AMET UNIVERSITY

KANATHUR, CHENNAI-603112

INTERNSHIP TRAINING REPORT

TRAINING AT

HINDUSTAN SHIPYARD LTD.

(13 DAYS)

Submitted By,

K. Gowtham Satya Kumar (NA1079)

B.E-NAVAL ARCHITECTURE &OFFSHORE ENGINEERING AMET

UNIVERSITY, KANATHUR,

CHENNAI-603112
 ACKNOWLEDGEMENT

FIRSTLY, WE ARE WHOLE-HEARTEDLY THANKFUL TO THE

ALMIGHTY, FOR CREATING US AN OPPORTUNITY TO TAKE INDUSTRIAL
TRAINING AT HINDUSTAN SHIPYARD LIMITED, VISHAKAPATNAM AND GIVING US
GOOD HEALTH CONDITIONS TO ATTEND TO OUR TRAINING AND FOR ASSIGNING
US EXPERTS TO SHARE THEIR KNOWLEDGE WITHUS.

SECONDLY, WE WOULD LIKE TO SHOW OUR GRATITUDE TO

K.V.SURYA RAO GARU, GENERAL MANAGER, HR DEPARTMENT FOR GIVING US
SUPPORT TO COME TO HINDUSTAN SHIPYARD LIMITED.

THIRDLY, WE WOULD LIKE TO SHOW GRATITUDE TO

Mr.G.PERUMAL, SENIOR MANAGERURAINING DEPATMENT FOR HIS
CONSTRUCTIVE _CO-OPERATION AND VALUABLE.

GUIDANCE THROUGHT THE TRAINING. WE ARE GRATEFUL TO

OUR GUIDES Mr. RAGHU, MANAGER OF HULL SHOP DEPARTMENT,

Mr. NAGESWARA RAO, DEPUTY GENERAL MANAGER OF PR6

FABRICATION DEPARTMENT, and Mr.R.RAJU, DEPUTY GENERAL
MANAGER,ERECATION DEPARTMENT FOR THEIR VALUABLE GUIDANCE AND

SUGGGESTON TO COMPLETE THIS REPORT SUCCESFULLY. WE

WOULD LIKE TO THANK ALL THOSE ENGINEERS AND SUPEERVISORS WHO HELP
US OUT OF INTENSIFYING OUR TECHNICAL KNOWLEDGE AND PROVIDE
SATISFYING SOLUTIONS TO OUR QUERIES.
.
INDEX

> INTRODUCTION

> DRAWING AND DESIGN OFFICE

> HULL OUTFIT

 CHAPTER-1
HINDUSTAN SHIPYARD LIMITED

INDIAN SHIP BUILDING INDUSTRY:

Indian Shipbuilding which was totally domestic till the late 1990's has become export
Oriented. ABG shipyard was the first to build and export a newsprint carrier for a Norwegian
client in the year 2000 and established India's competitiveness in building and delivering ships
adhering to international standards. There are five major shipyards owned by the Central Government.
HINDUSTAN SHIPYARD LIMITED (HSL) & COCHIN SHIPYARD LIMITED (CSL) are commercial
units. While the rest-GRSE, MAZAGAON DOCK LIMITED (MDL) & GOA SHIPYARD LIMITED
(GSL) are Defense yards where in 95% of the orders of which pertain to warships for the navy and patrol
vessels for Coastguard.

PROFILE OF HINDUSTAN SHIPYARD LIMITED:

HISTORICAL BACKGROUND:
HINDUSTAN SHIPYARD LIMITED, Visakhapatnam owes its existence to late Sri Walchand Hirachand
who as Chairman of the Scinda Steam Navigation Company Limited was responsible for the launching of
this venture. The site at Visakhapatnam which met the varied requirements to a very marked degree was
selected on the basis of the recommendations of M/s Alexander Gibb and partners consulting engineers,
UK. The foundation stone of the shipyard was laid by our former President Dr. Rajendra Prasad, on 21st
June, 1941.
THE INFRASTRUCTURE TO BUILD QUALITY SHIPS:
A wide range of vessels from conventional bulk carriers to general cargo and supply vessels, patrol
vessels to highly sophisticated drill ships were built at HSL aggregating to over one million Dwt for the
defense, Oil and other Maritime sectors. HSL's excellent infrastructure includes a modern covered
Building Dock supported by up-to-date steel working and outfitting facility.

