HALONG SHIPYARD QUALITY STANDARD BOOK 1

VIET NAM SHIPBUILDING INDUSTRY COrPORATION HA LONG SHIPBUILDING COMPANY

HA LONG SHIPBUILDING COMPANY

QUALITY STANDARD BOOK 1

H¹ LONG 2006 -0-

HALONG SHIP BUILDING Co.

preface

This HLSQS describes the quality standards and the inspection practice which are applied during repair and building ship process in HA LONG SHIPBUILDING Co.

This document is intended to provide standard instructions to Ship Owners, Class Surveyors, QC, inspectors, and the production workers, aiming that proper quality level is maintained during repair and building ship process and eliminating any possible, disputes among them.

The contents of this documents are applied for all kinds of cargo ships, barges, drilling rigs & special purpose etc. unless additional requirement are specified in the contract specifications.

-1-


* * contents * *

* * contents * * Part i:

quality standard …………………………… 1 1. hull construction 2. hull out fittings 3. machinery & out fittings 4. piping system 5. painting part 6. electric part

part II: inspection practice …………………………… 155 1. hull inspection 2. out fittings inspection 3. machinery inspection 4. piping inspection 5. electric inspection 6. painting inspection 7. list of inspection/test

part III

N.D.E technique...................................................... 210

part IV

appendix – I .............................................................. 225

part V

appendix - II ............................................................ 256 -2-


part I

quality standard

-3-

Halong shipbuilding co.


Section 1

Hull construction

1.1 material ........................................................................................... 5 1.2 gas cutting ..................................................................................... 7 1.3 fabrication..................................................................................... 9 1.4 deformation................................................................................... 12 1.5 accuracy of hull form ........................................................... 15 1.6 welding ............................................................................................. 17 1.7 alignment & finishing............................................................... 20 1.8 welding technique ..................................................................... 30

-4-


section I

Hull construction

* shipbuilding & repair

1.1 Material 1.1.1 Surface flaw 1) Pit Item

Remarks 1. Grade A: Repair is unnecessary 2. Grade B: 1) Outer surface of shell plates. To be repaired by grinding if necessary. When painting with epoxy can not be done, grinding is to be carried out. 2) Others: Repair unnecessary. 3. Grade C: To be repaired by grinding 4. Grade D: Repair method is to be determined after discussion with owner and class. * Recommended repair method: Grinding followed by welding. Area ratio (%) =

Area of pit x100 Total area of a plate

2) Flaking: Item

Remarks 1. Grade A: Repair is unnecessary 2. Grade B: Repair if necessary. 3. Grade C: Repair is necessary * Repair method (d=depth of defects ) 1) d  0.07t (max 3mm)- Grinding 2) 0.07t < d  0.2t: Welding and grinding ( The welded area should be less than 2% of the total area of a plate ).

-5-


Section 1

Hull construction


3) Other defects Item

Remarks 1. Grade A: Repair is unnecessary. 2. Grade B: Repair is necessary. * Repair method (d=depth of defects ) 1) d  0.07t (max 3mm): Grinding. 2) 0.07t < d  0.2t: Welding and grinding. ( The welded area should be less than 2% of the total area of a plate ).

1.1.2) Lamination Item

Remarks

Local

In case where the range lamination is

lamination

limited, it can be chipped out and built up by welding as shown in ( a ). In case where the range of lamination is limited, also but is near the plate surface, it is preferable to make the built up welding as shown in ( b ).

Severe

It is recommended to renew the plate

lamination

locally, in case where the range of

requiring a local

lamination is fairly extensive.

renew of a plate

The standard minimum breadth of a plate to be renewed is as below. 1) Shell and strength deck under large constraint : 1600mm 2) Not under large constraint: 800mm 3) Other structural members: 300mm.

-6-


Hull construction

Section 1

* shipbuilding

1.2 Gas cutting. 1.2.1 Notches.

Unit: mm Standard range

Item Free edges

Tolerance limits

1) Upper edges of sheer strake. 2) Strength deck within 0.6L

Indentation  0.5

and free

edges of opening of shell plate. 3) Main longitudinal strength members. Indentation  1.0

Longitudinal and transverse strength members.

Indentation  3

Others Weld grooves

Butt welds

Indentation  2

Shell plate and upper deck within 0.6L

Indentation  3

Others

Indentation  3

Fillet welds

Section 1.

Hull construction

* ship repair

1.2.1 Notches for repair ship

Unit: mm

Standard rang

Item

Tolerance limits

1) Upper edges of sheer strake 2) Strength deck within 0.6L Free edges

and

free edges of opening of shell plate.

Indentation  1.0

3) Main longitudinal strength member. Longitudinal transverse strength

Indentation  1.5

Others

Indentation  3 Shell plate and upper deck

Weld grooves

Butt welds

within 0.6L

Indentation  2 Indentation  3

Others.

Indentation  3

Fillet welds

-7-


Section 1

Hull construction

* shipbuilding

1.2.2 Dimensions

Standard range

Item

Tolerance limits

L 3d Length of taper ( L)

Depth of grooves General members compared with correct Sizes of members

ones. Depth of floors and girders in double bottom Breadth of face bars

Section 1

 0.5d

 1.0d

 1.5

 2.0

 3.5

 5.0

 2.5

 4.0

 2.0

3.0~4.0

Hull construction

* ship repair

1.2.2 Dimension for repair ship.

Standard range

Item

Tolerance limits

L 3d Length of taper (L)

Depth of grooves

-8-

 0.5d

 0.1d

 2.0

 3.0


Section 1

Hull construction


1.3 Fabrication. 1.3.1 Flange longitudinals

Unit: mm

Standard range

Item Breadth of webs and flanges

Angle between flange and webs

Tolerance limits

 3.0

 5.0

 2.5

 4.5

 10

 25

 10

 25

Compared with template per 100mm in breadth of flanges

Curvature or straightness in the plane of flanges Per 10m in length Curvature of straightness in the plane of webs. Per 10m in length 1.3.2 Flange brackets.

Standard range

Item

Tolerance limits

Breadth of webs and

 3.0

 5.0

 3.0

 5.0

flanges Angle between flanges and webs

Compared with template per 100mm in breadth of flanges. -9-


Section 1

Hull construction

* shipbuilding

1.3.3 Built-up plate.

Unit: mm

Standard range

Item

Tolerance limits

Deviation of face plates Frames and

 1.5

 3.0 per

longitudinals

per 100mm

100mm

b 100

a  5

Distortion of face

a  3

plates

Section 1

Hull construction

b 100

* ship repair

1.3.3 Built – up plates for repair ship

Unit: mm

Standard range

Item

Tolerance limits

Deviation of face plates Fames and

 3.0 per

 5.0 per

longitudinals

100mm

100mm

Distortion of face

a  3 .5 

plates

- 10 -

b 100

a  6

b 100

Section 1


Hull construction


1.3.4 Line heating method

Standard range

Item Water cooing just after heating

* 50 HT

Air cooling after heating

Tolerance limits

Under 6500C

Under 9000C

* TMCP Type 50HT

Under 9000C

(Ceq>0.38%)

(Starting Air cooling and subsequent water

temperature of

cooling after heating

water cooling to be under 5000C)

* TMCY Type 50HT

Water cooling just after heating or

(Ceq 0.38%)

air cooling

Under 1000C

* AH~DH * TMCP Type 50HT

Water cooling just after heating or

(Ceq 0.38%)

air cooling.

Under 900oC

* EH 1.3.5. Line heat/ cool’ cycles.

Item TMCP Type 50HT (AH - DH) TMCP Type 50HT (EH)

Remark Within 3 cycles as far as practicable Within 2 cycles as far as practicable

Others

Not defined

- 11 -


Section 1

Hull construction

* shipbuilding

1.4 Deformation 1.4.1.Unfairness

Unit: mm

Standard Tolerance range limits

Item Shell plates

Parallel part ( side )

4

6

Standard and/or

Parallel part ( bottom )

4

6

tolerance limits

Fore and aft part

5

7

are to be applied

4

6

Double bottom tank top plates Transverse bulkheads, Swash

per each frame, longitudinal and stiffener space

Longitudinal bulkheads, Bulkheads

Remarks

6

8

respectiveily. Where above is

bulkheads. Parallel part within 0.6L

4

6

not applicable , it

Fore and aft part

6

9

is to be applied

Covered part

7

9

per 1.8m in

Bare part

6

8

length.

Covered part

7

9

Forecastle deck,

Bare part

4

6

Poop deck.

Covered part

7

9

Super structure

Bare part

4

6

deck

Covered part

7

9

Lift-able

10

12

Fixed

6

8

8

10

Outside walls

4

6

Inside walls

4

6

Covered part

7

9

Webs of girders, transverses

5

7

6

8

Strength deck

Second deck

Car deck Intermediate deck Deck house wall

Interior members

Floors and girders in double bottom

- 12 -

(Where above space is over 1.8m paragraph 1.4.2 is to be applied)


Section 1

Hull construction

* ship repair

1.4.1 Unfairness for repair ship


Item Shell plate

Parallel part side

4

6

Standard and/or

Parallel part bottom

4

6

tolerance limits

Fore and aft part

5

7

are to be applied

6

6

Double bottom tank top plates Bulkheads

Remarks

longitudinal and stiffener space

Longitudinal bulkheads transverse bulkheads, Swash

per each frame,

6

8

respectiveily. Where above is

bulkheads. Paralleled part with in 0.6L

4

6

not applicable , it

Fore and aft part

6

9

is to be applied

Covered part

7

9

per 1.8m in

Bare part

6

8

length.

Covered part

7

9

Forecastle deck,

Bare part

4

6

poop deck

Covered part

7

9

Super structure

Bare part

4

6

deck

Covered part

7

9

Car deck

10

12

Intermediate

8

10

Outside walls

4

6

Inside walls

4

6

Covered part

7

9

5

7

6

8

Strength deck

Second deck

Deck house wall

Interior member

Webs of girders, trans.

Floors and girders in double bottom

- 13 -

(Where above space is over 1.8m paragraph 1.4.2 is to be applied))


section I

Hull construction

1.4.2 Deformation per basic length

Unit: mm


Item Shell plates


Parallel part Fore and aft part

Decks, Double bottom tank tops

2L/1.000

3L/1.000

3L/1.000

4L/1.000

3L/1.000

4L/1.000

Remarks Deformation per basic length means the deformation measured between one transverse space.

Bulkheads

4L/1.000

5L/1.000

For cabin walls and

Cabin walls

2L/1.000

3L/1.000

curtain plates, the basic

Curtain plates

2L/1.000

3L/1.000

1.4.3 Distortion

Unit: mm

Distortion of girder and transverses at the

Per span

5

8

L 1000

5

8

part of upper edge and flange. Distortion of longitudinals,

1000
3

2L 1000

6

2L 1000

transverses, frames, beams and stiffener at

L 3500

10

13

5

8

1/2t

t ~

the part of flange . Distortion of H type pillars between decks Distortion of tripping brackets and small stiffeners.

length is about 5m.

Distortion at the part of free edges

- 14 -


Section 1

Hull construction


1.5 Accuracy of hull form 1.5.1 Principal dimension

Item

Standard range

Tolerance limits

L.B.P.

