Final Report Colombo Dockyard PLC

Report on Industrial Training at Colombo Dockyard PLC 7903131
PREFACE
In my Marine engineering diploma Program Last part is dedicated for non-academic

industrial training on Colombo Dockyard PLC. I did industrial training period at Colombo Dockyard
from 20.01.2014 to 19.07.2014. Purpose of industrial training is to give hand experience and idea of
future job environment.
Colombo Dockyard is the best place to do industrial training for marine engineering students
because it is the one and only shipbuilding, ship Repair Company in Sri Lanka. During training period
I have learned how to apply theoretical knowledge in practically, and improved my technical skills,
communication skills. I have earned new tactics for problem solving and problem solving skill. One
of most important thing is I got new network in people who working in marine engineering field.
ACKNOWLEDGEMTN
First of all I would like to express my heartfelt gratitude to my Lecturers for themes immense
contribution and kind advices towards making success marine engineering career.
Also I would like to thank National Institute of Fisheries and Nautical Engineering
Institute for providing facilities and also for adding this kind of module to our diploma program.
My thanking also extends to the Colombo Dockyard PLC and Colombo Dockyard training
centre. Because without their support wouldn’t be feasible.
At last, not least I would like to thank all our colleagues as well. 1
National Institute of Fisheries and Nautical Engineering | Ocean University

Content
Preface
Acknowledgement
Chapter 1
Introduction to the Colombo dockyard Limited
Chapter 2
Maintenance shop (plant Shop)
Hull treatment
Machinery out fitting shop
Metal shop (Boiler shop)
Ship repair division
Dock side
Engine Fitting Shop
Pump House
Quality Control Department
Calibration
Chapter 3
Conclusion
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Reference

CHAPTER 01
INTRODUCTION TO COLOMBO DOCKYARD

LIMITED
Colombo Dockyard Ltd.
"The Nature gives gifts" Location of Port of Colombo is one of the highest gifts given by
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the nature to Sri Lanka. COLOMBO DOCKYARD LIMITED (CDL) is one of the leading Ship
Repairs, Ship building and Heavy Engineers Company in South Asia Region located in world-
renowned port of Colombo. The CDL is an enterprise that comes under the Board of Investment of

Sri Lanka after restructured. The company, which belongs to a public quoted limited liabilities
category entered in to a foreign collaboration with Japan Onomichi Dockyard Company Limited to
enhance the capacity as well as quality of service provided by Colombo Dockyard Ltd. When
comparing previous year’s financial figures, we can see that CDL has been steadily growing in all
directions.
COLOMBO DOCKYARD LIMITED own and operates four dry docks that are,
Dock No Length (m) Breadth (m) Depth (m) Capacity (Dwt) Carnage (t)
1 213 23.9 8.8 30,000 25
2 107 16.3 5.8 9,000 25
3 117.5 15 5.2 8,000 10
4 263 42 7.5 125,000 50
CAPACITY OF DRY DOCKS AND CRANES
ALSO OPERATES 11 PIERS

01. Guide pier no.1
02. Guide pier no.2
03. Launch pier
04. Dolphin pier no.1
06. New building no.1 pier
08. No.3 Cross birth pier
09. North pier
10. No.4 entrance pier
11. South pier
Afloat Repair Berths with available of services such as Fresh Water, Ballast Water,
Fire Line, High Pressure water jetting, Acetylene, Oxygen, Compressed Air, Cranes Electricity.
COLOMBO DOCKYARD LIMITED is engaged all kind of Ship Repairs (namely Hull repairs,
Machinery repairs including any kind and size of main engines, Propeller repairs, Pipe Repairs, 4
Electrical and Electronic Repairs, sand blasting, painting), Ship building and heavy engineering works
up to international market requirement. They will consult not only Sri Lanka but also foreign
countries.

They have a building berth (Capacity-3000 DWT, length 38m, breadth, 16.5m, height 12.4m)
and a building dock (Dry dock No.3), for new building requirements as well. With those facilities
they are building new vessels, those capable to compete with all kind of vessels in modern
application. CDL is capable of making patrol boats, all kinds of tugs, dredgers, fast landing crafts,
firefighting vessels, workboats, and coastal surveillance vessels.
Hear all workshops are equipped with modern and old machinery and equipment, which can
meet to almost all kind of ship repairs activity. All workshops are facilitated with over-head cranes
and other facilities such as Oxygen, Acetylene, and Carbon Dioxide on 24 hours basis. Colombo
Dockyard has geared itself to meet with the highly sophisticated needs of the demanding international
customer base, by gaining and maintaining the internationally recognized accreditation from Lloyd's
Register Quality Assurance. The ISO 9001 Certification has been awarded for Ship Repairs,
Shipbuilding, Engineering Project Management and Heavy Engineering. Also they win the award for
the best productivity in Sri Lanka.
In Colombo dock yard limited is pay attention about safety of the all the workers. SAFETY
IS FIRST is Main guideline in the factory for safety. In safety group has all the level of people in
CDL that mean engineers, supervisors, and also permanent workers. All so fire unit and medical
service is provided for argent situations.
Colombo Dockyard Limited it's all operation functions have divided in to 10 (ten) Divisions
operate under ten divisional heads and Quality Control Department and Warranty Repair Department
run directly under the Chief Production Manager.
Ten Divisions are as follows
1. Human Resource & Administration

2. Quality Assurance and Safety
3. Finance
4. Business
5. Production Hull and Deck
6. Projects and Engineering
7. Production Engine
8. Yard
9. New Building/Marketing
10. Material Procurement
In CDL will give the following works especially for any ship and heavy engineering field.
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Welfare
Welfare is one of the key to become standard company in locally and internationally. To become
standard company it is essential to pay EPF and ETF it is joint action plan by the employer and the
employee to save for the future retirement life of the employees in the Corporate and Private Sector.
The aim of the EPF is to prudently manage the Fund to ensure a better return to the members at
retirement. Colombo dockyard has pay for EPF 12% of employee salary, employer have to pay 10%
of his salary for ETF company pay 3% salary of employer. Also e following benefits is provided to all
employees together with a rich basket of benefit schemes
1. Bonuses for all employees

2. Loans for housing & vehicle purchasing
3. Subsidised meals, tea and snacks
4. Budget Shop, managed by Welfare Association, to procure essentials at lower prices
5. Laundry facilities for washing overalls
6. Canteens
7. Contributions at funerals and weddings
8. Distress Loans through the Welfare Association
9. Holiday Bungalow at Nuwara Eliya, managed and operated by the Welfare Association
Training and Development
Colombo dockyard understood human resource one of the key to reach their goals. Therefore they
have their own training centre with fully equipped training centre for industrial technical and
managerial training, which arranges a wide range of training programmes, seminars, workshops and
other awareness programmes. The Training centre is registered at TVEC according to Clause No. 14
of the Tertiary and Vocational Education Act no. 20 of 1990. The
Accreditation of the current Training programmes and the establishment of the Quality Management
system required by TVEC facilitated the Training Centre to be upgraded to Grade A+ Training centre.
The knowledge centre, which comes directly under the department of Human Resource Development,
they responsible to conduct and facilities for training and skill development programs for all
employees from welders to engineers and managers. They use the expertise of engineers, managers
and training coordinators based within the company, as well as external intellectuals, trainers and
other professionals sourced locally and overseas as resource persons at the knowledge centre. 6
Industrial Safety
Colombo dockyard safety policy
Colombo Dockyard PLC recognizes its corporate responsibility to provide a safe and healthy work
environment for all personnel who have legitimate business in such work environment.
Colombo Dockyard PLC shall:
 Provide safe plant, machinery, equipment and systems of work;

 Ensure compliance with relevant statutory and regulatory requirements; and
 Provide procedures, information, instructions, training and supervision to employees,
contractors, customers and visitors to ensure their safety.
Safety Department
In ship building and mechanical engineering field safety is essential factor to consider. In Colombo
dockyard has separate department which called Safety Department to carry all safety trainings, safety
monitoring, and inspection works. Most of training programmes are conduct according to Hazard
identification and Risk Assessment (HIRA) methodology. Yard Safety Assurance Committee is
observing and analysis of safety performance and also they take decisions, improvement, and
implements to improve safety at yard .According to
“Risk base previous accidents/near misses” and “Risk based on operational activity” yard was
divided in three zones, High, Moderate and Low based on the latent risks at these places.
Influence of Accident

Accident triangle
Fire
In order to understand how fire extinguishers work, you first need to know a little bit about fire. Four
things must be present at the same time in order to produce fire:
 Enough oxygen to sustain combustion

 Enough heat to raise the material to its ignition temperature
 Some sort of fuel or combustible material, and
 The chemical, exothermic reaction that is fire
Take a look at the following diagram, called the "Fire Triangle"
Oxygen, heat, and fuel are frequently referred to as the "fire triangle." Add in the fourth element, the
chemical reaction, and you actually have a fire "tetrahedron." The important thing to remember is:
take any of these four things away, and you will not have a fire or the fire will be extinguished.
Essentially, fire extinguishers put out fire by taking away one ormore elements of the fire
triangle/tetrahedron. Fire safety, at its most basic, is based upon the principle of keeping fuel sources
and ignition sources separate.
Classification of Fuels
 Class A - Wood, paper, cloth, trash, plastics

Solid combustible materials that are not metals.
Extinguishers: water, sand 8
 Class B - Flammable liquids: gasoline, oil, grease, acetone
any non-metal in a liquid state, on fire.

