ILLUSTRATION OF A PRLIMARY MARINE WORKSHOP FOR SUDAN SHIPPING LINE -: A- SMALL LATHE MACHINE ---------------------------------------------The Lathe M/C to carry

small jobs of turning , boring ,chamfering ,cutting ,threading .and surfacing at high accuracy The need for this machine is to make all engine machined spare parts or most of to To a very wide extend .Although many spares need no stress or rigidity tests for parts at plausible estimated load locations . More than 60% of machined ordered spares from manufacturers can easily be machined by this lathe M/C saving .a remarkable budget -:Examples Pumps shafts Bolts Spindles Flanges Plugs Washers Links Brass Bushes Conical rings Valves guides Hatch Cleats The benefit of this machine will be measured after a period ,one year , at least where . a full scope of possible locally machined items can be assorted and spotted The need of a high skill labouring beside material lab and drawing office are essential . Accuarcy of machined items can be attained after some experience and tests -: Specifications Perferable to bring a metric system M/C because all spares and units used in our Ships are based on the metric system units although conversion on the M/C have to .be applicable Lathe M/C --------------Distance between centres = 1000 mm min Height of centre from bed = 280 mm Height of centre from carriage = 125 mm Width of gap = 140 mm Spindle bore = 80 mm Width of bed = 260 mm Speed = up to 800 rpm ( Lead screw threads (mm) = 6mm ( 4 threads per inch for English M/C ( Metric pitches = 40 (from o.4 to 10 ( Inches pitches = 40 ( from 60 to 2.5 per inch Convertable gear 127 t( perferable than 51 or 63 t) and gear rang 20 to 150 t -

Electric Power (Elec. Motor ------------------ -------------A/C supply up to 10 HP Overload relay phase 3 V 440 HZ 50 to 1800 r/m 1400 -: Accessories -----------------Longitudinal and cross feed stop Taper turning attachement Grinding attachement way tool post-4 Self centring chuck with flange jaw independent chuck -4 -: Face Plate ---------------A face plate with clamps for holding work unaccessible at chucks Compound Slide --------------------For taper cutting i:e angle adjustement carried at tool . With indicating sleeve For longitudinal and cross movement -:Reversing Lever ----------------------For lead- screw to bring the tool to start in threading operation ( designs like ( Dialing ,marking not preferedb due complications and less accuracy

-: B SHAPING M/C ------------------------Small shaping M/C for jobs of flat surfaces at different levels and angles like . Frames ,shaped bars , angles and any part of irregular dimensions One machine will cover the needed range of ships repairs and needs at first .stage

-: Specifications --------------------Length of stroke = 500 mm Table (WxL ) = 500 x460 mm Horizontal slide travel = 550 mm Vertical Slide travel = 400 mm Tool box vertical adjust = 200 mm speed 6- 160 cycle /min Tool box of a swinging clapper box for vertical and angular cuts -: Electric Motor -------------------to 5 Kw 4 to 1500 r/m 1000 HZ 50 Tools -----------------( Same turning tools ordered for the lathe M/C ( codes 544.0 Issa Specified with robust bits and clearance angle 10 inch-12inch i:e items 544.05 , 544.15 ,544.8 ,544.2 C- DRILLING M/C ----------------------------A medium up- right drilling M/C which is needed to make holes covering .Jobs of different flanges for valves ,pipes ,bolted items and covers -: Specifications ------------Steel drilling capacity = 30 to 35 mm ( Table ( removable , stops and automatic feeds Quill stroke = 120 mm longitudinal travel of table =380 mm Cross table travel =150 mm Head stroke vertical travel = 370 mm -:Electric Motor ----------------Reversable Phase 3 V 440 HZ 50 HP 12 to 2000 rpm 1000 -