 50/100m

Not defined

Breadth ( Moulded )

 15

Not defined

Depth ( Moulded )

 10

Not defined

1.5.2 Deformation of hull form

Unit: mm

Item Flatness of keel

Deformation for the whole length

Standard range

Tolerance limits

 25

Not defined

 30

Not defined

 20

Not defined

 15

Not defined

Cocking-up

Rise of floor amid ships Rise of floor

1.5.3 Others Unit: mm

Item

Standard range

Tolerance limits

Draft marks

 1.0

 2.0

Free board marks

 0.5

 1.0

- 15 -

Section 1


Hull construction


1.5.4 Special sub-assembly Item

Standard Tolerance range

limits

Remarks

Distance between aft

Block sub-assembly stern frame

edge of boss and aft peak

Rudder

 10

5

10

4

8

bulkhead ( b). Twist of sub-assembly (c)

Deviation of rudder from shaft center line ( d )

Others

Other

main

Breadth and length of top plate of main engine bed Others

(C)Twist of plane including

Refer to the section of curved plate block 6

Twist of rudder plate

Flatness of top plate of Main engine bed

5

10

Correct or re-assemble partially

Refer to the section of the curved plate block subassembly

5

10

4

6

Refer to the section of the flat plate block sub-assembly

- 16 -


Section 1

Hull construction


1.6 Welding 1.6.1 Shape of bead Tolerance

Item

limits

Over-lap

Remarks 1.   90 0 : Repair



is unnecessary

Butt

2. In case   90 0 , grinding or welding   90 0

in necessary to make   90 0

 Fillet

Undercut

Skin

Butt

To be repaired by

plates

d 0.5

using fine electrode

and face

(over

( Avoid short beads

plates

90mm

for higher tensile

within

continuous) steel )

0.6L Others

d 0.8

Fillet

d 0.8

Leg length

L0: Design leg

and Throat

length

thickness

- 17 -

L

0.9L0

t0: Design throat

t

0.9t0

thickness


Hull construction

Section 1

* shipbuilding & Repair

1.6.2 Distortion of welding joints

Unit: mm Tolerance

Item

Remarks

limits

Angular

Skin plates within

distortion of

0.6L

weld joints

Fore and aft shell

In case where it is

6

over tolerance limits, it is to be

7

plating and

repaired by line

transverse strength

heating or re-

Span of frames or

member

welded after

beams

Others

cutting and

8

refitting 1.6.3 Short beads

Unit: mm Item

Tolerance limits 2

Higher tensile steel ( 50kg/mm class )

50

TMCP type 50HT (Ceq 0.36%)

10

Mild steel( including take and repair welding )

Remarks

Not defined

1.6.4 Arc strike

Unit: mm Item

Higher tensile steel ( 50kg/mm2

Tolerance limits Not allowed

Remarks In case where arc strike made

class ) and grade “ E “ of mild

erroneously, one of the following

steel.

repair methods is applied. 1) Weld over 50mm bead on the arc strike. 2) Remove the hardened zone by grinding.

1.6.5 Alternation case Item Short bead & Arc strike of Higher

Acceptable

Remarks

limits

In case of during repair, building up

10

tensile steel.

on surface after discussion with class & owner. 1) To be preheating at fault areas.

- 18 -

Section 1


Hull construction


1.6.6 Weld profile 1) Concave bead

Unit: Tolerance limits

Remarks

Unacceptable

L=min 0

2) Convex bead Max 1.6 L 8 Max 3.0 8 L 25 Max 4.5 25 L

3) Division of position

Machine

Manual welding Plat H 3.0mm

Vertical &

welding Overhead

horizontal H 4.0mm

H 4mm

H 4.5mm

4) Bead repair It the bead height is over the standard range which shows bad appearance, the bead will be repaired by grinding. - 19 -


Section 1

Hull construction


1.7 Alignment and finishing 1.7.1 Minimum distance of weld to adjacent weld

Unit: mm Tolerance

Item

limits

Remarks

a 30 Butt weld to butt weld

a 0

a 10

Butt

a 0

weld to filler weld

Smaller distance can be a 5

acceptable in special cases.

- 20 -


Section 1

Hull construction


1.7.2 Minimum distance between holes and between hole and end of member. Distance ( s)

Description

“A” Space

“B” Space

d1  d 2 2

d1+d2

Remarks

1) Between holes

2) Between hole and plate, and face d 2 S2  d (mi.n.75) S1 

S1=d S2=2d (min. 75)

3) Between hole and scallop d1  d 2 2 (min .50)

d+R (min. 50)

4) Between hole and slot

dB 2

s 200 (ABS) d+B

s 180 (LR) s D (NK)

5) Between slots s1 2B s2 2d and s2 2B

- 21 -


Hull construction

Section 1


1.7.3 Treatment of holes made erroneously. Tolerance

Item D<300

Skin plate

(D: diameter of holes ) Other d 300

Remarks

limits A*

Open the hole to over 100

Or B*


B*


or C*


Skin plate

B*

Others

B* or C*

Scallop, slot

B* or C*

* Method of treatment A: spigot patch 5

  400 0

B: Closing by butt welding with back gouging 5

  400 0 

C: Closing by lapping piece L 50 or L 2t1+25 Whichever is greater

- 22 -


Section 1

Hull construction

1.7.4 Gap of joints

* shipbuilding & repair Unit: mm

Item

Tolerance

Remarks

limits

1. Manual welding

1. 5
1) Welding with backing strip or flat type ceramic back material. 2) Welding at reverse side after chipping. 2. 16
1) Build-up edges with backing strip of a 5

flat type ceramic backing material to keep the gap less than 5mm ( make stringer beads )

Butt

2) Welding.

joints

3) Welding at reverse side after shipping 3. a>25

Repair method is to be determined after discussion with owner & class. Normally partial renew by min. size 300mm is applied. 2. Flexible asbestos

a>5

Backing ( F.A.B )

1) First or second pass by FCAW or a 5

GMAW as shown in 1.7.4 item 4. 2) The rest by automatic (SAW)

- 23 -


Section 1

Hull construction

1.7.4 Gap of joints


Unit: mm Item

Tolerance

Remarks

limits

3. Submerged Arc welding

1. 0.8
(S.A.W)

2. a>5: Refitting

a 8

4. F.C.A.W and G.M.A.W

1. 12< a 25

Butt

1) Build-up on edges with backing

joints

strip of flat type ceramic backing material to keep the gap within 12mm ( to make stringer beads.) Build-up on the edges should not a 12

exceed 1/2t1 . nor 12.5mm whichever is smaller. 2) Welding. 2. a>25

Repair method is to be determined after discussion with owner & class. Normally partial renew by min. size of 300mm is applied. - 24 -


Section 1

Hull construction

1.7.4 Gap of joints


Unit: mm Tolerance

Item

Remarks

limits

1. Filler joints without

1. 3< a 5

groove

Leg length to be increased: L=L0+(a-3) (L: increased leg length) (L0: Leg length indicated on drawing ) 2. 5< a 16 Welding with bevel preparation

t1

t2 a 3 (1) To make bevel edge of web to 300~450 (2) To attach backing strip or ceramic

Fillet

backing material.

Joints

(3) Welding. (4) To weld at reverse side after chipping. 3. 16< a 25 1) Bevel preparation (300~450) 2) Build-up of each plate edge should not exceed 1/2t1 nor 12.5mm whichever is smaller. Gap after build-up should not exceed 5mm. 4. a>25 Partial renew with a size of min. 300mm

- 25 -


Section 1

Hull construction

1.7.4 Gap of joints


Unit: mm Item

Tolerance

Remarks

limits

2. Fillet joints with

1. 5< a 16

groove

1) To attach backing strip or ceramic backing material. 2) Welding 3) To weld at reverse side after chipping. Fillet joints

a 5

2. 16< a 25 Build-up of base plate

Gap after build-up should not exceed 5mm. 3. Partial renew with a size of min. 300mm. a 3

1. 3< a 5 Leg length shall be increased by the amount of gap ( indicated leg length gap )

Lap

2. a>5

joints

Refitting.

- 26 -


Section 1

Hull construction


1.7.5 Alignment Item Butt joints

Tolerance limits Strength

a 0.15t1,

a>0.15t1, or a>3

members

(max.3)

Refitting

a 0.2t1

a>0.2t1, or a>3

(max.3)

Refitting

Others a: Difference t1 t2 Fillet joints

Strength

a 1/3t

members

1. 1/3t1
For “A” & “B”, increase leg length by 10%t1. a: Difference

2. a>1/2t1: Refitting

t1

* For members having small breadth ( i.e.

t2

face plate of built-up member ), doublers or carling can be attached after discussion with owner & class. Others

a 1/2t1

a>1/2t1 Refitting

- 27 -


Section 1

Hull construction


1.7.5 Alignment Item

Tolerance

Remarks

Flange width s 0.04b

If s 0.08b

max. 8mm

Grind corners to smooth. Taper over

Alignment of butt

distance min.

joints in stiffeners

L=30s If s>0.08b release and adjust over distance min. L=50s

Overlap brackets, gap before manual welding

For weld

If s 5mm

throat

Parts may be pulled

thickness

together and welded

a 4mm

If s>5mm

Gap s 2mm

Release and adjust

for a>4mm s 3mm

- 28 -


Section 1

Hull construction


1.7.5 Alignment Item Openings for

Tolerance

1. Position of nearest scallop

Remarks If d>75mm

stiffeners passing

The nib between scallop

through girder webs

and opening to be cut, and lug to be welded to d 75mm

2. Gap

plating, see figure

s 5mm. Weld throat thickness to be increased by one weld bead or 2mm. If 5
Chamfer and build up by welding. If s>10mm. Cut off nib and fit lug of same height as nib.

s 3mm

Sufficient for weld access.

- 29 -


Section 1

Hull construction


1.8 Welding technique 1.8.1 Welding sequence 1. Welding sequence is to be carefully planned for each structural member. So that the parts can be jointed freely without any deformation or residual stress after welding. 2. Welding sequence for each part actually have some varieties depending upon the surrounding circumstances, but in principle, the following sequences are to be kept at every welding stages. 1) Welding is proceeded symmetrically from center of joint both sides. E. G. incase of erection joint. Welding should be done from a mid-ship to stem or stern and from center line of the ship to the direction of side shell. 2) The part where the deformation or residual stress is anticipated to be welded first, and then others to be done secondly. 3. Welding sequence is generally adopted from be assembly stage. 1) Welding of panel.

2) Butt joints are welded prior to welding of seam line.

- 30 -


Section 1

Hull construction


2) Welding of profiles on panel

Note that a release length of 100mm is provided in the horizontal seams at each corner of the insert plate. 1. Weld framing to within 100mm of un-welded butts and seams. 2. Weld vertical butt

complete

3. Weld vertical butt

complete

4. Weld un-welded framing in way of vertical butts 5. Weld horizontal seam

including release lengths

6. Weld horizontal seam

including release lengths

7. Weld un-welded framing in way of horizontal seams

- 31 -


Section 1

Hull construction

3) Welding of insert

- 32 -



Section 1

Hull construction

4) Penetration parts

- 33 -



Section 1

Hull construction


1.8.2 Slot welding Symbol

Application for thickness

Kind of plate All

t 50.5

w=t t+8 2.25w t<16.0

L<10.0w

Details of weld joints

p>2L

w t/2 vµ w 16 t+8 2.25w t 16.0

L<10.0w p>2L

Beveled angle

Position welding

Application of member

00

All

All

- 34 -


Section 1

Hull construction

1.8.3 Bilge keel joint weld Welding detail ( For all type )

- 35 -



Section 1

Hull construction


1.8.4 Stern frame structure 1) Thicker material ( build-up )

Joint Details of Cast Steel Stern Frame 2) Butt joints

Details of butt joints of steel castings/ Forgings and steel plates 3)Lap joints

Details of Lap joints of steel Casting/ Forging and Steel plates

- 36 -


Section 1

Hull construction


1.8.5 Butt welding on permanent backing - In case where it is method are to be applied, after discussion & approved with class and owner.