Extinguishers: form, CO2
 Class C - Electrical: energized electrical equipment

As long as it's "plugged in," it would be considered a class C fire.
Extinguishers: CO2, dry powder
 Class D - Metals: potassium, sodium, aluminium, magnesium

Extinguishers: CO2, dry powder
Atmospheric monitoring
Safety department has taken action to monitor all spaces and tanks whether or not work. This
operation was carried by qualified person at least once a to check Oxygen level, Hydrocarbon gas
(LEL) and toxic gases. The results of these inspections, together with the date/time at which they were
carried out, are clearly marked at each entrance to the space concerned with a “Confined Space
Coordination Sticker” on the Vessel Safety Coordination Board
Safety notices in CDL
When working ship yard we have to involve using power tools, corrosive materials, naked flames,
burners or other dangerous items, therefore wearing overall is important to prevent unexpected
injuries. Every field work employers and trainers have to wear overall, due profession overall colour
may change as below.
Profession Colour
Engineers White
Forman, Supervisors Sky blue
Permanente employers Dark blue 9

Dockyard general Engineering Dark green
employers

Trainees Dark red
Fire mans Red
Labourers Orange
Overall colour due to profession
Personal Protective Equipment’s
Personal protective equipment (PPE) refers to protective clothing, helmets, goggles, or other garment
designed to protect the wearer's body from injury by blunt impacts, electrical hazards, heat, chemicals,
and infection, for job-related occupational safety and health purposes.
Head Protection
Safety helmets should be worn any place in the Dockyard. Even small bolt drop to the head from a
high place may cause to a serious injuries. Also there are cranes in most places. Heavy equipment’s
and parts (parts of hull of ships and boats, steel plates, pipes) are lifting and transporting using these
cranes. Also safety helmet is an important thing when we working in a ship. Because ship engine
room is a compact place, therefore our head may hit on pipelines, platforms, etc. Wearing safety
helmet is not sufficient; it should be worn properly. Chin guard should be used; harness should be
adjusted to tighten the helmet to the head sufficiently. Only we can get the full advantage of the safety
helmet by wearing it correctly
Eye Protections
 Face shield
 Eye goggles
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 Eye specs
Normal safety goggles, Caps or hair nets should be worn with machining, turning, shaping, boring and
grinding processes (when we are used machines like Lathe machine, Boring machine , milling

machine, Grinding machine) to prevent small particles strike on eyes. Dark glass (lenses) should be
worn with gas cutting and welding processes to prevent loss of sight due to ultra violet radiation. The
lenses resist impact and block harmful UV ray. When we are doing welding we select ampere for
welding position and according select ampere we must use dark glass
Hand Protections
Rigger gloves should be worn when working with sharp, corroded, damaged, heavy, etc. objects. It
prevents fingers and palm from injuries. Welding gloves should be worn during welding, gas cutting
processes and when handling hot items. Leather material of the gloves absorbs heats, but it is not
suitable for handling hot items for long time.
Foot Protections
Toecap prevents damages to the fingers in a case of falling high weights on the toe. Oil resistance,
non-slip sole is good protector while working along slippery oily surface. Steel innersole prevents
penetration of sharp objects
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Ear Protections
The unwanted sound is called as noise. Noise induces hearing damage. There is a standard
defined about sound level of the workshop should be. The maximum noise level in workplace
should be 85dB. Therefore, if it is more than that work place, ear protectors should be worn when
working in such places. Desirable ear protectors should be selected according to the sound level.
We use two ear protectors there are earplug and earmuff.
Body Protections
 Apron
 Safety belts
 overall
 dust masks
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Safety belt

Safety belt is very use full when work on Scaffolding, when work in higher place first we
have to fixed suitable place if we felled it help to hang until safety people comes.
Safety Belt
Safety Shoes
Safety shoes that have a protective reinforcement in the toe which protects the foot from falling
objects or compression, hot hazard, chemical hazard also shock load on the foot.
Safety Shoes
Chapter 2
Maintenance Shop (Plant Shop)
Introduction
All of the yards’ new installations of machinery and equipment, maintenance jobs, repairs are
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driven by this shop. This shop is also known as the plant shop. I have worked in the shop for 3 weeks.
Maintenance shop has several branches as it is easy to handle the jobs coming for the shop. They are,

 Machinery maintenance
 Gas equipment and gas line maintenance
 Pneumatic and hydraulic equipment, engine, generator, and compressor maintenance
 Pump repair division (Diaphragm and submerged)
 Chain block repairs
 AC repairs
 Paint machine repairs
 Electrical equipment repair
 Machinery maintenance
 Under this section have participated on several maintenance and one new installation with
workers as follows,
Repair of a lathe machine
Participated to a repair of a lathe machine at the machine shop. The fault was found to
be a worn out bearing. It was a ball bearing. Replaced the bearing.Observed the types of
mechanisms inside lathe. All the power transmissions are done via shafts, gears and belts.
Pneumatic and hydraulic equipment repair
Totally dismantled, cleaned and reassembled a pneumatic tip cleaner (jet chisel). We were
asked to do the maintenance of about 12 jet chisels; first we were shown how to do it. So I have
dismantled and cleaned it with diesel. The major problem of them was the trap of metal parts inside.
Holder of the jet chisel has several grooves in it. The tips reciprocate rapidly due to the pneumatic
operation. Pneumatic diagram can be shown as follows,
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1 – This is the pneumatic source
2 – These 2 by 2 control valve actions are attained by the grooves inside the jet chisel
3 – Is the representing the tip set

Pump repair division

I have participated in a repairing of a wilden diaphragm pump
Overhauled a wilden double diaphragm pump
 Wilden pump is a operates under pneumatic

 It is heavily used in marine field
 This is used to pump low viscosity fluid
 We can control its operation in simplest way by using air valve
Advantage of above pump
 Easily maintains
 This can use when air supply is needed
 Operation of this pump is simple and any one can operate without good knowledge about it
 Light weight and easily transport
Defects
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 Two diaphragm will damage because it’s not made by strong materials

 Maintain should be continues

 Pumping is hard when there is west consist in pumping fluid
How wilden pump works
The wilden diaphragm pump is an air operated positive displacement, self-lubricating pump. These
drawings show flow pattern through the pump upon its initial stroke. It’s assumed the pump has no
fluid in it prior to its initial stroke.
Chain block repair
There are 3 types of chain blocks and they are
1) electrically powered chain hoist

2) ratchet leaver chain hoist
3) differential pulley chain hoist
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I have totally overhauled a differential pulley chain block by myself. Understood all the available
mechanisms present in it. The mating surfaces of a hub which is inside the chain block must be lapped

to assure a smooth operation. It has a gear chain consisting of a one sun wheel, two planetary gears
and a one power output gear. The self locking mechanism is comprised with two gears known as
dogs.
The main reason for the repair of these chain blocks are the lack of lubricating media as
grease and oil of the equipment is driven away from it with time and trapping of dirt inside the chain
block. So the every chain block get repaired and cleaned twice a year. After repair these tested with
1.5 times weight from the rated weight. These come in capacities as .5, 1, 2, 3, 5, 10, 15, 25 ton.
Electrical equipment repair
This division gets all the electrical equipment as

1. electric grinders
2. electric jig saws
3. chain saws
4. wire cords
5. electric drills
6. fans (pedestal, sealing)
I have gained the knowledge to how to troubleshoot a pedestal fan. Learned the circuit
diagrams. Coil arrangement and there are three windings as starting, running and regulator windings.
The ac supply we give is of 90 degrees of phase change but to run a fan more efficiently and faster the
phase angle has to be 120 degrees. To gain the phase which is required, a capacitor is used on fans.
Airless Spraying Machine

