysis
Fatigue calculations for Hatch corners
» One Step: 3D Fatigue Analysis
3
Cracks in side shell longitudinal due to fatigue
BV HULL EXPERTISE FATIGUE ANALYSISFATIGUE ANALYSIS
57GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
3
Side Shell longitudinals
Fatigue
Hot spot 1
Fatigue
Hot spot 2
Damage Fatigue
Life calculation
to be over 20 years
To compare with Mars results
BV HULL EXPERTISE FATIGUE ANALYSISFATIGUE ANALYSIS
58GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
3
Hatch Corners
In order to increase fatigue life,
compromise between:
- sufficient reinforcement
- smooth grinding
Hatch corner in the midship and fore part
Hot spot edge of the corner
Especially fore part area due to high
torsional loads
BV HULL EXPERTISE FATIGUE ANALYSISFATIGUE ANALYSIS
59GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
3
Hatch CornersIn order to increase fatigue life,
compromise between:
- sufficient reinforcement
- smooth grinding
Hatch corner in the aft part at ER
Hot spot edge of the corner
Smooth Grinding improves
the fatigue life by 2
BV HULL EXPERTISE FATIGUE ANALYSISFATIGUE ANALYSIS
60GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
3
Slamming
Maximum impact in forward area:
- Buckling in transverse frames
- Buckling on side shell plate and stiffeners
- Detail connections in forward area
VeriSTAR calculations with maximum vertical
acceleration and in sagging condition.
Blow Blow flareflare analysisanalysis
BV HULL EXPERTISE SLAMMING/ BOW IMPACTSLAMMING/ BOW IMPACT
61GENERAL PROCEDURE OF SHIPBUILDING - DD/MM/YY
Buckling in transverse frame at fore part
3 BV HULL EXPERTISE SLAMMING/ BOW IMPACTSLAMMING/ BOW IMPACT
62
END
Thank You for
Your Attention !