Unit: mm Item

Tolerance limits

t 8

3–5

8
5–8

20

t<20

8 – 10

- 37 -

Remarks * Size of backing plates - Normal: 6 - 10

Section 1


Hull construction


1.8.6 Pre-heating of before welding 1) Environment Proper precaution are to be taken to insure that all welding is done under condition where the welding site is protected against the deleterious effects of moisture, wind and severe cold. 2) Method The use of preheat control are to be considered when higher strength steels, thicker cross section and subject to high restraint. - Range of heating areas: Min.75mm from weld points. - Heating direction: all direction

Item

Control of heat

Which is heat temp’

temp’

Mild steel

-50C

Min 160C

H.T steel

00 C

Min 160C Min 500C

Remarks

- Thicker plate - Restaint structure

TMCP type

-50C

0

Min 20 C

(Ceq 0.36)

- 38 -


Section 1

Hull construction

* modification

1.8.7 Bulb plate modification method Existing

L2 Type

* C=15 mm L3 type

* C=15 mm

Joint detail ( L3 type ) Looking down

- 39 -

xcx


Hull construction

Section 1

* modification

* Size comparative sheet ID.N

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

HT

Bulb plate B T

Area

HT

B

L3 Type T1 T2

A

HT

B

L2 Type T1 T2

A

(mm)

(mm)

(mm)

(Cm )

(mm)

(mm)

(mm)

(mm)

(Cm )

(mm)

(mm)

(mm)

(mm

(Cm2)

140 140 140 160 160 160 180 180 180 180 200 200 200 200 220 220 220 240 240 240 260 260 260 280 280 280 300 300 300 300 320 220 320 320 340 340 340 340 370 370 370 370 400 400 400 400 430 430 430 430

19.0 19.0 19.0 22.0 22.0 22.0 25.0 25.0 25.0 25.0 28.0 28.0 23.0 23.0 31.0 31.0 31.0 34.0 34.0 34.0 37.0 37.0 37.0 40.0 40.0 40.0 43.0 43.0 43.0 46.0 46.0 46.0 46.0 49.0 49.0 49.0 49.0 49.0 53.5 53.5 53.5 53.5 58.0 58.0 58.0 58.0 62.5 62.5 62.5 62.5

7 8 9 7 8 9 8 9 10 11 9 10 11 12 10 11 12 10 11 12 11 11 13 11 12 13 11 12 13 14 12 13 14 15 12 13 14 15 13 14 15 16 14 15 16 17 15 17 19 21

12.6 13.8 15.2 14.6 16.2 17.8 18.9 20.7 22.5 24.3 23.8 25.6 27.6 29.6 29.0 31.2 33.4 32.4 34.9 37.3 36.7 36.7 43.9 42.6 45.5 48.2 46.7 49.7 52.8 55.8 54.2 57.4 60.7 63.9 59.8 62.2 65.5 68.9 69.6 73.3 77.0 80.7 81.4 85.4 89.4 93.4 94.1 103.0 111.0 126.0

155 155 155 175 175 175 195 195 195 195 215 215 215 215 235 235 235 255 255 255 275 275 275 295 295 295 315 315 315 315 335 335 335 335 355 355 355 355 385 385 385 385 415 415 415 415 445 445 445 445

20 20 20 25 25 25 25 25 25 25 30 30 30 30 30 30 30 35 35 35 30 40 40 40 40 40 40 40 40 40 45 45 45 45 50 50 50 50 60 60 60 60 65 65 65 65 75 75 75 75

7 8 9 7 8 9 8 9 10 11 9 10 11 12 10 11 12 10 11 12 11 11 13 11 12 13 11 12 13 14 12 13 14 15 12 13 14 15 13 14 15 16 14 15 16 17 15 17 19 21

10 10 10 10 10 10 10 10 10 10 15 15 15 15 15 20 20 20 20 20 20 20 20 25 25 25 30 30 30 30 30 30 30 30 32 32 32 32 32 32 32 32 35 35 35 35 35 35 35 35

12.85 15.6 17.3 15.8 17.7 19.6 19.3 21.4 23.5 25.6 25.2 27.5 29.8 32.1 29.5 33.5 36 34 36.7 39.4 39.9 39.9 45.7 44.1 47.2 50.3 48.3 51.6 54.9 58.2 55.5 59 62.5 66 60.4 64.1 67.8 71.5 71.2 75.2 79.2 83.2 82.95 87.25 91.55 95.85 95.25 104.5 113.7 122.9

140 140 140 160 160 160 180 180 180 180 200 200 200 200 220 220 220 240 240 240 260 260 260 280 280 280 300 300 300 300 320 320 320 320 340 340 340 340 370 370 370 270 400 400 400 400 430 430 430 430

50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 62.0 62.0 70.0 75.0 75.0 75.0 80.0 80.0 85.0 85.0 85.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 95.0 95.0 95.0 95.0

7 8 9 7 8 9 8 9 10 11 9 10 11 12 10 11 12 10 11 12 11 11 13 11 12 13 11 12 13 14 12 13 14 15 12 13 14 15 13 14 15 16 14 15 16 17 15 17 19 21

) 10 10 10 10 10 10 10 10 10 10 12 12 12 12 12 12 12 15 15 15 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 25 25 25 25 30 30 30 30 35 35 35 35

14.1 15.4 16.7 15.5 17.0 18.5 18.6 20.3 22.0 23.7 22.9 24.8 26.7 28.3 28.0 30.1 32.2 32.5 33.8 36.0 38.4 38.4 43.2 41.9 48.6 47.8 45.8 48.6 51.4 55.2 52.0 56.0 59.0 62.0 56.4 59.6 62.8 66.0 67.4 70.8 74.3 77.7 78.8 82.5 86.2 89.9 92.5 100.4 108.3 116.2

2

- 40 -

2


Section 2

Hull outfitting

2.1 hatch cover ................................................................................. 42 2.2 hatch coaming ........................................................................... 50 2.3 small hatch .................................................................................. 52 2.4 air vent system .......................................................................... 53 2.5 steel inclined ladder……………………………………… 54 2.6 Steel vertical ladder............................................................ 54 2.7 Hand rail........................................................................................ 55 2.8 Storm rail ..................................................................................... 55 2.9 Guard rail ..................................................................................... 55 2.10 anchor chain ............................................................................... 56 2.11 Derrick boom ............................................................................... 58 2.12 derrick boom repair................................................................ 59 2.13 Deck covering ............................................................................. 60 2.14 insulation ..................................................................................... 63

- 41 -


Section 2

Hull outfitting

* h/c fabrication

2.1 Hatch cover

Unit: mm Item

Standard

Tolerance

range

limits

1) Hatch cover ( single pull type )

 (3 

4L ) 10,000

Length ( 1 hatch )

L

5

Length ( 1 panel )

W

3

Breadth

B

3

Height of hatch cover

h

3

4

5  (3 

4L ) 10,000

Diagonal difference ( hatch )

(L1-L2)

5

8

Diagonal difference (1 panel)

(L3-L4)

4

6

Vertical deflection

d1

3

4

Transverse deflection

d2

3

4

Deformation of top plate

d3

4

6

Height of packing gutter

d4

1

2


d5

1

2

Breadth of packing gutter

d6

- 42 -

1

2


Section 2

Hull outfitting

Item

* H/c fabrication

Standard

Tolerance

range

limits

3

5

Top plate clearance

d7

Top plate difference

(d8)

2

4

Side & end plate difference

(d9)

2

4

Width of packing groove

d10

1

2

Deviation of compression bar centering

d11

3



Compression of packing

d12

3

5

Span ( between centering )

d13

2

3

Installing height

d14

2

3

Installing pitch

d15

2

4

Installing pitch

d16

2

4

Balancing wheel height

d17

2

3

Balancing wheel distance

d18

2

4

Balancing wheel pitch

d19

2

4

- 43 -

t 2


Section 2

Hull outfitting

Item

* H/c fabrication

Standard

Tolerance

range

limits

2) Hatch cover ( side rolling type )

 (3 

4L ) 10,000

Length ( 1 hatch )

L

5

Length ( 1 panel )

W

4

Breadth

B

5


h

3

4

5  (3 

4L ) 10,000

Diagonal difference ( 1 hatch )

(L1-L2)

5

10

Diagonal difference ( 1 panel )

(L3-L4)

4

5

Vertical deflection

d1

3

4


d2

3

5


(d3)

3

4


D4

1

2


D5

1

2


D6

1

2

- 44 -


Section 2

Hull outfitting

Item

* H/c fabrication

Standard

Tolerance

range

limits

3

5

Top plate clearance

d7


(d8)

2

4

Sid & end plate difference

(d9)

2

4


d10

1

2


d11

3




d12

3

5


d13

2

3

Installing height

d14

2

3

Installing pitch

d15

2

3

Installing pitch

d16

2

3

- 45 -

t 2


Section 2

Hull outfitting

Item

* H/c fabrication

Standard

Tolerance

range

limits

3) Hatch cover ( folding type )

 (3 

4L ) 10,000

Length ( 1 hatch )

L

5

Length ( 1 panel )

W

3

Breadth

B

3


h

3

4

5  (3 

4L ) 10,000


(L1-L2)

5

10

Diagonal difference ( 1 panel )

(L3-L4)

4

5

Vertical deflection

d1

3

4


d2

3

5


d3

4

6


d4

1

2


d5

1

2


d6

1

2

- 46 -


Section 2

Hull outfitting

Item

* H/c fabrication

Standard

Tolerance

range

limits

3

5

Top plate clearance

d7


(d8)

2

4

Sid & end plate difference

(d9)

2

4


d10

1

2


d11

3




d12

2

3


d13

2

3

Height of wheel

d14

2

3

Distance of wheel & main hinge

d15

2

3

Distance of main hinge & inter hinge

d16

2

3

Distance of wheel & inter hinge

d17

2

3

Gap of main hinge & cylinder pin

d18

3

–

Height of main hinge & cylinder pin

d19

3

–

Height of main hinge

d20

2

3

Height of inter hinge

d21

2

3

- 47 -

t 2


Section 2

Hull outfitting

* H/c fabrication

Standard

Item

range

Tolerance limits

4) Hatch cover ( pontoon type )

Length ( 1 panel )

L

5

 (3 

4L ) 10,000

Breadth

B

5

 (3 

4L ) 10,000


h

3

4

5

10


(L1-L2)

Vertical deflection

d1

3

4

Diagonal difference

d2

3

5


d3

4

6


d4

1

2


d5

1

2


d6

1

2

- 48 -


Section 2

Hull outfitting

* H/c fabrication

Standard

Item

range

Tolerance limits

4)

Container cone level (20ft)

d7

Container cone level (40ft) Length ( container cone 20ft )

L3

Length ( container cone 40ft ) Breadth (container cone 20ft )

B1

Breadth (container cone 40ft ) Diagonal difference( 20ft )

(L4-L5)

Diagonal difference ( 40ft )

- 49 -

3

4

3

4

3

5

3

5

2

3

2

3

6

8

8

10


Section 2

*h/coaming fabrication

Hull outfitting

2.2 Hatch coming 2.2.1 Typical dimension Item

Standard

Tolerance

range

limits

Length

L

5

 10

Breadth

B

5

 10

Diagonal

(L1-L2)

Straightness of top plate ( side coaming )

d1

3

5

Straightness of top plate ( end coaming )

d2

4

5

Straightness of top plate ( partially/m )

d3

2

3

d4

3

Not

Straightness of hatch coaming ( partially/m)

10

15

defined d5

Straightness of hatch coaming ( all length ) Alignment of wheel & guide rail

d6 - 50 -

 (3 

–

4L ) 10,000

″ Min.0


Section 2

*h/coaming installation

Hull outfitting

2.2.2 Dimension of repair ship Item

Tolerance limits

Length d1 Breadth d2 Diagonal

(L1-L2)

A. H.coaming wall

d1

d2

L1-L2

1) Single pull type

 10

 10

 15

2) Side rolling type

 12

 12

 15

3) Pontoon type

 12

 12

 15

4) Folding type

 12

 12

 15

B. Compression bar fitting Item

Distance

Straight

Level

1) Single pull type

6

7

5

2) Side rolling type

5

5

5

3) Pontoon type

5

5

5

4) Folding type

5

5

5

- 51 -


Section 2

Hull outfitting

* small hatch

2.3 Small hatchs

2.3.1 Height ( refer to ILLC code ) 1) Position 1: H=600 mm 2) Position 2: H=450 mm 2.3.2 Dimension & Material. 1)New shipbuilding: As followed design factor. 2) General repair : As followed ship’s drawings. 3) Material: Mild steel ( Normal practice ) 4) Thickness : 10mm or more ( class require ) Item

Standard

Tolerance

a. Width or length d1,2

2

5

b. Difference between diagonal d3

2

-5

c. Straightness/m d4

1

+2

d. Bending/m d5

2

3

* Small steel hatch cover type ( square type )

- 52 -


Section 2

Hull outfitting

* Vent/ duct system

2.4 Air vent system 1) Height of air pipe - Position 1: Min 900m - Position 2: Min 760m 2) Height of others. - Refer to design standard or existing ones. 3) Installation/type or size ( shipbuilding ) - Refer to design dwg’ with class and owner requirement representative 4) General repair, when during dry docking for I.L.L Item

Wire net (SUS 304)