It is a pneumatic piston pump. They are applicable to industrial usage such as steel structures, ship
repairs. For the spraying of new coating or thick film, heavy, duty, anti-corrosive coating. In CDL
these spray machines are used to paint ship which newly constructed and come for repairs.
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The main working part of the sprayer is the double acting air driven high pressure painting pump.
When the compressed air flows into the cylinders, the piston moves to the upper part or lower part of
the cylinder, forcing, upper or lower pilot valve to operate.
The control air drives the air distributing reversing device to act in an instant. Therefor realizing stable
and continuous reciprocating movements of the piston of the air driven motor. The pressurized
coating is conveyed to the airless spray gun via the high pressure hose and finally released of the
hydraulic pressure and an atomized at the airless nozzle and then sprayed to the surface of the target
to form a coating layer.
Before starting first check all bolts, nuts, pipe connectors and the connecting nuts and hose clamps of
the suction system have tightened. Lean carefully about the opening and classing direction of gate
valve on each circuit and the rotating direction of pressure regulating valve and discharge valve.
Plug both the coating suction pipe and the discharge valve into the tank containing cooling, put
through the air source and adjusting the air intake pressure according to the type of cooling. To ensure
the safe use the maximum air intake pressure must not exceed 0.6MPa and is better to be kept at a
valve as long as possible as long as the atomization of the coating is good. open the discharge valve
do not open the spray gun .then the air driven booster pump of the sprayer will move and form a
continuous and stable way. During the spraying the spray gun should be painted vertically or almost
vertically at the work piece being coating and the moving direction should be parallel to the surface
being coated.
Trouble shooting;
1. No paint coming out of the gun;

Strainers are dirty/stacked
Suction line least
Piston ball valves damaged or not tighten to valve seat properly
2. Air bubbles in the paint mixture;

Suction ball valve or seat is damaged
3. Machine stops working;

No lubrication on the gland coupling
4. Relieving pressure through pressure relief valve;

Air pressure is too high
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Airless spray equipment is also capable of handling fluids like;

Solvent less coating
Polyurethane tap cools
Anti-corrosive ship coating
Typical fluids handled
Zinc Silicate and other Zinc base coating
Industrial paints
Polyurethane top coating
Hull Treatment
INTRODUCTIOIN
Ships can operate only a certain length of time without repair. To keep a ship on prime condition,
constant attention should be given to material upkeep and definite intervals of time must be allotted
for general overhaul and repair. Hull repair is the fundamental duty of the hull maintenance technician
in CDPLC. They will do pre fabrication work. Welding, job, some kind of pressure test, frame
bending, unit fabrication, identification of location of location in hull and ships.
MARKING OF A DECK PLATE
After laying the deck plates on the bed it was marked. By using deck production drawing with the
help of a thread it was marked. Then it was given to the unit fabrication.
Tagged the deck plates
According to the production drawing first the plates from pre fabrication were laid on the bed of the
unit fabrication. Then plate bed was levelled. Then they were tagged by using arc welding.
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CLASS INSPECTION OF A UNIT
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After assembling prefabrication, the unit was fabricated. It was checked by unit fabrication section.
After that the Class Inspection was done.
For that Quality Controller from Class, QC from ship owner’s side, QC from ship builder’s side was
participated. In addition to them unit fabrication section surveyor and unit manufacturing person were
joined.
With the reference of detail drawing faults were marked. The things still not fixed were pointed out to
the QC of ship builder from Class. The brackets still not fixed, sizes of the openings, girders, bulk
heads, and also the welding quality was checked.
The welding run of the one side should be in lined with the bracket or the welded bar. It was checked
by the QC by using a chalk, according to the bellow drawing. By using chalk rod sheet was pasted.
Other side welding was appeared. For all the welds the same procedure was done.
Welded plates ends also were checked. If blow holes were there, QC marked them as ‘Gauge + weld’.
It means the weld should be cut and re weld.
Sometimes the Production Drawing and the Detail Drawing slightly different. It because due to
machinery and other obstructions. If something was not been according to the detail drawing, the QC
from ship builder’s side explained it to the class QC with the reasons.
Blasting
Blasting is surface preparation for painting. Blasting cleaned surface when viewed without
magnification shall be free of oil, grease, dust dirt, mill scale, rust, coating, oxides, corrosion product,
paint and other foreign matter
Mill scale Types
Adherent mill scale grade A
Rusting mill scale grade B
Rusted grade C
Pitted and rusted grade D
Types of blasting
There are 3 types of blasting such as.
1. Hydro blasting
Use with high pressure water
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2. Slurry blasting
Used with high pressure water and sand mixture

3. Grit blasting
Use with steel grit or cupper slack. In the yard mostly used by this method for hull treatment
Steel grit blasting - new constructions
Copper slack blasting - ship repair
Blasting Standards
There are four standards of blasting
1. SA 1
Remove the rust, oil grease and other impurities
2. SA 2
Remove the rust and other impurities except that it removes about 66% of visible impurities
3. SA 2.5
Remove the foreign impurities except that it removes 95% of visible
4. SA 3
Remove 100% of visible impurities
Machinery outfitting shop
Introduction
This shop is mainly dealing with the pipes and fittings, shaft aligning, fabrication of tube
systems for heat exchangers, water supplies, etc. The power that moves the industry moves through
piping systems. As such, piping plays an important role in the development of modern industry. And a
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driving force behind this is the improvement in and increased range of application for pipe fittings.
Where piping joins, curves, branches out or tapers off, fittings are there. Also this shop is doing the

control valve circuit assembling of ships. As I have witnessed a 4 by 3 hydraulically operated,

solinoidally operated control valve which has used to control the CPP propulsion system of NC 228.
Pipe fittings
I have observed all the types of pipe fittings available in the shop. Also ran out a general
search of all the available piping fittings available in the global market.
Butt welding fittings for steel pipes, butt welding fittings for Stainless Steel pipes, butt
welding fittings for steel plates and butt welding fittings for boilers Steel pipes have the following
common fittings
1. 450 elbows
2. 900 elbows
3. 180 returns
4. Tees
5. Concentric reducers
6. Eccentric reducers
7. Caps
I have observed a variety of flanges in the fitting shop. Each of them is specifically designed
for different kinds of environments and applications. Even though a variety of flanges are available
the most widely used type in this yard is the slip on flange. It is simply for the simple design and ease
of fabrication compared to the other flange types.
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Slip on flange Welding neck flange

Reducing slip on flange Expander flange
Important factors of specifying a flange
 Working pressure range
 Flange standard as KS, JIS, ANSI, JPI, etc
 Nominal diameter of the flange
 Inside and outside diameter of the flange
 Number of bolt holes
 Thickness of the flange
 Pitch centre diameter (PCD)
CPP shaft alignment
 I have participated on a aligning of a CPP shaft on the NC 230 (mv corals). At that 24
time the CPP shaft was aligned up to the gear box. Power delivery to the propeller was as
follows and the gear box was closer to the propeller shaft.

 I have found out the clearance between the CPP shaft and the stern tube was 0.5 mm and
this clearance can be used in case of any misalignment is encountered during the aligning
of the CPP shaft. Two intermediate shafts were joined through couplings and the two
couplings were aligned axially as well as radially. To the aligning processes 2 dial gauges
were used.
Propulsion
Gear Box Propeller
Engine
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Metal work shop (Boiler shop)
INTRODUCTION
This work shop is responsible for maintenance, repairs and new constructions. Most of the time gets
repairs and maintenance jobs.
Area reserved for this shop is rectangular in shape and the jobs are carried out in an assembly line
procedure. The parts which have to repair or maintain are send to the front. Most of these parts are pre
cleaned, painted and some are not. So in the front end workers cut and replace the necessary parts,
apply weld tacks. Middle and the rear end are using for fabricating and welding.
These are some process done by calibration department.
 Metal marking
 plate cutting by shearing machine
 gas cutting
 manual arc welding
 TIG welding
 MIG welding
 MAG welding
 Plate rolling
 Pipe fabricating
 Gas welding
 Metal works
Welding process
Welding is a materials joining process which produces coalescence of materials by heating them to
suitable temperatures with or without the application of pressure or by the application of pressure
alone, and with or without the use of filler material
 Welding is used for making permanent joints 26

 Joint will be free from discontinuities, gas porosity, shrinkage, cracks
 Weld is able to perform under varying conditions or service (e.g., extreme temperatures,
corrosive environments, fatigue, high pressures, etc.)

