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INTERNSHIP PROGRAM

REPORT

Department of Ship Technology, CUSAT

(Dated: 18th May 2014- 30th May 2015)

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HINDUSTAN SHIPYARD LIMITED

(A Govt. of India Undertaking Ministry of defence)

Hindustan Shipyard Ltd.

Gandhigram (PO)

Visakhapatnam - 530 005

Andhra Pradesh

India

Report submitted by

Aswin K Das

Goshith Gopal

Mohammed Anas

Navas Paramban

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CONTENT Acknowledgement ……………………………….4

Introduction ……………………………….5

Hull shop ……………………………….8

Prefabrication ……………………………….29

Erection and Alignment ………………….…38

Dry dock and Ship repairs ……………………46

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ACKNOWLEDGEMENT

We, students of Department Of Ship Technology, Cochin University of Science and Technology sincerely thank our Head of the Department and Professors for the valuable suggestions and guidance rendered to us to ensure the smooth sailing of our industrial training.

We are deeply indebted to the management of Hindustan Shipyard Ltd. for providing us the necessary facilities to undertake training at their yard and office and hence our thanks are due to them.

We take this opportunity to express our deep gratitude to cmde P H M Salih, Director, Mr.soorya Rao, General Managing of Human Resource and Mr.Sanyasi Rao, Dy. Manager of Trining Department and all supervisors and executive officers of Hindustan Shipyard Ltd. for the keen interest shown by him during our training and for extending maximum possible co-operation from time to time.

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Introduction

HSL is located in Visakhapatnam on east coast side of India ,

founded as Scindia shipyard , it was build by the industrialist

Walchand Hirachand as part of The Scindia Steam Navigation

company Ltd. Walchand selected Visakhapatnam as strategic

and idle location and took possession of land in November 1940.

The World War II was going on and in April 1941, the Japanese

bombed the town. However, Walchand was unfettered and

decided to go ahead with his plan of building a shipbuilding

industry in India. In the days when it was unthinkable of

foundation ceremony to be done by anyone other than British

officials, the truly patriotic Walchand decided to break the

tradition and the foundation stone for the shipyard was laid by

Dr. Rajendra Prasad on 21 June 1941, who was acting Congress

President at that time. The first ship to be constructed full in

India after independence was built at Scindia Shipyard and

named Jal Usha. It was launched in 1948 by Javaharlal Nehru

by the first prime minister of India.

However, later on the government of India decided to

nationalize the Scindia Shipyard, as it was a sensitive and

strategic sector related to defense sector of the country. The

shipyard was finally nationalized in 1961 and renamed

Hindustan Shipyard Limited (HSL). In 2009, HSL was

transferred from the Ministry of Shipping to the Ministry of

Defence. The yard played a critical role in the development of

nuclear-powered, Arihant class submarine.

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The shipyard is relatively compact at 46.2 hectares (0.462

km2). It is equipped with the plasma cutting machines, steel

processing and welding facilities, material handling

equipment, cranes, logistics and storage facilities. It also has

testing and measuring facilities. It has a covered building dock

for building vessels up to 80,000 DWT. There are three

slipways and a 550 metres (1,800 ft) fitting­out jetty. HSL has

a dry dock, wet basin and repair delphin for ship and submarine

repair and retrofitting.

As of 2009, it had built over 170 vessels and repaired almost

2000 ships. It builds bulk carriers, offshore patrol vessels,

survey ships, drill ships, offshore platforms and repair and

support vessels. It also conducts major overhauls of Indian

Navy submarines, and is being equipped to construct

nuclear­powered submarines.

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Over a period of time the yard has been able to emerge as a

one of the major players in the Indian Maritime sector. The

factors that make HSL stand out are as under.

.

Largest shipyard on the East coast of India

Well laid out facilities with steel throught capacity of

20000 tons/year

Only shipyard with submarine repair capability on the East

coast

Large covered building dock for un-interrupted work

round the year

Strategically located at harbor entrance (water depth of

about 10m)

Capable of building ships upto 80,000 DWT

ISO 9001/2008 certified yard

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HULL SHOP

In Hindustan Shipyard limited steel plates are processed and

manufactured into panels for building of ships. These panels are

prepared in prefabrication by welding elemental sections together

that are being processed in hull shop where in turn steel plates and

sections are processed in hull shop that are being brought from

steel stock yard where all steel plate and sections are stored .

In steel stockyard the steel plates and sections are stored in

the form of stacks or piles which further are taken to hull shop

using Electromagnetic Overhead Tonnage(EOT) cranes.

Steel Stockyard

Steel stockyard is 9,293 sq-m of hard standing area for storing the

plates of 4 mm to 60 mm thick and other required sections of

various sizes. A 16 ton magnetic captivator is available for

material handing. One 10 ton EOT crane is also available for

handling of sections like flat plates, bulb angles, I beams, etc..

Capacity: 25,000 tons

Hull Shop

In this shop all marking, cutting of elements, forming them into

different shapes as per requirements and marking them unit wise

for feeding to the sub-assembly and assembly shop is done. It is

total area 11,152 sq-m and capacity is 2,500 tons per month. Hull

shop is divided into:

1. Plate treatment line

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2. Section treatment line

3. Bay1

4. Bay2

5. Bay3

6. Bay4

Process flow in Hull shop

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Steel drawing office will allocates the materials as per the

schedule. The steel stores will issue the material in requisition

of Hullshop

All plates are mangled and shot blasted and painted. And this

process is being done to prevent corrosion

Markers will all the markings on plates and sections with the

use of templates and drawing. They will write complete process

on marking, material, type of edge preparation, forming,

cutting line, dispatching, destination, etc..

Hull shop consist of several machines. The computer numerical

control(CNC) flame cutting machines can simultaneously cut 4

pieces from 1/10 scale drawing prepared on special paper in

mini loft drawing office to full size. Other elements are marked

on the steel plates using wooden templates prepared in mould

loft and cut in another gas cutting machines.

There are hydraulic presses with various capacities and up to

maximum 2000 tons forming the plates, rolling machines, cold

frame bending machine, shearing machine, cambering

machine, straightening machine, plate preparation plant etc..

are the important machines in the hull shop which have the

capacity to produce elements up to 2500 tons per month.