Remarks

Float type Air pipe head 2 mesh x # 19 S.W.G Louver and Mushroom vent

10 Mesh x # 31 S.W.G

Insect proof screen

2 Mesh x # 19 S.W.G

Rat proof screen

2 Mesh x # 19 S.W.G

B/fly closing device

- 53 -


Section 2

Hull outfitting

* ladder & rail

2.5 Steel inclined ladder 2.5.1 Installation

Unit: mm Degree (  ) 0

Breadth

Pitch

Normal

50 – 55

Min. 600

200 – 280

Tolerance

±50

-

-

Breadth

Pitch

MIN. 600

180 – 230

MIN. 800

250 – 350

2.5.2 Other rule & regulation Authority SBG

( ) 0

45 - 55

0

0

NMD

45

USCG

MAX.450

MIN. 710

-

NSASN

550 – 650

400 – 700

250 – 350

DOT

600

300 – 600

-

Breadth

Pitch ( step )

Depth ( support )

Normal

300

300

150

Tolerance

400

350

180

2.5.3 Clear height

2.6 Steel vertical ladder

- 54 -


Section 2

Hull outfitting

2.7 Hand rail

* ladder & rail

Unit: mm Item

Standard

Total height

Min. 1000

Clear lower height

Max 230

Clear middle height

Max 380

Clear upper height

Max 380

Space of stanchion

1200 – 1500

Space of stavs

3600 – 4500

Remarks

2.8 Storm rail

2.9 Guard rail

Gate type guard rail

chain rail type guard rail

DECK

DECK

- 55 -


Section 2

Hull outfitting

2.10 Anchor chain cable 2.10.1 Cable measuring

- Measure at 3 links of each shots - Loss limit: B.V = 13.5% Others =12.0% 2.10.2 Stud repair of common link 1) Loose stud: welding ( one side only ) 2) Missing stud: fabrication & welding - Grade U1: SF45 or similar - Grade U2: SF 45 or similar - Grade U3: SF 65 – 70 or similar (T.S: 690 N/mm2) 2.10.3 Shot marking 1) Paint: Kenter shackle : red color : Common links : white color 2) The cotton canvas shall be secured by wire ( sus or copper ) - Detail of cotton canvas

* D: Cable normal diameter

- 56 -

* anchor chain


Section 2

Hull outfitting

- 57 -

* anchor chains marking


Section 2

Hull outfitting

* derrick boom

2.11 Derrick boom construction Item

Standard

Tolerance limits

l

a. Length d1

7

 10

b. Bending d2

5

 10

c. Diameter d3

0 - 0.01d

0 + 0.01d

d. Roundness for piece fitting ( At boom seat ) DL- DS

1

0

20

*Boom & piece fitting d

10

20

       

- 58 -


Section 2

Hull outfitting

* derrick boom

2.12 Derrick boom repair 2.12.1 Boom insert repair

- Material: Same as original DWG - Bevel: 45 – 500 - Root gap: 4 – 5mm - Backing: Steel or pipe (Min’ : 5.0t) 2.12.2Boom reinforcement by double plate

- Material : Same as Dwg’ - Thickness: 10t 2.12.3 Test, after repair ( welding ) 1) Butt joint: visual & N.D.T ( P. T or U. T ) 2) Fillet joint: Visual inspection. 2.12.4 Test confirmation of load applied. - Load test: Proof load test with steel weight. * Following I.L.O guidance

- 59 -


Section 2

Hull outfitting

* in accommodation

2.13 Deck covering 2.13.1 A- 60 deck covering ( Floating floor type )

STEEL DECK

Vinyl sheet or

7

Finishing material

6

Top coat

Latex + powder

5

Middle coat

Latex + powder

14mm

4

Base coat

Latex + powder

3mm

3

Expanded metal

SS41 (galv’d)

2.3t

2

Mineral wool

40t

d=200kg/m3

1

Silica bond

silica

2mm

No

Description

Material

Size

carpet

- 60 -

1mm or 0.5mm

Q’ty

Remarks


Section 2

Hull outfitting

* in accommodation

2.13.2 A-60 deck covering ( Silicate board type )

STEEL DECK

Vinyl sheet or

7

Finishing material

6

Top coat

Latex + powder

5

Middle coat

Latex + powder

10mm

4

Metal lath

SS41 (galv’d)

#22

3

Base coat

Latex + powder

2

Silicate board

1

Silica bond

silica

2mm

No

Description

Material

Size

carper

25mm

- 61 -

Q’ty

Remarks

Section 2


Hull outfitting

* in accommodation

2.13.3 Gutter way ( for galley ) (1) SUS type (SUS-304)

(2) Tile type.

2.13.4 Finishing material. (1) Vinyl tile (2) Vinyl sheet (3) Carpet (4) Rubber mat 1) Perforated ( ring ) type: Outside floor 2) Groove type

: inside floor

(5) Tile 1) Non slip quarry tile 2) Mosaic tile 3) Ceramic tile 4) Corner tile 2.13.5 Wooden deck (1) Oregon pine (2) Apiton 3) Red pine (4) Cedar (5) Teak

- 62 -


Section 2

Hull outfitting

* in accommodation

2.14 Insulation ( Typical only ) 2.14.1 Deck insulation ( A-60)

2.14.2 Bulkhead insulation ( A-60 ) Vertical section

Horizontal section

- 63 -


Section 2

Hull outfitting

* in accommodation

2.14.3 Det. Of insulation bottom

Not sweat gutter way area

Note: finishing material is glass cloth where not covered with lining material

Sweat gutter way area

Note:

1. The A-60 class insulation should be wrapped 380mm to

adjacent deck head and steel bulkhead. 2. Finish material is glass sloth where not covered with lining material. - 64 -


Section 2

* in accommodation

Hull outfitting

2.14.4 Pipe insulation method (Typical of prov’ refr’ system )

Sketch

Mark

Name

Material

Pipe

Copper

Insulation mould

Material

Poly ethylene with al-foiled fiber glass cloth

Cable tie Type

Remark

Nylon

P=300(ABT)

Al-foiled fiber glass cloth

0.32mmx8

tape.

100

Application of insulation Piping system

Type of insulation Location Pipe

Flange

Thickness of piping insulation Nom. Dia.

Thickness of insul.

Refrigerant (R-22) pipe (return gas

Provision ref. system





All size

pipe oily)

- 65 -

25mm

Remark


3.1

Section 3

Machinery & outfittings

Main engine & shaft line ................................................................ 67

3.2 Rudder arrangement ....................................................................... 69 3.3 steering gear ........................................................................................ 70 3.4 Pintle / bush ............................................................................................ 71 3.5 Rudder repair( structure ) ............................................................ 73 3.6 Rudder repair( jumping ) .................................................................. 73 3.7 Rudder repair ( pintle locking ).................................................. 73 3.8 Rudder repair ( Gudgeon )............................................................... 74 3.9

Rudder repair ( alignment ).......................................................... 75

3.10 Propeller ( iso r4841).......................................................................... 76 3.11 Blade damage repair........................................................................ 79 3.12 Tip preparation for welding........................................................ 80 3.13 Propeller welding............................................................................. 81 3.14 Stern tube............................................................................................... 82 3.15 Tail shaft sleeve limit .................................................................... 82 3.16 Shaft cone ( taper ) part................................................................. 82 3.17 Coupling alignment.......................................................................... 83 3.18 Line shaft alignment ....................................................................... 83 3.19 Aux’ machinery.................................................................................... 84 3.20 D/G engine ................................................................................................ 86 3.21 traveling deck crane ..................................................................... 87 3.22 boiler tube deformation............................................................... 88 3.23 Boiler tube repair.............................................................................. 89 3.24 boiler tube repair.............................................................................. 89 3.25 boiler drum fab’ & welding ......................................................... 90 3.26 Boiler tube joint welding ............................................................. 94

- 66 -


Section 3


* Main machinery

3.1 Main engine & Shaft line

Unit: mm

Item

Standard range

Tolerance limits

1) Seating 8

Flatness of top of main engine bed

12

(before milling) 2) Crank shaft deflection



1 x stroke 10,000



1 xS 10,000

*Note: this range may

* Note: this

be changeable as per

range is repair

maker’s standard

ship practice

3) Installation (1) Contact, ratio - Main engine chock liner

70%

60%

- Bearing chock liner

60%

50%

(2) Clearance between liner and base

0.04

Not defined

(3) Chock fast orange 1. Thickness

t

25-35

2. Metal temperature

Min 12

160C

3. Curing time

130C external heat 210C 12 hour 160C 24 hour 130C 48 hour

- 67 -



Section 3

* Main machinery Unit: mm

Item

Standard range

Tolerance limits

4) Centering ( New shipbuilding ) (1) Diameter of piano wire: d

d=0.7

d=0.7  0.1

(2) Tension of piano wire : t

t=50kg

t=50  5kg

- Dead weight over 100.000 ton: t1

t1 5

t1 8

- Dead weight below 100.000 ton : t2

t2 4

t2 6

(1) Diameter of piano wire : d

d=0.5-0.7

 0.1

(2) Tension of piano wire :

t=50kg

 10kg

(3) Deviation between rudder center line and shaft center line.

5) Centering ( Repair ship ) t

(3) Deviation between rudder center line and shaft center line.

t1 10 t2 8

- 68 -


Section 3


* rudder

3.2 Rudder arrangement

Unit: mm

Item

Standard range

Tolerance limits

1) Installation (1) Contact ratio

60%

>50%

(2) Clearance between carrier and liner

0.04

<0.05

d<0.3

d 0.5

d<1.0

d<1.5

2) Centering Deviation between center line of rudder carrier and pintle.

3) Centering of repair ship for checking only

- 69 -


Section 2


3.3 Steering gear arrangement

* Steering gear

Unit: mm

Item

Standard range

Tolerance limits

1) Installation (1) Ram cylinder type - Contact ratio - Clearance between liner and base

<0.06

Not defined

(2) Rotary vane type - Contact ratio

Not defined

60%

- Clearance between liner and base 2) Alignment

(d1)

1

(H1-H2)

3) Alignment for general repair

- 70 -

(d1)

0.08

2

(H1-H2)

0.15

d1 1.5

d1 2.0

H1-H2 0.2

H1-H2 0.5



Section 2

* Rudder pintle/ bush

3.4 Pintle/ Bush Item

Standard range

Tolerance limits

1) Contact ratio of cone part

60%

50%

2) Pintle clearance

Builder’s practice

Metal:

3) Material: sleeve

bc/sus, bc/resin

0.8~2.0mm

4) Thickness ( bush/ sleeve)

Non metal: Unit: mm

Dia

<100 100-

150-

200-

150

200

300

1.5~2.5mm >300 Metal:

Sleeve

7.5

9

10

12

15

Bush

10

12

15

20

25

- Sleeve: 6.0 - Bush: 8.0 Non metal

* NK:

- Bush:10.0 - Thickness of pintle sleeve - Thickness of pintle bush

0.03dp+5

- dp<300

0.05dp+5

- dp>300

0.05dp+11

- Thickness of stock sleeve

0.03dp+3

- Thickness of neck bush

0.05dp+2

- dp<300

0.03dp+8

- dp.300 5) Non-Metallic bush material (HMD) * Brand: HFG-LITE CR 510 * Max’ surface pressure: 56kg/cm2 * Class authority: KR, NK, BV, LR, DNV, GL, ABS

- 71 -

Section 2



* Rudder pintle/ bush

3.4.2 Rudder bearing clearance recommended values ● A.B.S guidance Approximately 1% of the pintle diameter to a maximum 6.3mm Other: R/100x3.0 or 0.4 mm/inch ● N.K guidance The limit of wear down of the pintle bush is 5 to 6mm the bearing clearance in diameter, and the neck bearing is 3 to 4mm abnormal wear-down. ● B.V guidance * Pintle diameter 50 to 100 = 5mm * Pintle diameter 100 over = d/100+4 ● Yard guidance * D/100+2= Upper pintle clearance * D/100+3= Lower pintle clearance ● D.N.V guidance I = Renewal necessary II = Renewal recommended III= New/ repaired

● L.R guidance - Recommend: 4.0+0.002 pintle diameter - Renewal: 5.0+0.02 pintle diameter ● K.R guidance - 0.01 Dia’+4mm of pintle - 0.01 Dia’+2mm of neck - 72 -