 It is used in the manufacture of automobile bodies, aircraft frames, railway wagons, machine
frames, structural works, tanks, furniture, boilers, general repair work and ship building
Shielded Metal Arc Welding (SMAW)
Intense heat at the arc melts the tip of the electrode
Tiny drops of metal enter the arc stream and are deposited on the parent metal
As molten metal is deposited, a slag forms over the bead which serves as an insulation against air
contaminants during cooling
After a weld ‘pass’ is allowed the cool, the oxide layer is removed by a chipping hammer and then
cleaned with a wire brush before the next pass.
Gas Metal Arc Welding-GMAW (metal inert gas-MIG)
Weld area shielded by an effectively inert atmosphere of argon, helium, carbon-dioxide, and various
other gas mixtures
GMAV process is suitable for welding a variety of ferrous and non-ferrous metals
Process is versatile, rapid, economical, welding productivity is double that of SMAW
Easily converted for
Automatic welding machines, computer controlled welding machines, and robotics control.
Gas Tungsten ARC welding - GTAW (Tungsten inert gas-TIG)
Tungsten electrode not consumed, but surrounded by an inert gas and produces an arc.
Filler material is usually applied.
Gas tungsten arc welding does not produce as deep a penetration as stick or other types of welding.
GTAW is a slow method of welding, which results in an expensive product. 27
It can be used to weld aluminium, magnesium, titanium, and stainless steels.

Welding Process
Gas welding
Oxy-Acetilyne
welding
Electric Arc
Welding
Non
Consumable
Consumable
Electrode
Electrode
Shield Metal Arc Gas Metal Arc Gas Tangston

Welding welding Arc welding
(SMAW) (GMAW) (GTAW)
Metal Inert Gas

(MIG)
Metal Active
Gas (MAG)
Welding Rods
MT E6013
MT E6013
 MT : Manufacturing code(mild steel)

 E : metal arc weld electrode
 60 : Strength (60,000 psi)
 1 : All position
 3 : current to be use and the type of the flux coating
 (flat butt weld and horizontal/vertical) 28

The thickness of the plate is most important thing in welding. We cut bevels regarding with thickness.
 Up to 30 mm - Single Bevels
 More than 30 mm - Double bevels
Welding Positions
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30
 To get well finished from the welding we must wave the welding rod 3 times of it diameter.

 To get high quality weld penetration we cut the weld penetration by using carbon rod and
reweld by sing the overhead process. This process called Gouging (cut groove). But
nowadays we use ceramic pack for it.
Welding defects and reasons
Welding defects
Porosity
1. Oil heavy rust, on plate

2. Wire may need wire higher in Mn and Si
3. Welding over slag from covered electrode
Undercutting
1. Travel speed too high

2. Welding voltage too high
3. Excessive welding currents Cracking
Cracking
1. Incorrect wire chemistry

2. Poor quality of material being welded Excessive spatter
Excessive spatter
31
1. Arc voltage too low
2. The arc is too long.

Metal cutting and deforming
Oxyacetylene gas cutting
All over the yard oxyacetylene gas cutting is heavily deployed so it is no exception for this
shop too. It is Acetylene and Oxygen, who are generating the required heat to melt and cut the metal
by two exothermic reactions,
Primary combustion process
C2H2 + 2O2 → 2CO2 + H2O+ heat
 This reaction dissociates into carbon monoxide and hydrogen.
Secondary combustion process
2CO + H2 + 1.5 O2 →2CO2 + H2O + heat
To cut a metal plate first we have to heat up a single spot to red hot condition, it is preferable
if the spot you are heating is an edge. Once it has got red hot introduce the compressed Oxygen flow
on there by pressing the lever on the gas torch. With the introduction of compressed Oxygen to the red
hot metal there forms a weak iron oxide which will be easily melted due to the available high
temperature. After this all we have to do is to advance the torch in the direction of cutting where rapid
forming of iron oxide and melting will cut the plate.
Acetylene hose is red in colour and oxygen is blue. Pressure ranges for these gases are as
follows
Oxygen = 1.0 bar
Acetylene = 0.5 bar
If we exceed these pressure limits the hoses will be in danger of bursting off. Even though the
standards are those while in working we used 1- 1.5 bar pressure for Oxygen and 0.5-1 bar of pressure
for acetylene.
Gas cutting nozzle has six peripheral holes and a single centre hole. Peripheral holes supply a 32
mixture of Oxygen and Acetylene while the centre hole supplies only pressurized Oxygen only. When
cutting different thicknesses of plates we have to change the nozzle size. Size of the nozzle is the size
of the diameter of the centre hole of the nozzle. It s diameter is given in inches so as the nozzle size.

Some of them are 1/8, 1/16, 1/32, 3/64, etc. the largest size is 1/8 which is used to cut plate
thicknesses beyond 50 mm.
When lighting up the gas torch we have to open the Acetylene valve a little and light up. Then
we can control the type of flame we need by adjusting the Oxygen and Acetylene valves. Once the
work is done first we close the Acetylene valve and then the Oxygen valve.
Apart from the manual gas cutting here we have PAG (Portable Automatic Gas) cutting
machines, pipe cutting machine. Pipe cutting machine is a semi automated one where we have to
place the chain around the pipe and place the machine on the chain. This chain acts as a guide and it s
length can be adjusted by removing or adding chain links. Main advantages of this machine are its
high speed, accuracy and quality. This machine has a tension screw for small adjustments.
Rest of the processes available in the metal work shop for metal cutting and deforming can be point
out as follows,
Shearing machine
There are 2 shearing machines in the metal work shop. They can cut up to 30 mm
from 6 mm of thickness.
Plate Thickness (mm) Blade Clearance (mm)

6 0.25
8 0.3
10 0.35
. .
. .
30 30
Table of blade clearance for plate thickness.
This shearing machine provides a shearing power of 200 tons per 1 mm. it s rated
capacity is 10 mm thick x 2500 mm long MS(Mild Steel) plate of UTS 42 kgs/mm2. Rake
adjustment is 0.50 – 2.50 and the length of the knife is 2550 mm.
33
Hydraulic press

I have actively participated on working in this press with a worker. First we have to
alter the deforming power provided by the press according to the thickness of the plate. Then
we also have to change the face of the block according to the thickness of the plate. First the
bending is done from the middle of the die and finally the work is pulled to one edge and
subject to bend from the edge of the die. It is compulsory to have 2 workers for job in this
machine.
Roll bending machine
This one is also hydraulically operated. It has a digital display. It shows the positions of the
ends of the rollers. I have participated on making U bolts from this machine
SHIP REPAIR DIVISION
Introduction
Ships have large engines. Normally about 15,000 hp. Most of these engines are two stroke engines.
Because two strokes slow speed engines have high efficiency. Ship engines have to run long periods
in the sea. Then the efficiency is much more important. Normally these engines consist of 5 ~ 9
number of cylinders. Earlier engines were very large. Sometimes a piston is higher than even 6 feet
and larger in diameter. But in new engines pistons are small and have long stroke lengths.
Normally these engines are running in around 80 – 150 rpm. They use heavy oil as the fuel. It
uses diesel as fuel while starting, before stopping and before to entering to a harbour. For the starting
purpose there is no any starting motor. For the starting, compressed air is used. There are huge
compressed air cylinders in the engine room for storing the compressed air. Using this air initial
turning of the engine is achieved and after specific speed is reached fuel is injected into the cylinder
and the compressed air supply is stopped.
In the case of inspection, propeller shaft removing and piston removing processes engine has
34
to turn slowly. For this purpose there is an electric motor which is connected to the gear on the fly
wheel. This gear is called as the turning gear. This motor can engaged and disengaged manually by a

lever. Most of the engines have direct coupled generators after the flywheel. This is easy in
controllable pitch propeller ships because, it has constant engine speed at any time. But in fixed pitch
propeller driven ships engine speed has to be changed to control the speed of the ship. In such it uses
special methods to generate electricity without coupling with the main engine.
Most of the ship engines can run in both directions. It depends on the direction of starting
torque apply. Therefore most of the engine’s cam profile is symmetrical. Some engines have exhaust
valves and inlet ports. Some engines have inlet and exhaust ports. Such engines have reed valves to
prevent mixing of inlet and the exhaust gases.
Reed valve is spring tensioned metal diaphragm valve which is smoothly lapped. It is automatically
open and close due to the pressure and the vacuum.
The exhaust valve is normally opened by hydraulically. The valve opening pump is operated
by a cam. For the cooling purpose of the engine, cylinder liners, etc it uses fresh water. Then the fresh
water is cooled by sea water using heat exchangers.
Exhaust valve removal
Engine Information
Engine builder - Hyundai Man-B&W
Engine type - 6550MC
Engine no. - B489
No. of Cylinders - 6
Cylinder bore - 500 mm
Stroke - 1910 mm
35
Procedure
01. Remove all the pipe connection with the Exhaust valve. (before remove mark them)