THE SHIP REPAIRS:

The Hindustan Dry Dock is an important adjunct to the shipyard for undertaking repairs of ships. It is
capable of handling vessels up to 70,000 DWT. Hindustan Dry Dock, the biggest and modern dock in the
East Coast, has accomplished intricate repair jobs on a variety of sophisticated Naval Ships including
submarines, Merchant ships and oilrigs/ships. Foreign and Indian Flag ships totaling over 1350 no's have
undergone hull and engine repairs.

2. THEORGANISATION
Hindustan Shipyard Ltd. A public sector undertaking under the administrative control of ministry of
shipyard Govt. of India.
SHIP BUILDING DIVISION:
 Capacity to construct vessels up to 50,000tonnesDWT.
 Two slipways [164*24] have capacity for construction of vessels up to 30,000tonnesDWT.
 One slip[140*22.7]for small crafts
 Building Dock [247*53*11.25M] has capacity up to 50,000tonnesDWT.
SHIP REPAIR DIVISION:
It has the following facilities
 Wet basin has the capacity to accommodate vessels for repairs while it's afloat
 HSL's ship repair department has accomplished maintenance & repair jobs on variety of
naval vessels including submarines, merchant ships and oilrigs.
RETOFIT DIVISION:
 An exclusive division was added in 1995 to undertake medium of submarines.
OFFSHORE PLATFORM DIVISION:
It has been engaged in the construction of platform, jackets and other related structures. It has well
established and experienced production organization with adequate facilities and is supported by
necessary expertise divisions of planning, purchase and production.

3. SHIP BUILDINGMETHODOLOGY
The construction activities of the ship fall into categories namely, steel complex and outfit complex. The
major activities of the steel complex are processing of steel plates assembly of plates and elements into
fully welded panels, erection alignments and full welding of these panels on building berths as complete
hull. Ventilation, electrical, communication system, accommodation works, works surveys, tests and trails
of equipment dock trails, sea trails and delivery to the owners. After the design and drawing are
completed, ship's hull form is screwed on the mould loft wooden floor to the full scale development of
critical shapes are done. Wooden templates and markups are made to full size to process the elements of
the ship's hull. The elements proceeded in the hull processing shop and assembly units inspected for the
workmanship of the steel complex, dimensional accuracy by the quality control on the steel complex and
presented to the classification society surveyor for inspection because they dispatched to brick storage
area or berth for assembly erection.

The pre fabrication units (called panels/block) are transported to storage area/berth from the assembly
shop by 100 ton & 150 ton capacity self-elevating & propelling low bed trailers on trestles. They can load
and unload themselves without the help of any cranes. Thus the fabrication panels can be transported
without much difficulty. HSL has 3 building berths/slipways for construction of ships up to maximum
30,000 DWT. These berths re served by 5 no's of heavy duty cranes of 35T to 100T.After the assembly
and inspection, the ships outside hull portion is painted as per the approved painting scheme.
 DRAWING
&
DESIGN OFFICE
Our stay at the design department was constructive one week of our internship. We had the privilege to work
with the brains behind the functioning of the shipyard. We were taught about the various design levels and how
each of them worked in coordination with each other and the production. For the ease of our learning were
divided into groups and visited the following departments -