Section 3


* rudder repair

3.5 Structure welding

Plate thickness

Dimensions ( m)

(mm)

a

b

Up to 6

65

35

7~18

75

40

19

85

45

Kind of fillet weld F1

Slot welding

Aft end construction of rudder 3.6 Jumping stopper

Unit: mm Item

Standard range

The clearance between jumping stopper and

C 2.0

rudder carrier 3.7 Pintle locking Locking device for pintle nut

Locking ring or bar

- 73 -

Tolerance 2.0


Section 3


* rudder repair

3.8 Center of gudgeon Tolerance

1.50mm - Carrier - Upper - Lower

3.8.1 Gudgeon repair ( case 1) 1) Build –up by welding

smaw

2) Re- boring

Machine practice

3) Re- alignment check

Piano wire

3.8.2 Gudgeon repair ( case 2) 1) Boring to oversize

Machine practice

2) Fabricated steel liner

Forged steel

3) Inserted the steel liner

interference 0.005~0.01 T: Min 6.0mm W: 0.35xL

- 74 -


Section 3


* rudder repair

3.9 Rudder alignment Item

Standard range

Tolerance limits

Deviation of height(H)

0.5

1.5

Deviation of center line

0.5

1.5

3.9.1 Adjustment Min thickness

1) Machine-up the palm

0.03 x stock dia 0.04mm

2) Contact ratio

(70%)

3) Distance of bolt hole and flange edge

(50%)

DE: 0.75xF.T

- 75 -


Section 3


* propeller

3.10 Ship Scrw propeller * Refer to ISO 484/1 or 484/2 Ship building manufacture tolerance 1981(E) 3.10.1 Classification Choice of the class should be made by the user: the indications in table 1 below afferent guidance for this choice. Class

Accuracy of manufacturing

Normal use

S

High precision

I and II

Medium precision

For majority of merchant vessels

III

Large tolerances

For vessels without special characteristics

Screw propeller of superior quality for special purposes

Note-class III: Applies in general only to cast iron screw propellers. 3.10.2 Tolerance of pitch Description Local pitch with a minimum of Mean pitch per blade at any radius With a minimum of Mean pitch per blade with a minimum of Total pitch with a minimum of

Class S

I

II

III

 1.5%

 2%

 3%

15mm

20mm

30mm

 1%

 1.5%

 2%

 5%

10mm

15mm

20mm

50mm

 0.75%

 1%

 1.5%

 4%

7.5mm

10mm

15mm

40mm

 0.625%

 0.75%

 1%

 3%

6mm

7.5mm

10mm

30mm

Note: 1. For screw propeller with constant as well as for screw propellers with variable pitch, the pitch of screw propellers according to classes S. I and II should be measured at least on 5 radius ( e.g 0.3R; 0.5R; 0.8R; 0.95R and for class II on 3 radius ( e.g 0.5R; 0.7R; 0.9R ). As far as possible the measurements should be taken on at least 3 point on each radius.

- 76 -


Section 3


* propeller

3.10.3 Surface finish The surface texture of the blades, expressed as an arithmetic mean deviation, R 2 , in micrometers, in accordance with ISO/R 468, shall have a roughness not greater than: - 3 from the hub for propellers of class S; - 6 from the radius 0.3 R for propellers of class I; - 12 from the radius 0.4R for propellers of class II; - 25 from the radius 0.5R for the propellers of class III;

The smoothness of the surface of the propeller blades should be determined by the mean height. Hm of the surface roughness of the blades at least for the radius of the screw propeller over 0.3R.

Hm 

1 ( H 1  H 2  ...  Hn) n

- 77 -


Section 3


* propeller

3.10.4 Static balancing Unit: mm Item

Standard range

Tolerance limits

Deviation of blade ( maximum )

150

Refer calculation

* Max’ permissible unbalancing mass. ( According to ISO R481/1 1981)

pC

m or Rn2

Km, whichever is the smaller.

P =............................ p=

Km=

x m=

kg

kg

Where : m: propeller weight in (kg) R: propeller radius in meter (m) n: propeller r.p.m C&K: factors of class given. S

I

II

III

C

15

25

40

75

K

0.0005

0.001

0.001

0.001

* Actual unbalancing mass at the blade deviation m: 0.269 =

M .H  0.269 R.Sin kg

Where M: test ( attached) weight in kg H: length of deviation ( Hmax-H min) R: propeller radius in meter Sin  : angle of propeller blade (sin 900 : 1.0, 720 : 0.95, 600 : 0.87)

- 78 -


Section 3


* propeller repair

3.11 Damage repair areas 3.11.1 Yard’s practice

R= propeller radius C1= chord length at radius Section

Repair jones of blade

Propeller

A

B

C

D

boss

x

O

O

O

-

Crack part welding

x

O

O

O

O

Partly renew

x

O

O

O

-

Straightening

O

O

O

O

-

Cold straightening

x

O

O

O

-

Grind out

x

x

x

O

-

Kind of repair Damage & cavitation part build up welding

3.11.2 Classification practice * Refer to class permissible rectification range - 79 -


Section 3


3.12 Blade tip repair preparation

- 80 -

* propeller repair



Section 3

* propeller repair

3.13 Propeller welding 3.13.1 Welding process ( refer to W.P.S) 1) minor repair: in use GTAW 2) Major repair: in use GTAW + GMAW 3.13.2 Temperature control 1) Pre heating: propane torch 2) Stress relief: induction PAD/ COIL analysis ( Electric heating element ) 3)Cooling: should be retarded by asbestos blankets. Straightening

Material

Preheat’ Temp 0C

Stress relief Temp 0C

Mn-bronze

150-250

350-550

500-800

NiMn- bronze

150-250

350-550

500-800

NiAl-Bronze

50-150

Kh«ng

700-900

MnAl-bronze

100-250

450-600

700-850

U.T.P

Gricu

Ampco

Temp. 0C

3.13.3 Welding material Material Mn-bronze

A-34

ALBZ-9

Trode 10

Ni-Al-bronze

A-3444

ALBZ-26

Trode 46

Mn-Ni-Al-bronze

A-34N

T-8

Trode 40

AWS SPEC’ = A 5.7 CLASS = ER CU x x x x * Refer to propeller welding procedure

- 81 -



Section 3

* stern tube/ shaft

3.14 Stern tube clearance Item

Standard

Tolerance

Stern tube lignum vitae clearance a. Tail shaft dia < 230mm

4.5mm

6.0mm

b. 230mm

6.5mm

8.0mm

7.5mm

9.5mm

Tail shaft dia < 305mm

c. Tail shaft dia

305

- Builder’s

Stern tube simplex Type clearance

practical Tail shaft dia. ( mm)

400~500 500~600 600~700 700~800 800~900 900~1000

0.7~0.8 0.8~1.0 0.9~1.2 1.0~1.3 1.0~1.4 1.2~1.5

2x Original clearance (builders practice)

3.15 shaft sleeve thickness loss limits N.K.G.L

L.R, DNV

t= 0.03DS+7.5

T=

T1≠3/4T

Remarks

ds  230 32

ds: Shaft dia’ T: Brg’ surface

T1=0.75T

T1: non Brg’ surface

3.16 shaft cone part Item

Standard range

1) Contact ratio of propeller / shaft

90%

2) Shaft crack detection

* Smooth ground

Tolerance limits 70%

* Decide by class / owner for * ABS repair guidance

renewal

- Max’ depth - Max’ length ( total circ’ )

1/4’’(6.35mm) 1/4C(0.25C)

- 82 -


Section 3


* shaft alignment

3.17 Coupling alignment

Unit:

mm Item 1) Simplex ( oil – bath ) type - gap

Standard

Tolerance

range

limits


– Sag

0.20 0.30

2) Lignum vitae ( water lub’ ) type

Builder’s

- Gap

practice

- Sag

0.30 0.70

a. Gap = (g1-g2) b. Sag = (s1-s2) 3.18 Line shaft alignment 1) Reaction load on the bearing surface


- 83 -


Section 3


3.19Aux’ machinery

* Aux’ machinery

Unit: mm Item

Standard range

Tolerance limits

1) Classification of auxiliary and deck machinery (1) Grade “A” Windlass Diesel generator (2) Grade “B” Turbo generator Mooring winch & turbine Cargo winch (3) Grade “C” Other machineries which are not listed in Grade “A” and “B” 2) Installation (1) Clearance between liner and base Grade “A”

0.04

0.05

Grade “B”

0.08

0.1

Grade “C”

Not defined

Not defined

(2) Liner contact ratio Grade “A”

60%

60%

Grade “B”

50%

50%

Grade “C” (3) Chock fast orange thickness

- 84 -

Not defined

Not defined

25-35t

Min’ 12t

* Other maker

guidance


Section 3


Item

* Aux’ machinery

Standard

Tolerance

range

limits

3) Alignment ( solid type ) Grade “B” only ab 2 Gap  b  c Sag 

S 0.05

Not defined

G 0.07

Not defined

Gap/sag 0.15 Gap/sag 0.18 4) Alignment of deck machinery - Solid type - Shaft type 5) Alignment of pumps ( flexible coupling type )

Gap/sag

- Shaft dia’ <50mm - 50

Shaft dia’<100mm

0.15

- Shaft dia’>100mm

0.20 0.25

- 85 -


Section 3


3.20 Diesel generator

* D/G engine

Unit: mm

Item

Standard range

Tolerance limits

1) Crank shaft deflection - New installation Cold condition

Hot condition



1 x stroke 10,000



2 x stroke 10,000



2 x stroke 10,000



3 x stroke 10,000



2 x stroke 10,000

- General repair ship Cold condition

- 86 -


Section 3


* deck crane

3.21 Traveling deck crane Item

Standard range

Tolerance limits

(1)Installation of rail - Distance between center of rails ( common type )

d1  5

Not defined

- Distance between center of rails ( Gantry type )

Not defined d2  10

- Straightness of rail ( transverse, vertical direction )

Not defined d3 5 (per 10m)

- Difference of height between port and stb’d Not defined d4

8

To be measured at each 5m

- 87 -


Section 3


Item

Standard

*boiler tube damage

Tolerance

* Boilers

3.22 Boiler tube deformation 1. Water tube

d 0.5d

Not defined

d 0.3d

Not defined

* d = tube dia. 2. Smoke tube

* d = tube dia

- 88 -


Section 3


Item

Standard

* boiler tube repair

Tolerance

3.23. Edge preparation of the pipe or tube and cutting of the window patch method A=50  50C

A=50  100

B=1.5  1mm

B= 2 12

3.24 Procedure for effecting a

A=1.5  1mm

A= 1.5 2

permanent repair mono wall tubes.

B=50  50C

B=50  100

C=2  1

C=2  2

( with wedge in place )

- 89 -


Section 3


* boiler repair

3.25 Boiler repair procedure 1. Applicable to aux boiler drum repair ( partly ) 2.Pressure range: 7.0~12.0kg/cm2 3. Material grade: for pressure vessel jis SB410 or similar 4. Working sequence 1) Material confirmation - Same as original maker or similar - Confirmation of the material mill sheet * Class certificate * Chemical composition * Mechanical property 2) Fabrication of the drum shell * To be rolled to circumference( mm in diameter ) 3) Preparation 1) To be made edge shape the end of plate by grinder and machining. 2) Refer to attached joint details. 3) Permissible misalignment at the butt joint - Longitudinal: 1/4t or max’ 3.0mm - Circumferential: 1/4t or max’ 4.0 mm

- 90 -

Section 3



5. Welding 1) Welding is to be performed by approved welders. 2) Preheating : temp: 100-1500C Method: Propane torch. 5-1) Electrodes 1) Manual: S7016-LF (produces by HWMCO ) LB-52 (produce by kobe steel ) 2) TIG : TGS-50 (produce by kobe steel ) 3) MIG: MGS-50 (produce by kobe steel) 5-2) Size of rods 1) Manual: (3.2-5.0  ) 2) TIG & MIG: (1.2-1.6  ) 5-3) Post weld heating ( if necessary ) 1) Temperature: 6250C  250C (According to Class rules ) 2) Holding time : One ( 1 ) Hour/25 t * To be smooth ground to unbeaded weld metal and spatters. 6. Test and inspection 1) Fit –up and Edge – preparation ( Class, Q.C, owner ) 2) Visual inspection after grinding ( Class, Q.C, owner) 3) N.D.T. 3-1) Radiograph test (100%): Drum shell butt & seam joints. 3-2) M.P.I or DYE – check (100%) : Fillet and other joints. 4) Hydro static test: test pressure: D.Px1.5 time 5) Final dimension check if necessary.