02. Connect the hydraulic jack to exhaust valve. Studs.
03. Unscrew the tension bolts by about ½ turn.
04. Check the oil level in the hydraulic unit.
05. Remove vent screw actuate the hydraulic unit until the oil comes out bubble-free from the
vent screw of the hydraulic jacks.
06. After all the air goes out close the vent screws.
07. Actuate the hydraulic unit until a pressure of 620 bars has been reached.
08. When nut has been released, using a Tommy bar loosen nuts one turn.
09. Lower the pressure to zero, and then remove the jacks and the nuts.
Piston Removal
After the cylinder head is removed, clean the carbon deposits from the upper part of the liner. Clean
the lifting holes in the piston crown top. Tap the treads of the hole. Pit the lifting tool in to the tread
holes in the piston crown and attached the tool to the crane.
The piston rod palm nut is removed hydraulically. The weight of the piston is now taking by the
engine room crane.
Turn the engine with the turning gear and lower the crosshead bearing so that it is
separate and clear from the piston rod. In some engines the stuffing box is taken out along with the
piston .whilst in other. Engines it is taken out after the piston is removed.
Removed the piston and land it in the space provided, through the engine platforms.
Supporting devices in two halves are provided for the purpose. A rubber sheet or a wooden board is
placed over the cross head to protect it from dirt falling from the top.
36
Piston inspection

Check the crown surface for any traces of fuel, water or cracks.
The piston crown is cleaned and the burn away on the surface is checked with the help of a
template for cracks use a simple white chalk test or dye penetrate test .Remove the piston rings with
the expand tool.
Remove the Crosshead bearing
 Got clearance reading before removing
 First all the precaution were carried out to prevent the accidents while work inside the
crank case
 Took crosshead clearances (Top half F.P/F.S &A.P/A.S)
 Loosen the crosshead tightening bolts
 Remove the upper cross head bearing cover (2nos)
 Fixed a special stud to cross head pin &lift it by the over head crane. Then cross head slides
upwards through guide shoes and locked.
 Before this lower part of the cross head with connecting rod is fixed by tightening 2 chain
blocks in two sides.
 Measure cross head pin & check & inspection the lower half of crosshead bearings.
Dismantling Propeller shaft
Ship Name - MV. Annapurna (India) 37
Engine - Hyundai Man-B&W (6 Pistons)

Cross section of Propeller Shaft with coupling
01. Mark the coupling position and seal position
02. First dismantle the after stern tube seal.
03. Removed spare seal, old seal with housing & tube seal.
04. Removed the o’ring.
05. We Used the 1 Ton chain block to hold after side coupling
06. After that coupling bolt removed.
07. Then propeller shaft drawn 100 mm ~200 mm to outside (after side)
08. “Shaft Nut” Removed.
09. After that propeller shaft drawn until pull out the coupling.
10. When propeller shaft came out from coupling all the seal parts removed.
38
11. Propeller shaft fully drawn to outside.
12. We had to turn the shaft to get the key side up.

13. Then removed forward side coupling and the key.
DOCK SIDE
Introduction
Colombo Dockyard is the unique and largest ship building and ship repairing place in Sri Lanka. In
that case Dock Side is very important for dockyard because of the all ship repair, ship building works
carried in dry docks. Ship docking operation carried from dock side
Dry docks
Dry docks are used for the construction, maintenance and repair of ships, boat and other water craft
(for a repair a underwater engine room sea valve, propeller, rudder etc.and painting the hull and
bottom of the ship also Routing inspection)
The four types of dry docks are known,
Graving docks
Floating dry docks
Slip ways
Mechanical Lift
Colombo Dockyard has four graving dry docks with a maximum capacity of 125,000 Dwt.Also have
11 piers
39

Dock No Length(m) Breadth(m) Depth(m) Capacity(m) Carnage(t)
1-A 148 26 9.7 30000 160
1-B 65 26 9.7 30000 160
2 107 18.5 6.7 9000 160
3 122 16 5.5 8000 10
4 263 44 8.9 125000 50
Graving docks in Colombo Dockyard
Graving dock is a narrow basin, usually made of concrete, closed by gates or by a caisson, in to which
a vessel may be floated and the water pumped out, leaving the vessel supported on blocks. The keel
blocks as well as the bilge block are placed on the “Docking Plan” of the ship.
Colombo Dockyard dock No: 1
This graving dry dock with a length of 213m and breadth of 26m, this dock has a DWT capacity of
30,000. It is serviced by 5 cranes with carnage from 15 to 50 tones. This facility is used to service
mainly general cargo vessels, dredgers, container vessels, offshore support vessels and cement
carriers. These days it is also using as a building dry-dock.
Colombo Dockyard Dock No: 2 [Building dry dock]
This graving dock has a capacity of 9000 DWT. It is 107m in length and 18m in breadth. The
carnage which services this dock, consist of one 50 ton and two 15 ton cranes. This graving dock
which is located in tandem with the Dock No. 01 is a sheltered dock exclusively dedicated for ship
building projects.
40
Colombo Dockyard Dock No: 3

This graving dock has capacity of 8000 DWT. Constructed initially to accommodate submarines
during the World War II, this dry-dock consists of a long and narrow construction. The length of
this dry-dock is 123 meters x Breadth 16 meters. The carnage consists of one 10 Ton and one 6
Ton. This dry-dock has facilities to accommodate offshore support vessels, tug boats, naval
vessels, work boats and dredgers.
Colombo Dockyard Dock No: 4
This is the largest graving dry-dock with capacity of 125,000 Dwt, 263meters in length and
44meters in breadth. This dry-dock commissioned in 1988 is capable of handling a wide spectrum
of vessels. The dry-dock has state of the art facilities with carnage consists of 3 cranes, 18 tons, 20
tons and 50 tons. This dock is also serviced with two traveling dock arms of 450 kg. Equipped
with a service tunnel. This dock accommodates tankers, bulk carriers and dredgers.
Piers
1. Guide pier no.1

2. Guide pier no.2
3. Launch pier
8. No.3 Cross birth pier
9. North pier
10. No.4 entrance pier
11. South pier
In my one week training period carried out following works in this section. 41
Prepared a bed for MV. Sunmar Majesty ship, NC 228, Barge, Toller boat and Nan Cowry
passenger ship on No: 4 Dock.

Works Carried on No: 4 dry-dock. Which is Lilly Regale ship placed in to Dock?
Observed process on wire splicing.
Work Procedure of preparing a bed
Firstly all the drawing of the ship which is going to be dock should be brought they are docking plan,
General arrangement plan, midships plan using them a docking bed will be, Created to take a
maximum load distribution keel blocks are placed where the transverse bulkheads and longish are
there.
Keel block
Keel blocks are used to the ship in the dock. Mainly there are two kinds of keel blocks. They are
concrete and cast iron. Keel block is covered top and bottom with timber plates specially keel block’s
top is created by soft wood because of not having any damage to the hull.
Keel block arrangement
After docking bed is done dock is filled by sea water in valves which are both side of the dock. The
flow of water runs by gravity. When the sea level and dock water same the main gate will open.
In the Dock No: 1 there is a cession gate and Dock No: 2, 3, and 4 has a dock gates. 42

Undocking
Docking and undocking is a main work of a dock side shop.
In this movement we had to undock the ship “Jindal Tara” There for undocking the ship we had to
clear the dock that mean we had to take away scaffolding and other thing from the dock. Then we had
to fill the water. Therefore we were filled water to the dock by operating the pump from pump room.
After that we had to identify the flouting position point of the ship. There for after some time forward
side of the ship was slightly moved up and we were identify it as a flatting position. Then we were
identifying it to ship crew. Because we can identify if it had any water leak. Then that ship crew was
tell to us “ok” and then again filled water to the dock. After we undock the ship by using tug boats
Making an Eye Splice
43
Illustration "A", Illustration "B", Illustration "C",