 Machinery and Piping Design Department

 Basic Design Department

 Electrical Design Department

 Hull Department

Machinery & Piping Design Department

It is one of the most important department related with design. Machinery is that part of the ship, which are
inserted on later stages after completing the basic hull parts and which are not the part of the hull. Machinery
department, according to shipyard capacity, is either design machinery part to be built in the shipyard or it
suggest to outsource the part according to requirement of the ship.
In Hindustan shipyard limited most of the machinery parts are outsourced by tendering process in which
complete detail of machinery is given according to requirement of the ship. The work of machinery department
is to arrange and locate the machinery part. Another work associated with the machinery department is that if
any problem comes in the machinery part of the ship which is designed by it, should be treated by the
department in effective way. HSL is also having the expert team of dealing with older machinery parts of the
ship which comes for the repair in the shipyard. To increase the life span of machinery parts of the ship, HSL
design department also suggest modifications in the same. Along with machinery builder guideline HSL
machinery design department also suggest the guidelines for its healthy operation and function. Different
machinery like pumps, generators etc. are designed according to its requirement. In HSL design department
calculations are done to calculate the machinery capacity. For example to calculate the capacity for main engine
generator, speed and resistance are taken into consideration.
Layout of machinery in engine room; layout of steering gear; layout of anchor gear, pumps etc., then preparation
of technical specification for main engine auxiliaries, propellers and shafting; diesel alternators and its
auxiliaries; steering gear engine; windlass, mooring winch, deck cranes etc., evaluation of tenders and
preparation of comparative statement of various offers to a common base and finalization of technical offers,
preparation of necessary working drawing as per manufacture plans.
Piping
Layout piping system wise i.e. fuel oil supply system, fabrication oil system, cooling system etc.,; layout of
piping for all auxiliaries in the engine room i.e. bilge system, ballast water system, firefighting system etc. , and
their respective working drawing are done.
Finally the cost estimation for machinery, piping and other equipment is done.

Basic Design Department

Basic design deals with the hull form design i.e. outer watertight envelop of the ship. This is done thorough the
different types of lines plan of the ship. Through the plans shapes as well as dimensions are drawn. Basic design
department of the shipyard prepare the design drawings. These design drawings are key to hull design.

Lines Plan
The lines plan (lines drawing) consist of projections of the intersection of the hull with a series of planes. The
planes are equally spaced in each of the three dimensions. These set of planes are mutually perpendicular or
orthogonal in nature. The point of intersection of these planes with the hull results in a series of lines that are
projected onto a single plane located on the front, top, or side of the ship. This results in three separate
projections, or views, called the Body Plan, the Half-Breadth Plan, and the Sheer Plan.

Each station plane will intersect the ship's hull and form a curved line at the points of intersection.
These lines are called sectional lines and are all projected onto a single plane called the Body Plan.
The bottom of the box is a reference plane called the base plane. The base plane is usually level with the keel. A
series of planes parallel and above the base plan are imagined at regular intervals, usually at every meter. Each
plane will intersect the ship's hull and form a line at the points of intersection. These lines are called waterlines
and are all projected onto a single plane called the Half-Breadth Plan.

A plane that runs from bow to stern directly through the center of the ship and parallel to the sides of the
imaginary box is called the centerline plane. A series of planes parallel to one side of the centerline plane are
imagined at regular intervals from the centerline. Each plane will intersect the ship's hull and form a curved line
at the points of intersection. These lines are called buttock or butt lines and are projected onto a single plane
called the Sheer Plan.

In Hindustan shipyard limited most of designs are prepared on software like Maxsurf and Tribon.
Basic ship data are provided and shape along with its hydrostatic detail comes automatically HSL is having
properly trained staff who are expert in design and run the software smoothly.

Electrical Design Department

The department consists of the following –

1.) Electrical Design Office
Preparation of layout of electrical, electronic, navigational installation, preparation of layout of
communicational system, layout of cable routing to various parts of the ship. The electrical part of machinery
and equipment are dealt by this office and given their comments to machinery division.
2.) Electrical Design (materials)
They deal with the preparation of specification for all electrical, electronic and navigational equipment, to be
sent to purchase department for procurement action. Then the evaluation of tenders and preparation of
comparative statements of various offers to a common base, finalization of technical offers.