- 91 -

* boiler repair


Section 3


Typical joint detail

- 92 -

* boiler repair


Section 3


6.Burner Plate

7. Flue Pipe

- 93 -

* boiler repair


Section 3


3.26 Typical joint of boiler tube within tube nests 1) Plan tube seal welding

2) Stay tube welding

3) Flange connection

- 94 -

* boiler tube joint


section 4

piping system

4.1

general .................................................................................................... 96

4.2

Fabrication ............................................................................................ 99

4.3

installation.......................................................................................... 104

4.4

ship side line repair ........................................................................... 106

4.5

Scupper pipe ........................................................................................... 107

4.6 Hull piping in accommodation .................................................... 110 4.7

P.V.C piping in accommodation .................................................... 113

4.8

Pipe support in accommodation ................................................. 114

4.9

hyd-line grade .................................................................................... 115

4.10 piping joints............................................................................................ 116

- 95 -

section 4


piping system

* piping grade

4.1 General 1. Grade of pipe The grade specified by each classification society shall be divided as follows (1) LR Grade Service

Class 1 Press.

Class 2 Temp.

Press.

Class 3 Temp.

Press.

Temp.

Steam

P>16.3 or T>300

7.1

P 7.1

T 170

Fuel oil

P>16.3 or T>150

7.1

P 7.1

T 160

Other media

P>40.8 or T>300

16.3

P 16.3

T 200

(2) ABS Grade

Class 1

Service

Press.

Class 2 Temp.

Press.

Temp.

Vapor and gas

P<10.5 or >343

P 10.5

T 343

Water

P<15.8 or T>177

P 15.8

T 177

Lubricating oil

P<15.8 or T>204

P 15.8

T 204

Fuel oil

P<10.5 or T>66

P 10.5

T 66

Hydraulic fluid

P<15.8 or T>204

P 15.8

T 204

Lethal gas & liquids

All

-

-

(3) KR & NK Grade Service

Class 1 Press.

Class 2

Temp.

Class 3

Press.

Temp.

Press.

Temp.

Steam

P>16 or T>300

7

170
P 7

T 170

Fuel oil

P>16 or T>150

7

60
P 7

T 60

Water, lub. oil, comp. air, Hyd.

P>40 or T>300 (Only KR)

oil

16

200
P 16

T 200 (Only KR)

Primary Refrigerant

All

All

-

-

-

-

-

-

-

-

All

All

( ammonia ) Primary refrigerant (R12,R22) - 96 -


section 4

piping system

* piping grade

(4) U.S.C.G. Service

Temp (0F)

Class

Pressure ( psig )

I

Any

and

0 and above

Class B&C

I-L

Any

and

<0

poisons

II

(3)

(3)

(3)

II-L

(3)

(3)

(3)

I

>150

or

> 650

Gases and

I-L

>150

and

<0

vapors

II

150

and

0 to 650

II-L

150

and

<0

I

>150

and

0

I-L

>150

and

<0

II

150

and

0

II-L

150

and

<0

or

>330

Liquefied flammable Gasses Molten sulphur Cargo liquids Grades A Through D

I

>225

II

225

I

>225

or

>150

I-L

>225

and

<0

II

225

and

0 to 50

II-L

225

and

<0

and

330

I

>225

or

>400

Cargo liquids

I-L

>225

and

<0

Grade E

II

225

and

0 to 400

II-L

225

and

<0

or

>350

Water Fuel ( bunker diesel, gasoline, etc...) Lubricating oil Asphalt

I

>225

II

225

I

>150

II

150

I

>225

II

225

I

>225

II

225 - 97 -

and or and or and or and

350 >150 150 >400 400 >400 400

section 4


piping system

Heat transfer

I

>225

oil

II

225

I

>225

II

225

Hydraulic fluid

* piping grade

or

>400

And

400

Or

>400

And

400

Flammable or combustible dangerous cargoes ..... Refer to specific requirements of Part 40 of this chapter. Other dangerous cargoes .... Refer to specific requirement of part 98 of this chapter. 1. Where doubt exists as to proper classification, refer to the Commandant for resolution. 2. For definitions, see 46 C. F. R Part 30, 151. Note that the category “B” and “C” poison is not used in the rules applying to self Propelled vessels ( 46 CFR Part 153 ). 3. Not permitted except inside cargo tanks approved for Class B and C poison. ( 5 ) D. N. V Piping

Class I

Class II

system

p/bar

0

tC

0

Steam, Fuel

>16

Or >300

16

300

7

170

oil, Other

>16

Or >150

16

150

7

60

media

>40

Or >300

40

300

16

200

p/bar

tC

Class III p/bar

t0C

p: Design pressure, as defined in Sec. 6 A303 t: Design temperature, as defined in Sec.6 A303 1) For Class II and III piping both specified conditions are to be met, for Class I piping one condition only is sufficient. 2) Air, Water, lubricating oil and hydraulic oil. 3) Cargo oil and open ended pipes ( drains, overflows, vents, boiler escape pipes, ... etc ) independently of the pressure and temperature, are pertaining to class III. 4) Thermal oil pipes independently of temperature and pressure are pertaining to class I. 5) Hyd’ oil piping in engine room with design pressure above 40bar are pertaining to class II.

- 98 -


section 4

piping system

4.2 Pipe fabrication

* Fabrication

Unit: mm Item

Standard range

Tolerance limits

d=  4

1)Dimension (1) Straight pipe

Not defined

d=  5

(2) Bending pipe

d   10

1   2  2 0

Not defined

(Two dimensional bending )

d=  5 d   10

Not defined

(Three dimensional bending ) (3) Branch pipe

d=  4 d   10

Not defined

(4) Penetration piece

d=  4 d   10 Not defined

- 99 -


section 4

piping system

* Fabrication Unit: mm

Item

Standard range

Tolerance limits

2) Attachment of flange to pipe (1) Angle of flange to pipe a 2

Not defined

(2) Distortion of flange face D>200 a 0.5

<1

200 D≤450 a 1

<2

D>450 D: out dia. Of pipe

a 1.5

<2.5

L 5

Not defined

a: max. 1.5

Not defined

(3) Distance between fillet and butt welding bead

(4) Distance between face to flange and welding toe

- 100 -


section 4

piping system


Item 3) Pipe bending

Bending

Pipe

(1) Elliptically (E)

method

material Steek pipe

Cold or

Copper

hot

Dl  Ds E x100% D

bending

pipe

D: Out dia of pipe

Al-Br &

R: Bending radius

kunifer

(2) Thickness reduction ratio ( T)

pipe

T

t  tr x100% t

t: Original pipe thickness tr: Thickness after bending D: Out dia. of pipe (3) Wrinkle & swelling

H: Height D: Out of pipe

- 101 -

Division

Standard

Tolerance

range

limits

Bending radius 3D R 4D

4D R

E(%)

≤10

≤10

T(%)

≤20

≤15

H

H

E(%)

≤10

≤10

T(%)

≤25

≤20

H

H

E(%)

≤10

≤10

T(%)

≤20

≤15

H

H

1 D 100

1 D 100

1 D 100


section 4

piping system


Item

Standard range

Tolerance limits

4) Sleeve joint (1) Steel a: Min.1.5 l1:

Not defined

Min.10(D≥65A)

″

Min.20(D≤80A)

″

(But max.1 only for U.S.C.G)

(2) Copper , Al-Br

0.05 a 0.15

Not defined

a 1.0

a 1.5

b 0.2

b 0.8

5) Socket joint

- 102 -


section 4

piping system


Item

Standard range

Tolerance limits

6) Welding of steel pipe ( 1 ) Edge Preparation

d

1.6

a = 2.4 ± 0.8 

140

0

d1

Not defined

( 2 ) Back bead

d2

( Class I, II pipe )

2

Not defined

0.5

( Other pipe )

( 3 ) Under cut

d

- 103 -

0.3

d

0.8


section 4

piping system

* Installation

4.3. installation

Unit: mm Item

Standard range

Tolerance limits

1) Pipe hole cutting & penetration ( 1) Hole cutting

d

D 100

d

D 100

l = 0.1D But min.50

Not defined

T

Not defined

( 2 ) Pipe penetration A-Type

T1

10 ~ 100A

“

b = 30 ± 5

“

125 ~ 500A b = 40 ± 5 “ D- type

550 ~ 700A b = 50 ± 5 “ D1 = D + Max.15

65A & below L = 100

“ Not defined

80a & above L = 150

- 104 -

“


section 4

piping system

* Installation Unit: mm

Item

Standard range

2) Alignment

a

Not defined

2

c–b

3) Bolting

Tolerance limits

2

a=0~3

Not defined

a2 + a3 = 0 ~ 3 b1 = 0 ~ 5 threads b2 = 0 ~3 threads H/coil only ( U bolt )

( Flange bolt )

a=1~3 a1 = 0 ~3 a + a1

3

4) Air vent pipe

H = 10

Not defined

5) Sounding pipe

H = 20 ± 5

Not defined

t = 15

6) Dresser coupling

Short type

Not defined

l = 40

d2

5

d1 = ± 5 d2

3

Long type l = 70 d1 = ± 30 d2 - 105 -

6

Not defined


section 4

piping system

4.4 Ship side line repair

* Installation

Unit: mm

Item

Standard range

7) Suction mouth ( hull part ) ( 1 ) A – Type Pipe dia. (D)

G

Main suction

80A & below

20

H = ± 10

100A
25

200A

35

Stripping H=±5

( 2 ) B – Type Pipe dia. (D)

G

150A

40

200A

45

250A

55

300A

65

350A

65

400A

75

450A

85

500A

100

550A

110

600A

120

650A

140

- 106 -

Main suction H = ± 10 Stripping ( Including main & stripping ) H=±5

Tolerance limits


section 4

piping system

* Installation

4.5 Scupper pipe Tolerance

Item

Limits

For ship side

C

3

Distance

L

15

Piece

D

500 ± 10

C

3

L

15

D

500 ± 10

C

3

L

15

D

500 ± 10

L1

15

L2

15

C

3

D

450 ± 5

For boiler Blow down Distance Piece

For ship side Distance piece

For pad flange

For Echo sound, Pad flange

- 107 -

Remarks

General adapting

Boiler blow down or general adapting

Sea chest on the sea side

BOILER BLOW DOWN ( Soviet Russia Shipyard, but required class surveyor owner )

Style

Standard 10K >SCH’80

Pressure

Remark

thickness

7.0

t(min)

Normal pipe

25A 32

7.5

50 65

9.0

7.6

125

11.0

80

150

12.7

8.6

200

17.4

100

300

1. flange:

remark

1) Existing using

2) Same size use with valve

material

2. Material

component

STPG38 STPT38

flange

pad

SM41, SF45 or S20C

pipe

Note :

1. The carbon content of the

material shall be 0.23% or less.

2. The material of S20C shall be heat treated.

- 108 -

* Installation

piping system section 4 HALONG SHIP BUILDING Co.

Section 4

piping system


1) Deck penetration

2) Ship side discharge penetration the hull

3) PCLE deck or weather deck installation

- 109 -

* Scupper piping


Section 4

piping system

* hull piping

4.6 Hull piping in accommodation 4.6.1 Detail of welding method 1) Butt weld No.

Methods

Dimension

Application

t 3.2 t=t1 S=2  1 1

 1  20 0 S=2  1

Pipe to pipe

 2  20 0 B=1.6  0.8

t >3.2 50

 1  30 0 00 t=t1 S=2  1 t >3.2

Pipe to fitting ( Elbow,

2  1  10 0 S=2  1

reducer, tee )

50

 2  30 0 00 B=1.6  0.8 t = t1 t >3.2 t < t1

S = 2 1

a 1.6 B =1.6  0.8  : Refer to  1 or  2

Specified above. 3

t >3.2

Pipe to pipe or

a>1.6

Pipe to fitting

 : Refer to  1 or  2

Specified above t >3.2

- 110 -


Section 4

piping system

* hull piping

4.6.2 Weld profiles and tolerance limit for piping ( 1 ) Jointing and welding shall be carried out to have satisfactory weld profiles. ( 2 ) Tolerance limits and repair procedures are as follows. Item

Tolerance

Methods

Limit

Repair procedure When the depth of under

Under cut

D

0.8 mm

cut exceeds the limitation, to be repaired by welding with small dia, electrodes.