If all of the tucks have been made correctly, the eye splice should look like Illustration "B".
Left hand strand "A" leads off to the left, right hand strand "C" to the right of the standing part.
Tucking the strand ends "A", "B" and "C" under three strands of the standing part is the next step. Get
this right and the rest is a piece of cake!
Next form a loop in the rope by laying the end back along the standing part. Hold the standing part
away from you in the left hand with the loop toward you. The unpaid end can now be worked with the
right hand.
Next take left hand strand "A" and tuck it under strand 1(Which is left of strand 2). And then take
strand "C" and tuck it under strand 3(Which is right of strand 2). Tuck from right to left against the
lay of the strands for each of these also.
Starting with the centre strand "B", Select the topmost strand of the standing part and tuck "B" under
it.(right to left against the lay of the strands) Tighten but do not distort the natural lay of the strands.
The size of the loop is determined by the point at "X" where the strands are first tucked under the
standing part of the rope. Now lay the three opened strands across the standing part as shown in
Illustration "A", so that the centre strand "B" lies directly over and along the standing part.
The splice is completed by continuing to make at least four full tucks with each of the strands. As
each added tuck is made be sure it passes over one strand of the standing part, then under the next
strand above it, right to left against the lay of the strands. The completed splice should look like
Illustration "C".
Engine fitting Shop
Introduction
Engine fitting shop mainly operates these operations
 Repairs and cleaning of valves, turbochargers, pistons, etc
 Repairs of bow thrusters, propellers, etc 44
 New installations of CPP propellers

 Cleaning of oil coolers in ships
And I have participated in many different types of work and activities during the time in this
Maintenance and cleaning of pistons, stuffing box
I have participated on dismantling, cleaning and reassembling of 5pistons and 5 stuffing

boxes. First of all stuffing boxes were removed from the piston rods. Then the removing of piston rod
from the piston can be started. After the removing of bolts and nuts from the collar of piston it was
held by the crane. Then the puller nuts were inserted to the piston which had loosened up the tight fit
of piston and its rod.
All the pistons and the neck of the piston rods are subjected to die penetrate test. First the
cleaner is sprayed and rub the surface with a cloth to clean it up. Then the white penetrate is sprayed
after several minutes the red die is sprayed. After some time the cracks will start to appear in red
colour if there is any present. There were no cracks on the pistons and piston rods.
Then the piston was reassembled to the piston. After this cleaning and repairing of the
stuffing box started. This is fit to the engine steadily and the piston rod slides through this. The
stuffing box is fitted with fit bolts and spring washers. It comprises from 5 to 8 grooved steel rings.
The ring is cut in to several parts. Within the grove there runs a spring to hold the parts of the ring.
The main functions of stuffing box,
 It prevents back pressures released by piston rings from getting in to the sump and
blowing it off
 Scrapes the oil which on the piston rod back to the oil sump
 Prevents some heat transfer from the piston crown to the sump.
45

The holes in the piston liner are to provide compressed air to the combustion. The air is
compressed through a turbocharger.
I have also participated in overhauled turbocharger, Air starting valve and heat exchangers.
Before dismantle a devise like this we need to mark its components as it is easy for us to reassemble
them later. This is done by applying a centre punches for detachable parts. In some occasions the gas
cutter had to use cause the bolts were corroded that much.
46
Exhaust gas turbocharger

By turbo charging an engine, the following advantages are obtained:
 Increased power for an engine of the same size OR reduction in size for an engine with the
same power output.
 Reduced specific fuel oil consumption - mechanical, thermal and scavenge efficiencies are
improved due to less cylinders, greater air supply and use of exhaust gasses.
 Thermal loading is reduced due to shorter more efficient burning period for the fuel leading
to less exacting cylinder conditions.
The turbocharger consists of a single stage impulse turbine connected to a centrifugal impeller via a
shaft.
The turbine is driven by the engine exhaust gas, which enters via the gas inlet casing. The gas
expands through a nozzle ring where the pressure energy of the gas is converted to kinetic energy.
This high velocity gas is directed onto the turbine blades where it drives the turbine wheel, and thus
the compressor at high speeds (10 -15000 rpm). The exhaust gas then passes through the outlet
casing to the exhaust uptakes.
On the air side air is drawn in through filters, and enters the compressor wheel axially where it is
accelerated to high velocity. The air exits the impeller radially and passes through a diffuser, where
some of the kinetic energy gets converted to pressure energy. The air passes to the volute casing
where a further energy conversion takes place. The air is cooled before passing to the engine inlet
manifold or scavenge air receiver.
47

The Air Starting Valve
The valve is fitted into the cylinder head. It is opened

by control air from the starting air distributor.
The valve shown is from a slow speed MAN-B&W two

stroke engine but a lot of modern engines have valves
working on similar principles and design.
How it works
48
Main starting air at about 30 bars from the manifold enters the chamber
above the valve via the circumferential ports in the valve body.

The air pressure will not open the valve because a spring is holding the valve shut, and the area of the
balance piston is the same as that of the valve lid so the valve is pneumatically balanced.
When the valve is required to open, air at 30 bars from the air start distributor enters the top of the
valve body and acts on a piston. This force overcomes the spring force holding the valve shut, and the
valve opens. When the air signal from the air start distributor is vented, the spring closes the valve
When the start sequence is finished the main air start pressure is vented through holes in the main start
air manifold.
Maintains
After certain periods of service starting air valves are changed and overhauled. If piston rings are
fitted, care must be taken to ensure that they are free in their grooves. Should it be necessary to fit
new rings, the butt clearances of the rings must be carefully checked by placing the ring into the
operating cylinder and measuring the clearance this is especially important if they are usually made of
brass
which has
a larger
49

coefficient of expansion than the other parts of the valve. The valve and valve seat are ground with
grinding paste and finished to a fine surface with lapping paste. It is essential to ensure that all parts of
the valve are scrupulously clean before reassembly. Lubricate all sliding surfaces sparingly with
molybdenum disulphide grease.
50
Pump house

Introduction
Colombo Dockyard is mainly carried on ship repair and ship building process. In that case dry docks
and carnage facilities is most important for CDPLC. Pump House is responsible for that kind of works
.This is oldest workshop in the dockyard and providing high quality service since 1930.Pump house
carried on following works in dockyard such as,
All the Dock side Crane, Dock Arm (Dock No-4) operation and maintain.
Pump house operation and maintenance.
Operation and maintain high pressure pump (for ship Cleaning process).
Compressors air operation and maintain (for grid blasting process, ship painting process
etc.).
Repair cooling lines of ship.
Colour codes of pipe lines
 Green - Sea Water

 Light Blue - Fresh water
 Dark blue - Oxygen (O2)
 Black - Carbone Dioxide (CO2)
 Red - Acetylene (C2H2)
 Gray - Compressed Air
 Red - Fire Hydrant
Pumps
Various types of pumps were found in this workshop. They were the pumps that were used to pump
seawater, fresh water, water for fire fighting, etc.
Mainly there are two categories,

51
 Centrifugal pumps and
 Reciprocating pumps
Most of time we were involved with repairs of centrifugal pumps. Various type and sizes of
centrifugal pumps are available in yard. Developing pressure is varied with number of impellers. The
pumps with one impeller is known as ‘single stage pump’, and it is known as ‘multi stage pump’ if
two or more impellers available.
Lack of pressure and leakage are the common faults found with these types of pumps. Those are cause
of worn parts of the pumps. Misalignment or the improper assemble of the pump may the cause to
wear of the pump. Mainly a centrifugal pump is consisting of;
 Housing
 Impeller(s)
 Shaft
 Sealing units
 ‘O’ ring
 Bearings and wearing
Housing
Impeller
Shaft Bearing Housing

Key Bearing 52
Gland

Mainly we have to inspect each of above parts, during the repair of centrifugal pumps.
Types of Impellers
1. Open type
2. Semi-Open type
3. Closed type
Globe Valve
These types of valves are used to control flow. It can be used in high temperature applications
such as to control steam or high pressure applications such as to control pump flow rates.
The flow path is far from straight and is fairly tortuous. The flow must change direction
through 90 ~ in order to pass through the seat and then another 90 ~ to return to the original direction.
Because of the internal passage construction, globe valves cannot be cleaned with rods. They are also
not recommended for solids handling applications or dirty fluids.
When we look at the globe valve body there is some notations DN (Diameter Nominal) PN
(Pressure Nominal) and Flow Direction (using Arrow mark).
Parts of a Globe Valve
 Body
53
It contains all of the valve's internal parts that will come in contact with the substance
being controlled by the valve. The bonnet is connected to the body and provides the containment
of the fluid that is being controlled.