Hull Design Department

1) Working Design Steel

Class drawing are 1st done in this department using the lines plan provided by basic design office.
These drawing include mainly the midship section, and some sectional drawing at limited frames, shell
expansion etc… which are sent to the classification society for approval.
After approval of class drawing is done working and production drawing are made which includes all the three
views with structural members (girder, frame, stringer, longitudinal etc…).
These spacing for all the mentioned structural members and their respective scantling calculation are done in
compliance with the class rule.
2) Mini Loft Drawing Office
The working which are obtain from WDS are taken and surface modeling and nesting is to be handled in this
sector.
Nesting tapes are prepared and provided to the CNC machines and the PMC of plate, bracket etc… are provided.
Production documentation is also given which includes the numbering of different parts i.e. the parts list is
made.
SHIPS
A ship is in any way a structure of metal, usually steel or wood that will float in water and carry a load from one
place to another i.e. large sea going vessel, suitable for deep water navigation.

TYPES OF SHIPS
General cargo ships, bulk carriers, containers, oil tankers, ships, floating docks ,drill ships, tugs, dredgers
,pontoons, cattle ships, Borges ,submarines, warships, patrolling vessels, oil pollution control vessel, oil
recovery vessel etc.

Three Liner Motions

 Surge(x axis), Lengthwise:
Propulsion and drag act along this axis Surfing is an example of surge caused by a wave.
 Sway(y axis), Sideways:
Generally a minor movement in a large vessel caused due to waves and wind loads
 Heave (z axis), Up and Down:
The wave motion causing the whole ship to rise and fall

Three Rotational Motions

 Roll (Around x):
It is caused by waves, wind and can be induced by yaw.
 Pitch (Around y):
It is a rocking motion between bow and stern of the ship. It is mostly wave induced.
 Yaw (Around z):
Rudder corrections for course keeping illustrate that wind and waves can cause yawing motions.
 HULL OUTFIT

BLACK SMITH DEPARTMENT:

a. TO fabricate and to install the outfit items in a ship i.e. water tight, weather tight and non-water tight steel
doors; steel ladders; access hatch covers; stair case ladders; ventilators; outfitting of masts, derrick post; sky
light; gang way; fixing of windows, side scuttles.
b. To make forged items for ships.
c. To install and operate weather deck hatch covers and second deck hatch covers.
d. To cut flanges required for the pipes and blanks.
e. Fixing of windows and side scuttles.

JOINERS AND CARPENTRY:

a. Fabrication and installation of wooden furniture and fittings in accommodation spaces; wooden racks where
ever-necessary, wooden gratings; wooden battens; sparring (cargo batten) in the holds; tank top ceiling, wooden
sheathing on decks.
b. Processing of wooden logs to the required sizes
c. Polishing of wooden items.
d. Upholstering wherever required.

SHEET METAL:
a. Fabrication of trunks for ventilation to the spaces such as engine room, cargo holds, stores, accommodation
spaces etc; Gauge work or sheet work (steel plates of 4mm or less).
b. Erection of trunks on board the ship and make them air tight.
c. Testing of ventilation trunks.
d. Air conditioning conduits in accommodation spaces.
e. Erection of metallic furniture such as lockers, dresses in galley and pantries, fittings in toilets and stores and
other places.
f. Record of air quantities area wise / compartment wise.

To preserve the plates they are painted

a. Preservation of hull structure with primers during the construction and until the surveys and pressure testing
of hull are completed.
b. Then the application of painting scheme agreed between ship owner and ship builder. The painting
department is also responsible for surface finish before the application of painting scheme.

STEEL OUT-FIT:
This department was formed in 1984 or so to take out the load from the erection department to facilitate the
progress of outfit works so that erection department can fully concentrate on the hull of a ship. Erection
alignment and welding of foundations/seats for auxiliary machineries and other equipment’s and get them
surveyed by the classification societies before the erection of machinery and equipment.