All pipes 

10

When the tolerance exceeds the limitation, flange to be refitted.

D: Pipe N/D

Alignment

D<200: a

0.1mm

200 D 450: a

2.0mm D>450:

a 2.5mm

L 5mm

Dimension

- 111 -

When the tolerance exceeds the limitation, flange to be renewed.

Section 4


piping system

* hull piping

4.6.3 Filet weld ( 1 ) Pipe to flange W: 1.5t but not less than 5mm. C: Maximum 2mm ( not to be tight fit ), but sum of the clearances diametrically opposite is to exceed 5mm. *

t1 : but need not to exceed 0.3T

( 2 ) Pipe to sleeve W : Refer to page 52/86. C : See “ C “ value of pipe to flange weld. * Mark part to be at least 9.5mm

( 3 ) Welding to structure ( for pipe penetration piece ).

- 112 -

Section 4


piping system

* hull piping

4.7 PVC A/B class penetration piece type in accommodation * Application : A/B – class steel deck/ bulkhead penetration for PVC pipe.

Pipe

Steel sleeve

H

L

e

50

60

89.1

78.1

6.0

65

76

114.3

102.3

126.6

6.6

75

89

139.8

126.6

151.0

7.1

100

114

165.2

151.0

N.D

O.D

D

d

t

N.D

50

60

89.1

78.1

5.5

65

76

114.3

102.3

75

89

139.8

100

114

165.2

Note : 1) “ PANDA-90” fire sleeve transit device for the penetration of A or B class division for PVC pipe. 2) Noncombustible material certificate of PANDA -90 fire sleeve. LR: SVG/F91/355 DNV: F-11314 ABS: 91-BK-27245-X KR: BU-02901/03 BV: 5031/5042/A1/0 GL: 67951 HH 3 ) *** Mark : PANDA-90 length 180mm, steel sleeve 200mm.

- 113 -


Section 4

piping system

* hull piping

4.8 Pipe support for steel and PVC pipe in accommodation 1) Standard distance of steel and PVC pipe ( 1 ) Distance ( interval ) of pipe supports to be based on the flowing table, but may be increased up to the maximum 1.2 times of the standard distance in consideration of hull structure. Steel pipe

PVC pipe

Nom. dia

Out dia.

Distance

Nom. dia.

Out dia.

Distance

(A)

(mm)

(m)

(A)

(mm)

(m)

15

21.7

1.0

20

27.2

1.5

25

34.0

1.5

32

42.7

1.5

40

48.7

2.5

40

48

1.0

50

60.5

2.5

50

60

1.0

65

76.3

2.5

65

76

1.2

80

89.1

3.2

75

89

1.2

100

114.3

3.2

100

114

1.5

125

139.8

3.2

125

140

1.5

150

165.2

3.9

Remark

L=1.2S (L: Maximum allowable distance of pipe supports. S: Standard distance of pipe supports )

Note: Theoretical criteria is guided by a limitation of about 3mm deflection with piping filled fully between pipe supports one another. ( 2 ) Stays for pipe supports to be fitted on or close to stiffening beam as far as possible. ( 3 ) Stays for pipe supports to be sniffed to avoid sharp ends and to be paint finished.

- 114 -


Section 4

piping system

* Hyd-line design

4.9 Pipe grade of hyd-line Symbol JIS G 3452

Grade/ name SGP

Range of applicable LOW PRESS SYSTEM * Pump suction pipe MIDDLE PRESS SYSTEM

JIS G 3454

STPG

HIGH PRESS SYSTEM * SEAM LESS PIPE

JIS G 3455

STS

Remark

HIGH PRESS SYSTEM * SEAM LESS PIPE

- W.P≤100kg/cm2 - W.T≤3500 - W.P≥100kg/cm2

HIGH PRESS SYSTEM

JIS G 3459

SUS ( stainless ) (304, 306 TP)

CORROSION RESISTANCE HIGH TEMPERATURE SERVICE SYSTEM

- 115 -

SPECIAL REQUEST ONLY BY OWNER


Section 4

piping system

* Hyd-line design

4.10 PIPING JOINTS KIND OF JOINTS Socket welding and threaded fitting

MATERIAL

PIPE DIA. (mm)

WORK PRESS (kg/cm )

SF45 S25C

6A~100A

Max.500

6A~50A

Max.210

15A~80A

Max.210

SUS BsTF4

Sliver brazing fitting

BsBF CNTF1

Square flange

SF45 S25C

Tween ferrule compression fitting

SUS

Max.210 6A~25A

Brass

Max.20

S25C Multi bite type fitting

SUS

Max.250 6A~25A

Brass

Max.100

S25C Flared fitting

SUS

Max.210 6A~25A

Brass

Quick coupling

MATERIAL

2

Max.20

RANGE * STEEL OR SUS PIPE *AL- BRASS * Cu –Ni PIPE * STEEL PIPE * STEEL OR SUS PIPE * COPPER TUBE *STEEL OR SUS PIPE * COPPER TUBE * STEEL OR SUS PIPE * COPPER TUBE

6A~25A

Max.210

* STEEL PIPE

25A~40A

Max.180

IF

50A

Max.140

NECESSARY

- 116 -


SECTION 5

PAINTING PART

5.1

PRIMAY SURFACE ................................................................................... 118

5.2

preparation grade…………………………………………………119

5.3

shop priming.......................................................................................... 119

5.4

D.f.t control ( new shipbuilding ) ............................................ 120

5.5

D.f.t control ( repair ship )........................................................... 120

5.6

pre- treatment .................................................................................... 121

5.7

treatment of weld part................................................................ 122

5.8

damage part ......................................................................................... 125

5.9

Management ( pre- coating ) ....................................................... 129

5.10

environmental ( temp/ humidity ) .......................................... 129

5.11

final coat condition ..................................................................... 130

- 117 -


section 5

painting part

* steel surface

5.1 PRIMARY SURFACE PREPARATION ITEM

Method

Surface preparation grades Sa2

6 t

Shot blasting

1 2

When shot blasting is considered

Rolled hull

impracticable, sand blasting may be

structural steel

applied. 6>t

Pipe 250 d

Sand blasting Sand blasting or hand/ power tooling

Sa2

1

Sa2

1

2

2

or St2-St3

pickling Hand/ power tooling

Outfitting, pipes, supports,

250>d

seat, etc...

pickling

St2-St3 or Sa2

1

St2-St3 or Sa2

1

2

( Blasting at yard’s convenience )

Support, seats, aux. mach. Etc.

Hand/ power tooling ( Blasting at yard’s convenience )

- 118 -

2


section 5

painting part

* steel surface

5.2 PREPARATION GRADE IT is assumed that prior to treatment the steel surface has been cleaned of dirt and grease and that the heavier layers of rust have been removed by chipping. ( 1 ) Sa2 1/2 : Blast cleaning. Very thorough blast cleaning, Mill scale, rust and foreign matter shall be removed to the extent that only traces remaining are slight stains in the form of sports or stripes. Finally, the surface is cleaned with a vacuum cleaner, clean dry compressed air or a clean brush. It shall then correspond in appearance to the prints designated Sa 2 1/2. ( 2 ) St2 : Power tool cleaning Thorough scraping and wire-brushing, machine brushing, grinding –etc. The treatment shall remove loose mill scale, rust and foreign matter. Finally, the surface is cleaned with a vacuum cleaner, clean dry compressed air or a clean brush. It should then have a faint metallic sheen. The appearance shall correspond to the prints designated St2. ( 3 ) St3 : Power tool cleaning Very thorough scraping and wire-brushing, machine brushing, grinding-etc. Surface preparation as for st3, but much more thoroughly. After removal of dust, the surface shall have a pronounced metallic sheen and correspond to the prints designated St3. 5.3 SHOP PRIMING Item Shop primer ( Pre- treatment )

D. F. T 15   5

- 119 -

Surface preparation Shop or sand blasting Sa2 1/2


section 5

painting part

* D. F. t Control

5.4 Dry film thickness control ( New ship building ) Item Measuring points

Tanks Outside shell

Standard One point/ five square meters One point/ ten square meters 1. Average dry film thickness of the paint to be attained as the specification. 2. At least 85% of the measuring points to meet the specified film thickness. 3. Min. 85% of the specified film thickness to be attained on remaining 15% measuring points.

5.5 Dry film thickness control ( General repair ship ) Item Measuring points

Tanks Our side shell

Standard One point/ Ten square meters One point / 50 square meters 1. Average dry film thickness of paint to be attained as the specification.

D. F. T Control

2. At least 80% of the measuring points to be met the specified film thickness. 3. Min 80% of the specified film thickness to be attained on remaining 20% measuring points.

- 120 -

section 5


painting part

* Pre- treatment

5.6 PRE- TREATMENT FOR PAINTING Kind of paint Item MOISTURE

Epoxy resin

Inorganic zinc

Not to be visible to the naked eye

Salt Oil/ grease

“” Not to be visible. Trace of thinner wiping is permitted

Fat Soap solution Zinc salt Fume by welding or cutting Chalk/ slate pencil mark

conventional

“” White deposits are not to be visible To remove white deposits, but the remaining trace may be visible after sweep-blasting or power tooling Not to be remained. To be wiped with rags or brush. The trace be visible In general, not to be removed. In general,

Marking paint

not be removed

But if highly sophisticated special coating system to be applied,

Not to be

usage of marking paint will be

removed

advised by paint manufacturers. Remaining trace may be visible.

Dust or mud contaminants to be removed with rags, broom or Dust/ mud contamination

vacuum cleaner to the possible extent. Flying or suspension properties of fine-dust which could be excluded by self-pressure of spray – gun may be accepted in the normal shipbuilding practice.

- 121 -

section 5


painting part

* Pre- treatment

5.7 TREATMENT AT WELDING PART Item

Remarks Stable spatter contracted surface with mother plate more than two-third of spatter width not to be removed.

1) Spatters

Stable spatters

Stable spatter ( O ) Removable or unstable spatters to be removed with grinder, disc-sander or chipping hammer. Unstable spatters

Unstable spatter ( x ) For non-exposed

Remain welding beads

areas. ( Cargo hold spaces, C. O. tanks, W. B tanks, void spaces, covered parts 2) Repair welding bead of notches

of superstructures, etc... ) Welding and grind flush

For exposed areas. ( Exposed deck, outside shells, engine room passageways etc... )

- 122 -


section 5

painting part

Item

* Pre- treatment

Remarks Slag to be removed with grinder or disc-sander up to the standard. But if not completely removes, trace or stain may be left.

3) Slag

Rust and heat scale

4) Rust and Heat scale

- 123 -


section 5

painting part

Item

* Pre- treatment

Remarks Weld-fume

5) Weld fume

After secondary surface preparation at each stage, the welding defects found are to be repaired as follows Grade

Area

Defects

Repair Method

Butt & Seam lines 1

of side shell

Blow hole

Welding and

Air, Water tight

pin hole

Grinding

boundaries Blow hole

6) Repair of welding defect

pin hole 2

Major structural

3
members

Blow hole pin hole 3

D

Common members 3

Blow hole

rolled angle, flat

Pin hole

- 124 -

Fill up with epoxy putty “

(Bracket, Stiffeners, bar)

“

( Not welding) Repair


section 5

painting part

* damage part

5.8 DAMAGED PART Item

Remarks

Preparation and Feathering

1) Rusted part and block joint ( Wire brushing and/ or disc-sweeping etc... ) The surface between coat and touch-up to be treated with an elaborate workmanship as smooth as possible.

Touch-up

Roughness of the profile after feathering to be treated with an elaborate workmanship as smooth as possible. Roughness

- 125 -


section 5

painting part

Item

* damage part

Remarks ( 1 ) In case damage reaches to bare steel:

- Adequate cleaning to bare steel according to the standard referred. 2) Mechanical damage on painted area.