 Bonnet
Provides leak proof closure for the valve body. The threaded section of stem goes through
a hole with matching threads in the bonnet. A bonnet attached with bolts is used for larger or
higher pressure applications. Bonnets also contain the packing, which is a wearable material that
maintains the seal between the bonnet and the stem during valve cycling operations.
 Disc or Lid
The closure device of the valve. Disks are connected to the stem which is screwed up or down
to throttle the flow.
 Stem
The stem serves as a connector from the actuator to the inside of the valve and transmits
this actuation force. The stems are surrounded by packing material to prevent from the valve. This
packing is a wear material and will have to be replaced during maintenance. The end of the stem
threaded to allow connection to the Disk and the actuator. The stem must be very straight to
ensure good valve closure.
 Seat ring
The seat ring provides a stable, uniform and replaceable shut off surface. Seat rings
threaded and screwed into a thread cut in the same area of the valve body. Seat rings are also
typically bevelled at the seating surface to allow for some guiding during the final stages of
closing the valve.
Cross Section of a Globe Valve
54

Handwheel Handwheel Nut
Yoke Sleeve
Gland Collar Stem
Gland Stud
Bonnet Stud & Nut

Gland Packing
Bonnet
Bonnet Bush Bonnet Packing
Stem Nut
Body Seat Ring
Size
Disc / Lid
Body
Cross Section of a Globe Vale
Gate Valve
A gate valve is a linear-motion manual valve that uses a typically flat closure element
perpendicular to the process flow, which slides into the flow stream to provide shutoff. It can be
applied to both liquid and gas services, although it is mostly used in liquid services. When compared
to other types of manual valves, the gate valve is relatively inexpensive as well as easy to maintain
and disassemble.
Cross Section of a Gate Valve

55

Cross Section of a Gate Valve
56
Quality Control Department

Introduction
Quality control department plays a big role in the Company. All the imported materials such
as steel plates, pipes, various types of machines…etc should be with high quality. The overall
checking process is done by quality control department. Also every well-meant are checked by very
expire aced quality inspectors of that department. In addition to that the thicknesses of hull plates are
estimated using thickness gauge. Many kinds of none-destructive testing methods are used to check
the defects.
Non-destructive Testing
Non destructive tests are carried out to detect flaws in the structures of materials, components
and assemblies without damaging their future usefulness. Although NDT can reveal flaws in the
structure of a product, it cannot predict where flaws will develop due to the design itself.
Methods of Non Destructive Tests
 Visual Test
 Magnetic Particle Test
 Dye Penetrate Test
 Ultrasonic Thickness Gauging
 Radiography Test (X - ray Test)
 Hose Test
 Kerosene Oil Test (Chalk Test)
Ultrasonic Thickness Gauging
As the ship travels in the sea it always gets contact with sea water or with sea breeze. It makes
the metal sheets to get corroded, which reduces the thickness of the plates thus reducing the strength.
57
Therefore plate thickness is measured annually to verify the strength of the plate is within the
acceptable limit. Most frequently used method for thickness gauging is the multiple echo method. A

special instrument is used for this purpose. The Ultrasonic Thickness measuring instrument works on
the pulsed-echo principle. The probe is made to vibrate for a very short period, creating a pulse of
ultrasound which enters the test piece. The probe waits for the returned echoes and acting as a
receiver, converts them into electrical signals which are processed to produce timings in digital form.
The beam path is straight, at 90’ to the surface and the ultrasonic energy reverberates up and
down within the metal. Each time the echo is reflected back down, a small portion of the energy
comes up through the coatings striking the probe which now acts as a receiver.
The delay between echoes at the probe-face is exactly equal to the time taken to pass through
the metal twice, therefore coatings such as paint are ignored and the measurement displays the metal
thickness only.
Operating Procedure of Ultrasonic Thickness Gauging
Calibration of sound velocity
 The principle of operation of an ultrasonic thickness gauge is that the instrument measures the
time of flight of an ultrasonic pulse through the test piece and multiplies this time by the
sound velocity of the material.
 The instrument was calibrated on a velocity reference block made from the same material as
the test piece. This block was flat and smooth and as thick as the maximum thickness which
can be measured from it.
 The calibration was carried out on the site where the thickness was being measured in order to
minimize errors due to temperature variations.
 Copland was applied to get proper contact with the plate.
 If the measuring thickness is smaller than the minimum thickness which can be measured
from the instrument, it displays a wrong thickness. Therefore user should always be aware of
the minimum thickness.

58
 Sound velocity may not be constant in the material which is being tested. For example heat
treating can cause significant changes in sound velocity.

Thickness Measurement
 The loose material, dirt and Copland residue were removed from the surface of the material at
points where measurements were taken. First they were removed from a chipping hammer
and then grinded. When measuring thickness in ballast water tanks where electrical supply
was impossible a portable grinder was used.
 A drop of coolant was placed on the material surface at the measurement point.
 When a detectable echo was received from the back surface of the material, the echo indicator
in the upper right of the display indicated the detection of an echo by changing the appearance
to present contact between the transducer and the sample surface.
 The measuring range of the instrument was 1 mm ~ 500 mm.
Penetrate inspection
Penetrate inspection is sensitive, non-destructive methods of locating minute flaws open to the
surface
For example, cracks, pores, and leaks. It is particularly valuable for examining nonmagnetic
materials, on which magnetic particle inspection cannot be used. Penetrate inspection is used
extensively for exposing surface defects in aluminium, magnesium, and austenitic stainless steel
weldments, and for locating leaks in all welds. Dye penetrate procedures usually require ground
surfaces, although some “as-welded” surfaces can be inspected.
Inspection procedure
1. Either the visible or fluorescent dye penetrate method can be used between a series of
2. Stringer welds or on a completed weld. There are types of penetrant: water washable, post
emulsifying, and solvent removable. Intermixing these penetrant materials is not permitted.
59
Procedures for inspection depend on the specific type of penetrant the method used; therefore,
only a general approach is outlined in this manual.

3. The surface must be clean and dry. The discontinuity must be free of oil, water, or other
contaminants so that the void is open and the penetrant enter. The method of cleaning the
weld area is unimportant part of the test procedure.
4. The penetrant is applied to the surface by spraying or brushing. The inspector must allow
5. Enough time for the penetrant to enter all discontinuities. A minimum time of 10 minutes at a
temperature of 60 to 125 degrees F is normally recommended. The smaller the defect or the
higher sensitivity required, the longer the penetrating time must be.
6. Excess penetrant can be removed from the surface by wiping with an absorbent cloth, either
or moistened with a solvent. Removing the surface penetrant by spraying with solvents gives
a clean surface; however, penetrant can be washed of defects if the spraying is not done very
carefully. Therefore, this technique is not recommended.
7. The developer should be applied carefully it does not produce a coat so thick that indications
masked. The developer acts as a blotter to draw penetrant to the surface, where it can be seen
with the naked eye or viewed under an ultraviolet light (in fluorescent penetrant inspection).
The developer must be applied as soon as possible after penetrant removal operation; the time
between application of the developer and interpretation should be controlled ((6) below). The
true size and type of defect are difficult to appraise if the dye diffuses too much in the
developer. The recommended practice is to observe the surface during application of the
developer in order to see certain indications which might tend to bleed out quickly.
8. Interpretation must be done within a specified time. The specification might indicate,
9. example, that interpretation must be done no sooner than 7 minutes and no later than 30
minutes after application of the developer.
10. Most acceptance standards specify similar limits on cracks and linear indications, rounded
indications of a specific size and quantity, or number indications in a given area.
60

Radiographic inspection
Radiographic inspection is a non-destructive testing technique which involves taking a picture
of the internal condition of a material. This picture is produced by directing a beam of short wave-
length radiation (X-rays or gamma rays) through a material that would be opaque to ordinary light.
This radiation exposes a film which is placed on the opposite side of the material. When developed,
the film (called a radiograph) shows the presence or absence of internal defects. Radiographic
inspection is called for in many specifications because it provides a permanent record. Different types
of internal defects can be identified, and flaws such as cracks, porosity, lack of fusion, and entrapped
slag can be differentiated. Radiographic inspection has its limitations,
Visual inspection
Visual inspection, which is the most widely used inspection method, is also the quickest,
easiest, and cheapest. The only equipment commonly used is a magnifying glass (1 OX or less) and a
flashlight or extension. Other tools, such as a bore scope and dental mirrors, are useful for inspection
inside vessels, pipe, or confined areas. Visual inspection is always required in weld evaluation.
However, it will not reveal interval defects or minute surface defects.
61
Magnetic Particle Inspection Test
01. Cleaned well test area

02. Sprayed “White Contrast Paint” (Magnaflux WCP-2) to the test area. (Spray can should be 20
cm ~ 30 cm away from the object)
Test Piece Yoke
03. The yoke flexible legs shall be positioned longitudinally on the axle test surface ensuring the
leg poles are correctly touching onto the axle surface.
04. Put the test pies between yoke legs and spray prepared bath on to test piece, if it shown it’s
cracks mark we can identify yoke is in good condition.
05. Spray the area between the legs, Prepared Bath (Magnaflux 7HF), whilst energizing the
magnetic flux field.
06. Viewing for indications shall be carried out as the area is being tested.
Calibration
Introduction
This section is involving with every section of the Dockyard. Finding errors of equipments, measuring 62
initial and after dimensions of overhauling equipment, etc. are carried out here.

