General Procedure of Shipbuilding Soo-Kwan Oh Technical/ Marketing Manager For the benefit of business and people

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


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



GENERAL ARRANGEMENT



75K MIDSHIP


1 From Contract to Delivery

75K MIDSHIP

INITIAL STAGEINITIAL STAGE



DIAGRAM OUTFIT



1 From Contract to Delivery INITIAL STAGEINITIAL STAGE

DIAGRAM OUTFIT


1 From Contract to Delivery INITIAL STAGEINITIAL STAGE

DIAGRAM OUTFIT



DIAGRAM-MACHINERY




DIAGRAM-MACHINERY




DIAGRAM-MACHINERY




ACCOMMODATION PLAN




ACCOMMODATION PLAN




ACCOMMODATION PLAN



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


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


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


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


1 PRODUCTION STAGEPRODUCTION STAGEFrom Contract to Delivery

Pre-OutfittingIn Block

OutfittingIn Dock

OutfittingIn Quay

Block Painting Dock PaintingCosmeticPainting

OUTFITTING PRODUCTION

PAINTING


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


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


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 :


CLASS PROCESS

Design review : basically 4 BV actors

Field surveyor

LPO

Marine Center

BVN surveyors

DTM support


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 )


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


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


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


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


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


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


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


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


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


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)





» 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


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


< 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


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


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


» 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


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



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)



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%)



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


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


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



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:



Typical stress range in head sea Typical stress range in oblique sea

HATCH CORNERS

3 BV HULL EXPERTISE TORSION ANALYSISTORSION ANALYSIS


Support Bulkhead

3

Shear stress

at maximum draft

Maximum pressure

in alternate condition

one bay empty



Connection with superstructure

3

Stress concentrations



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


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



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



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



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


Buckling in transverse frame at fore part

3 BV HULL EXPERTISE SLAMMING/ BOW IMPACTSLAMMING/ BOW IMPACT

62

END

Thank You for

Your Attention !

Documents

General Procedure of Shipbuilding Soo-Kwan Oh Technical/ Marketing Manager For the benefit of business and people