- Repair coating as original system. ( 2 ) In case damage dosen’t reach to bare steel:

- adequate cleaning by appropriate methods to the paint film affected. - Repair touching-up as damaged film. Repair criteria of paint film damages. Profile view of typical.

3) Wooden block boundary area. ( New ship building )

- 126 -


section 5

painting part

Item

* damage part

Remarks A’ Detail

Repair method Flat Bottom

1. Scraping 2. Fine papering 3. Touch up as specified delicately. * To be repaired as it is.

- Squeezes - Compression

Spot-rusted part 4) Spot rusted area

- 127 -


section 5

painting part

Item

Remarks

5) Burnt part

- 128 -

* damage part


section 5

painting part

* environmental

5.9 MANAGEMENT OF PAINTING WORKS 1) pre-coating ( Stripe coat )

2) Overrall coating

Airless spraying or air spaying ( if necessary ) to be applied

5.10 ENVIRONMENTAL STANDARDS

1) Substrate temperature to be kept above 50C 1) Temperature

2) Surface temperature to be kept more than 30C above the dew point.

2) Humidity

Relative humidity to be kept below 85%

- 129 -


section 5

painting part

* final condition

5.11 SURFACE CONDITION OF FINAL COATING Item

Where appearance of special importance ( Exposed superstructure, cabin, passages, etc...)

For visible parts other than above ( inside of engine room outside shell, exposed part of decks, stores and cargo hold, etc...)

For invisible part, void spaces and cofferdams, cargo tanks, W. B. tanks, etc...

Check Points

a ) Sagging, missing, brush mark, cracking, wrinkling and holiday are not to be visible. b) color of final coating is not to be different from the specified. c) Spray dust is not to be visible.

a) Missing, cracking, wrinkling and holiday are not to be visible remarkably. b) Sagging and brush mark not to be continued to large extent on the surface. c) Final color is not to be different from the specified color but difference of color by aging at working stage which will be equal in the end is permitted.

a) Missing, cracking and holiday are not to be visible remarkably. b) Heavy sagging are not to be continued to large extent on the surface. c) The difference of the appearance is not to be severe.

- 130 -


Section 6

Electrical part

6.1 CABLE INSTALLATION…………………………………………………………………….132 - CABLE WAY - UNDER FLOOR METHOD - CABLE TIE & BAND TAPE - CABLE STAIR - ROUND STAIR - STAIR HEIGHT - CABLE PIPE/ DUCT - CABLE RADIUS ACCEPTANCE - CABLE PENETRATION - METHOD OF ENTERING CABLE INTO EQUIPMENT - DETAIL OF CABLE THROUGH WITH M. C. T 6.2 WEATHER DECK FITTINGS ………………………………………………………………148 6.3 CABLE EXPANSION METHOD ……………………………………………………………150 6.4CABLE CONDUCT EARTH METHOD…………………………………………………… 150 6.5 STANDARD OF OPENING THE HULL ……………………………………………………151

- 131 -


SECTION 6

ELECTRICAL PART

Item 6.1. Electric cable installation 1.1 Turning method of main cable ways 1.1.1 In case of same height.

* In case of same height in relation to one and another way. 1.1.2. In case of different height

* In case of different height in relation to one and another way.

- 132 -

* CABLE INSTALLATION


SECTION 6

ELECTRICAL PART


Item 1.1.3. In case of curved way * The cable shall be installed on adequate supporter as shown on following figure.

1.2. Branch cable way ( for example )

- 133 -


SECTION 6

ELECTRICAL PART

Item 1.3. Vertical main cable ways

- 134 -



SECTION 6

ELECTRICAL PART

Item 1.4. Under floor method

- 135 -



SECTION 6

ELECTRICAL PART

* CABLE Band

Item 1.5. Cable tie and binding tape 1.5.1. Cable tie * The cable tie to be applied inside of switch board, control console, etc cable fastening.

Symbol

L

Remark

CT- 100

100

MIL – S – 23190 D MS 3367 – 4

Ct – 175

175

MIL – S – 23190

- 136 -

MS 3367 - 1


SECTION 6

ELECTRICAL PART

* CABLE Band

Item 1.5.2 Cable binding tape

* These binding tapes shall be used for cable securing and selected in accordance with cable kind and / or their location. P. V. C coated BTN – 3, 4 type shall be used for non-metallic sheath or non-armoured cable others ( BTM-1, 2 ) shall be used for metallic sheath or armoured cable. For cable which are exposed to weather or installed in refrigerated rooms, laundry, etc.. stainless steel tape shall be applied. Symbol

w

t

remark

BTN-1

15

0.5

BTN-2

-

“

stainless

BTN-3

“

“

elec. ‘ glav. ‘ steel ( PVC coating )

BTN-4

“

“

Stainless ( P. V. C coating )

elec.’ glav. ‘ steel

- 137 -


SECTION 6

ELECTRICAL PART

* cable stair

Item 1.6 Cable stair 1.6.1 Single stair combined method

Type

Hanger

Runner bar

L

LA – 2

L- 2

25x 6 F. B

LA – 3

L–3

LA – 4

W H < 300

H > 300

200

224

292

“

300

324

392

L–4

38 x 6 F.B

400

424

492

LA – 5

L–5

“

500

524

592

LA – 6

L–6

“

600

624

692

LA - 7

L–7

“

700

724

792

LA – 8

L–8

“

800

824

892

LA – 9

L–9

“

900

924

992

LA – 1m

L – 1m

“

1000

1024

1092

H < 300 = 50 x 6. F. B

H > 300 = 40 x 40 x 5 ANG.

- 138 -


SECTION 6

ELECTRICAL PART

1.6.2 Double stair combined method

1.6.3. Reversible single stair combined method.

- 139 -

* cable stair


SECTION 6

ELECTRICAL PART

1.6.4 Round type stair

1.6.5 Adjustment of stair height

- 140 -

* cable stair


SECTION 6

ELECTRICAL PART

* penetration

Item 1.7 Deck and wall penetration 1.7.1 Collar and coaming Coaming dimension.

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

COAMTING A B 100 60 80 ″ 150 60 80 ″ 100 ″ 200 60 80 ″ 100 ″ 160 ″ 250 60 80 ″ 100 ″ 160 ″ 300 60 80 ″ 100 ″ 160 ″ 200 ″ 350 60 80 ″ 100 ″ 160 ″

n

TYPE

NO

30 40 30 40 50 30 40 50 50 30 40 50 50 30 40 50 50 50 30 40 50 50

1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 2 2 1 1 1 2

23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

- 141 -

COAMTING A B 350 200 400 60 80 ″ 100 ″ 160 ″ 200 ″ 450 80 100 ″ 160 ″ 200 ″ 500 80 100 ″ 160 ″ 200 ″ 600 80 100 ″ 160 ″ 200 ″ 700 80 100 ″ 160 ″ 200 ″

n

TYPE

50 30 40 50 ″ ″ 40 50 ″ ″ 40 50 ″ ″ 40 50 ″ ″ 40 50 ″ ″

2 1 1 1 2 2 1 1 2 2 1 1 2 2 1 1 2 2 1 1 2 2


SECTION 6

ELECTRICAL PART

* penetration

Item 1.7.2 Substantial for cable penetration a. Substantial for non-watertight penetration i) In case of no heat resisting steel wall, beam, girdes and long etc... to depend the substantials as shown below.

ii) In case of heat resisting. to be fitted to put about 10mm from the heat resisting surface a shown below.

- 142 -


SECTION 6

ELECTRICAL PART

Item b. Substantial for watertight penetration i ) In case of fitting of one by one gland

ii) Assembly fitting stuffing gland.

- 143 -

* penetration


SECTION 6

ELECTRICAL PART

Item 1.7.3. Method of entering cable into equipment a. For water tight gland

b. For coaming

- 144 -

* method of entering cable


SECTION 6

ELECTRICAL PART

Item 1.7.4 Detail of cable through deck & wall a. A and B class steel Wall i) Rectangular collar type

ii) Round collar type

Cable

- 145 -

*wall collar


SECTION 6

ELECTRICAL PART

Item b. A class deck i ) Rectangular coaming type

ii ) Round coaming type

- 146 -

* coamings


SECTION 6

ELECTRICAL PART

Item c. Multi cable transit For A class deck in electric cable trunk shall be supplied.

- 147 -

* M. c. t

SECTION 6


ELECTRICAL PART

* fittings installation

6.2 WEATHER DECK FITTINGS 2.1 Distance between steam pipe to cable

2.2 Cable grand install

2.3 Cable pipe thickness range for on deck and W.T or F.O tank penetration parts. PIPE INTERNAL DIAMETER ( I. D )

MINIMUM THICKNESS

ID < 57.0

4.0

57.0

4.5

ID <152.4

152.4

ID <304.8

5.5

304.8

ID

UNACCEPTABLE

- 148 -


SECTION 6

ELECTRICAL PART

- 149 -

* fittings installation


SECTION 6

ELECTRICAL PART

6.3 CABLE EXPANTION METHOD * MINIMUM RADIUS: CABLE O.D x 12 Times 3.1. CABLE HANGER TYPE

3.2. CABLE PIPE TYPE

6.4 CABLE CONDUCT EARTH METHOD

- 150 -

* cable expansion

SECTION 6


ELECTRICAL PART

* HULL OPENING METHOD

6.5 STANDARD OF OPENING 5.1 TYPICAL

SPACE CONPENSATION

“A” SPACE

“B” SPACE

WITHOUT

WITH

WITHOUT

WITH

CARGO OIL

d 1/5D

d 1/2D

d 1/10D

d 1/4D

TANK

MAX=300

MAX=300

CARGO HOLD

d 1/4D

d 1/2D

d 1/8D

d 1/4D

d 1/3D

d 1/2D

d 1/6D

d 1/4D

d 2/5D

d 1/2D

d 1/5D

d 1/4D

d 3/5D

d 2/3D

-

-

POSITION

REMARK

GIRDER, WEB

ENGINE ROOM SUPER STRUCTURE

SOILD FLOOR, CONFFERDAM WEB DOUBLE BOTTOM SIDE GIRDER, DIAPHRAGM * NOTE:

GENERALLY IN “ C” SPACE, OPENING SHOULD NOT BE CUT, IF UNAVOIDABLE FOR PIPING, ETC.. OPENING COMPENSATION SHOULD BE DESIGNED AFTER CONSIDERING TYPE OF STRUCTUAL MEMBER AND ITS SIZE OF LOAD, ETC. IF TO BE FITTED DOUBLING PLATE COAMING ( RING ) S1 = ( S – 1/2h ).

- 151 -

section 6


electrical part

* hull opening method

5.2 MIN. DISTANCE BETWEEN HOLE & HOLE, HOLE & END OF STRUCTURE MEMBER A SPACE

B SPACE

C SPACE

1) HOLE AND HOLE

S

d1  d 2 2

S=d1+d2

1 d 2

S=d

2) HOLE AND DECK S

3) HOLE AND FACE BAR S=d

S=2+d

(Min.75mm)

(Min.75mm)

4) HOLE AND SCALLOP

S

d r 2

(Min.50mm)

S=d+R (Min.50mm)

5) HOLE AND SLOT

IF S  S

Bd 2

S=B+d

Bd 2

S=B+d TO BE FITTED COLLAR PLATE

* NOTE: GENERALLY WHEN DOUBLING PLATE OR F.B COAMING HAD SAME AS HULL THICKNESS TO BE DESIGENED, “S” MAY BE REDUCED BY HALF OF DOUBLING PLATE OR F.B COATING. HOWEVER “ S” IS NOT TO BE LESS HALF OF STANDARD. - 152 -


section 6

electric part

* hull reinforcement

5.3 HULL STRUCTURE OPENING HOLE REINFORCEMENT METHOD 5.3.1 DOUBLE PLATE INSTALL

a

b/2

t1

t

5.3.2 RING STIFFENER INSTALL

a

b/2

t1

t

d

Min. 25

5.3.3 PARTIAL INCREASING OF WEB DEPTH.

a

1.5h

b

L

h

3d-H - 153 -

HALONG SHIPYARD QUALITY STANDARD BOOK 1

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