DESCRIPTION OF STEEL COMPLEX

In Hindustan Shipyard Ltd steel plates are manufactured into panels for building a ship. These panels are
prepared in prefabrication chamber by welding elemental sections together that are being processed in hull
shop where in turn steel plates and sections are processed in hull shop that are being brought from steel stock
yard where all steel plates are being stored.
In general steel complex is divided into 3 main sections. They are listed as below:
1. STEEL STOCKYARD
2. SHOP
3. PREFABRICATION CHAMBER
In steel stock yard the steel plates and sections are stored in the form of stocks or plates which further are
taken to hull shop and prefabrication chamber for the preparation of ship panels.

TESTS AND TRIALS

During the period from launching to deliver the main engine, and its auxiliaries and all other auxiliaries in
engine room are erected on the foundations or stools, tested and commissioned. Then the dock trials will be
conducted.

DOCK TRIALS: Dock trials require the erection, alignment, bolting to foundations, testing and
commissioning of auxiliaries such as pumps, heaters, purifiers, compressors etc. which are required for
commissioning of main engine after erection of main engine, alignment and fixing of main engine with
holding down bolts with mild steel chocks or chock fast on the tank top of double bottom. Dock trails
are mainly to commission the main engine and retesting of its performance.

SEA TRIALS: The windlass, mooring winch, deck cranes and other miscellaneous deck M/C
are to be erected, aligned and bolted to the foundations. All other equipment such as lifesaving
appliances fire-fighting appliances, navigational equipment are to be in position before sea trial.
Then the ship goes for sea trials with surveyors of classification society, M.M.D., service
engineers of machinery and equipment, ship owner’s representatives including officers. The
performance of machinery and equipment are recorded and compared with assured performance
of suppliers of machinery and equipment. The sea trials include the following:

1. Compass adjustment
2. Adjustments on main engine and then

3. Endurance test of the main engine i.e. two hours on light diesel oil, 3hours on heavy fuel oil,
1hour on light diesel oil.

4. Running of main engine without efficient booster

5. Running of main engine at max. Attainable r.p.m.

6. Turbo charger washing.

7. Crank web deflections.

8. Speed trials at 50% and 100% powers.

9. Turning Circle at 50% and 100% powers.

10. Z – maneuvering.

11. Course keeping test.

12. Crash stop ahead to astern.

13. Astern running.

14. Crash stop astern to ahead.

15. Dead slow.

16. Anchor trials.

17. Emergency hand steering.

18. Steering gear trials.

19. Local hull vibrations.

20. Noise levels.

21. Adequacy of single generator to meet sea load.

22. Emergency generator operation, vibration measurements, local hull vibrations, torsional and
axial vibration measurements.

23. Donkey boiler.

24. Exhaust gas boiler.

25. Navigational aids.

 26. Engine room temperature checks.
FOLLOWING CERTIFICATES ARE REQUIRED TO BE FURNISHED UPON DELIVERY OF
THE SHIP:
1. Classification society certificate for hull and machinery.

2. ILLC (International Load Line Committee) certificate.

3. Trim and Stability certificate

4. IOPP (International Oil Pollution Prevention) certificate

5. Tonnage measurement certificate

6. Safety equipment certificate

7. FFA (Fire Fighting Appliances) certificate

8. Builders certificate

9. Compass adjustment and deviation table

10. Radio telegraphic certificate

11. DE ratification certificate

12. Dead weight certificate

13. Wind lass, mooring winch and steering arrangement

14. Anchors, anchor cables, anchor shackles, joining shackles, mooring ropes, tug line

15. Cargo gear and derrick test certificate

16. Grain loading and stability particulars

 CONCLUSION
This industrial training at Hindustan Shipyard has helped us gain a vast amount of practical knowledge and the
real difficulties associated in the shipbuilding. We as the students of Naval Architecture & Offshore Engineering
believe that this training experience will help us in building a successful career. We are very thankful to the
training department and all the engineers in the shipyard who guided us for the past two months.

We the students of NAVAL ARCHITECTURE AND OFFSHORE ENGINEERING of AMET UNIVERSITY

had trained for a period of 13 days in the HINDUSTAN SHIPYARD LTD with a great encouragement and
worthful knowledge of work and systematic process in constructing a ship to the builder’s satisfaction.