-: ( Tools ( Issa code ------------------------Drill sleeves 044 2 more taper shank drill sockets according to the M/C shank size 2 set high speed steel straight shank RH cutting 002.02 1 - pcs straight long drill ( 003.19 -003.24-003.29-001.33 -001.3 7 ( 001.24- 001.28 Drill gauge Morse taper drills ( 004.08- 004.14-004.15-004.17-004.21-004.25 (004.27-004.33 (Straight hand reamers ( 007.05 007.07-007.09-007.11-007.15 -( Morse taper reamers ( 008.17-008.15-008.19-008.21-008.23-008.08 Flat drills for boring before twist -

D- FORGING OPERATIONS -------------------------------------: For small jobs , 5o kg max , of shaping which includes Bended bars Pipes Bars of different shapes Hydraulic pipes Hinges Rails Cargo holds pattern holders This phase covers a remarkable quantity of items of simple manufacter . can easily be prepared at the workshop and save remarkable budget These items are in range of not precise accurate dimensions +/- 3mm . Heating can be by use of gas procedure since all this phase jobs are small -:(Tools ( Issa code ---------------------(vices (490.02-490.04 2 Anvils 40-30 kg 2 Double face sledge hammer 5kg &7 kg 2 Smith hammers 1.5kg &2 kg 2 Hot chisel 1 (Hardie (Anvil fit 1 Cold Chisel 1 (Set Fuller ( top and bottom-Anvil fit 1 (Set swages (Diff. Dim each of 2 top and bottom-Anvil fit 1 Pc sweage block 1Pc flatter 1 Set round punchers 4-20mm 1 Set square punchers 4-20 mm 1 -

Set each of open mouth ,round mouth tongs 1 (Pc tube bender with set of formers ,guide capacity of 40mm(280.02 1 Pc tube bender with set of formers guide capacity 80 mm 1 E- RIVITING ---------------------Riviying jobs are very few and simple ,includes only brakes lining .assemblies , zinc covers of Engine room ceilings , other carpentering jobs -: Tools ------------Rriveters 2 (Alumnium rivets(1.4 mm to 3.0 mm Issa code 336 (Steel rivets (1.8mm to 2.6mm F- MARKING TOOLS AND APPLIANCES --------------------------------------------------------( Marking out table ( an essential part Plate angle : for supporting a surface at right angles to the surface of the table modern type is the adjustable angle plate (Vee blocks (made in pairs supports shafts and soft jobs Dial indicator (Parallel strips ( several sets of strips of varing widths ( Tool making clamps ( two to three pairs Spirit level (Dividers and trammels (2 each of diff. Sizes (Calipers (one odd leg +2 others (feeler gauge (2 diff. Sizes (Copper sulphate solution ( for clear marking and surface cleaning -: G- MEDIUM SIZE LATHE MACHINE --------------------------------------------------------Medium size lathe M/C of Height of centres from bed = 600 mm Distance between centres = 2000 mm Width of gap = 500 mm Other specifications same as the small one This M/C for large rough jobs like exhaust valves spindles and seats of Main ..Engine , adjustement of moulded items like pumps casings ,cages etc E- BIG SIZE LATHE M/C -------------------------------------Accumlating big items , like coolers casings , shafts of big lengths , cylinder ...Covers and M.e exhaust valves casings etc Not advised at this stage of establishment

-:N SPECIAL LATHE M/Cs -------------------------------------------Machines with certain facilities like automation ,or for certain jobs like Connecting rods machining or cranks machining to be advised in future and . Not at this stage for low jobs requirements now -: M- ATTACHMENTS ------------------------------------Store for tools and equipment ( Inventory books ( can use the working ships books Records of carried jobs and remarks .Availabilty of books , drawings needs .Safety fire extiguishers -:L- SAFETY ------------------------A record to be used for the registering accidents and an analysis to show types , causes ,remedies . Accidents to be statistically analysised to reach origin whether in range of control by construction or personnel awareness labours must examined properly and trained to be capable of safety as well as skillness even in works uniforms Clear instructions to follow check lists and forms which confirm safety like secure of rotating parts attention and driving plate cleaning , exact . clamping of works , moving belts

Prepared By Eng. Tagelsir Bakri Idriss Ass. D.G and technical manager Jan.2000