In this section calibration of bushes, bearings, shafts etc. are being done. Also alignment of shafts,
bushes, impeller housings are being done.
Alignment of shafts can be done using several methods. Most common method is the piano wire
method, and most advanced method is the telescopic micro-alignment. Shafts should be aligned
accurately; otherwise unnecessary vibrations may occur thus reducing the lifetime of bearings and
couplings.
Most commonly used tools to calibrate machine items are outside micrometers, inside micrometers,
dial gauges, deflection gauges, feeler gauges, vernier callipers etc.
Accuracy of calibration
Accuracy defines how closely the pen (or indicator) agrees with the input. A recorder (or indicator)
can never be any more accurate than the calibration standard because if the recorder were 100 percent
accurate, it still would only be reproducing the measurement fixed by the calibration standard. If the
standard were of by 2 percent, then the recorder would also be of by 2 percent.
As a practical matter, the instrument being calibrated is always a bit less accurate than the “standard”
instrument.
Crankshaft Deflection
Crank shaft deflection is carried out for,
1. Miss alignment of an engine crankshaft due to wear of main bearing.
2. Distortion of the engine bedplate.
3. Damage of the ship structure
63

Procedure of measures Crankshaft deflection,
1. Open all the crankcase openings at both side of the engine.
2. Check whether is inside temperature reduced to a safe value, enter to the engine.
3. Made sure engine turning gear is working properly and checked the engine unit numbers.
4. We have to take four readings, when the dial gauge is at top, bottom, port and starboard. But
we can’t get the dial gauge to the top due to obstruction of the connecting rod. Therefore we
have to always take two readings, when the dial gauge is at ‘top-port’ and ‘top-starboard’
positions.
5. We are taken all readings respect to the ‘top-port’ position. (Dial gauge reading ‘0’).
Therefore checked, which unit can be easily turned to the ‘top-port’ position and turned the
crankshaft to that position after placing the dial gauge between crank webs firmly.
6. Then the dial gauge is set to ‘0’.
7. Crankshaft is rotated until dial gauge is approach to the ‘port’ position, and stopped the
turning gear and noted down the dial gauge reading.
8. Similarly, readings are taken on the ‘bottom’, ‘starboard’ and ‘top-starboard’.
9. Then looking for a proper unit and above procedure is followed. This is done to every unit.
10. Dial gauge is taken away and clean it carefully.
64

Main bearing connecting rod
Dial gauge
Top-port Port Bottom Starboard Top-starboard
Top-starboard Top-port
Starboard Port
65
Bottom

DEFLECTION GAUGE
It is the gauge, which is used to measure the deflections of the crank webs. Bottom of the gauge is
additionally weighted in order to keep the dial gauge facing up all the time while the crank rotates
CHAPTER 3
Conclusion
Colombo Dockyard is one of the best places for marine engineering trainees who can uplift a good
knowledge in regarding Marine Engineering studies. It is a one and only ship building company in our
country. It gives lots of job opportunities to the country as well as earns lots of foreign currency.
Colombo Dockyard has maintained a leadership through continued emphasis in research and
development and investing in the large technologies as an example Colombo dockyard currently have
160 Ton Level Luffing crane it was the South Asia biggest crane currently.
CDPLC was my first industrial training period, so according to my experiences i understood i have
successfully absorbed lot of knowledge according to marine engineering field.
I suggest making video tutorials for training students leering purpose. It is easy to do in Colombo
dockyard because they have separate media unit. It is important because lot of training student didn’t
get chance to participate all the process, repairs, jobs that shop carried.
According to my experiences, I believe that I have successfully gained the knowledge during my
training period at Colombo Dockyard PLC. Since the CDPLC was my first industrial training
establishment I had lots of things to learn. To carry out the work assigned to me, the theoretical
knowledge that I got from the Institute was unforgettable. Colombo Dockyard is a large yard and
there are so many things which cannot cover within 6 months.
Finally i want to tell the training engineer. Mr.Helavikum took a tremendous effort to guide us in
correct path of our industrial training. I believe this training will change my life in future.
66

References
 Colombo Dockyard Annual report 2013

 Colombo Dockyard PLC [Online] Available: http://www.cdl.lk/ [Accessed 3 March 2013]
 Unknown (2013). Gas Metal Arc Welding (GMAW). Available:
http://www.praxair.com/na/ca/en/can.nsf/21849aac40b0e04085256d7300798c14/ad20f1ed6a
438aca852576bb005d2dc5!OpenDocument. Last accessed 14 Feb 2013.
 Unknown. (2012). List of welding codes. Available:
http://en.wikipedia.org/wiki/List_of_welding_codes. Last accessed 1 MAR 2013.
 Unknown. (2006). Welding Defects. Available:
http://www.slideshare.net/djhelliweld/welding-defects#btnNext. Last accessed 12 MAR 2013.
67

CERTIFICATION
I’ am certify that D.S.Dissanayaka had been trained in Colombo dockyard PLC as an in plant trainee
since six month and this report is self-constitution. He had trained on following shops at Colombo
dockyard PLC.
1. Maintenance shop (Plant shop)
2. Hull treatment
3. Machinery out fitting Shop
4. Metal shop (Boiler Shop)
5. Ship Repair Division
6. Dock side
7. Engine Fitting Shop
8. Pump house
9. Quality Control Department
10. Calibration
Name : D.S Dissanayaka

NIC No. : 921572166v
Service No. : 7903131
Course : Diploma in Marine engineering
Field : Marine engineering
Institute : National Institute Of fisheries and Nautical Engineering
PERIOD : 20.01.2014 – 19.07.2014
Establishment : Colombo Dockyard PLC
………………………… ..……………………………..
Date Signature of Trainee
68
…..……………………. …………………………………
Date Signature of Training Engineer

(Colombo Dockyard PLC)
69

Final Report Colombo Dockyard PLC

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Report on Industrial Training at Colombo Dockyard PLC 7903131

In my Marine engineering diploma Program Last part is dedicated for non-academic

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Machinery out fitting shop

Metal shop (Boiler shop)

Ship repair division

Engine Fitting Shop

Quality Control Department

National Institute of Fisheries and Nautical Engineering | Ocean University

INTRODUCTION TO COLOMBO DOCKYARD

Colombo Dockyard Ltd.

National Institute of Fisheries and Nautical Engineering | Ocean University

1 213 23.9 8.8 30,000 25

2 107 16.3 5.8 9,000 25

3 117.5 15 5.2 8,000 10

4 263 42 7.5 125,000 50

CAPACITY OF DRY DOCKS AND CRANES

ALSO OPERATES 11 PIERS

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Ten Divisions are as follows

1. Human Resource & Administration

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1. Bonuses for all employees

Training and Development

Colombo dockyard safety policy

Colombo Dockyard PLC shall:

 Provide safe plant, machinery, equipment and systems of work;

National Institute of Fisheries and Nautical Engineering | Ocean University

 Enough oxygen to sustain combustion

Take a look at the following diagram, called the "Fire Triangle"

 Class A - Wood, paper, cloth, trash, plastics

National Institute of Fisheries and Nautical Engineering | Ocean University

Extinguishers: form, CO2

 Class C - Electrical: energized electrical equipment

 Class D - Metals: potassium, sodium, aluminium, magnesium

Safety notices in CDL

may change as below.

Forman, Supervisors Sky blue

Permanente employers Dark blue 9

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Trainees Dark red

Fire mans Red

Overall colour due to profession

Personal Protective Equipment’s

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National Institute of Fisheries and Nautical Engineering | Ocean University

National Institute of Fisheries and Nautical Engineering | Ocean University

Maintenance Shop (Plant Shop)

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Repair of a lathe machine

Pneumatic and hydraulic equipment repair

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Pump repair division

Overhauled a wilden double diaphragm pump

 Wilden pump is a operates under pneumatic

Advantage of above pump

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 Maintain should be continues

How wilden pump works

Chain block repair

There are 3 types of chain blocks and they are

1) electrically powered chain hoist

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