NSWLC Shipyard Modernization Project. Bob Hillstrom, SMP Project Manager October 16, 2014

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1 NSWLC Shipyard Modernization Project Bob Hillstrom, SMP Project Manager October 16, 2014

Shipbuilding Stages of Construction Fabrication

Subassembly Joining of parts by welding to create

Assembly of 12m x 12m standard hull blocks

blocks Blast and Paint Abrasive blasting for

outfit items Pre-Erection Joining of blocks to

2 Shipbuilding Stages of Construction Fabrication Cutting of parts from raw material Forming of parts Subassembly Joining of parts by welding to create interim products up to ~20 tonnes Block Assembly Assembly of 12m x 12m standard hull blocks Pre-Outfitting Installation of outfit on hull blocks Blast and Paint Abrasive blasting for surface preparation Coating of hull structure and outfit items Pre-Erection Joining of blocks to create grand blocks Erection Erecting and joining of grand blocks to create the vessel 2

3 Building and Area Identification Panel Shop Forming Shop Block Assembly Pre-Outfitting Repair B&P N/C B&P Careen Drydock Loadout Pier Erection Pre-Erection

4 Facility Process Flow

Subassembly Shop (24m x 168m) Cranes (1) 20-tonne with

handling profiles (3) 10-tonne to support subassembly

marks and provides layout information from N/C files

5 Subassembly Shop (24m x 168m) Cranes (1) 20-tonne with permanent magnet lifting beam for plates (1) 5-tonne for handling profiles (3) 10-tonne to support subassembly operations Robotic profile line Automatically cuts, bevels, marks and provides layout information from N/C files Subassembly Shop Cranes Plasma Cutting Machine Robotic Profile Line Plasma cutting machine Cuts plates up to 3m x 10m from N/C files Oxy-Fuel cutting machine Used for fitting aids and small parts 5

6 Forming Shop (14m x 130m) New 1000T plate press Forms compound shape in hull plating Capacity up to 60 mm thick plate Existing forming equipment 1000T press brake 300T press brake 400T stiffener forming 500T C-frame press 8 ft plate rolls 1000T Plate Press 6

Panel Shop (28m x 170m) Panel Line Automated conveyor

Single-side plate welding Panel cutting, layout & marking

at end of line for installation of web frames, bulkheads,

7 Panel Shop (28m x 170m) Panel Line Automated conveyor line to produce 12m x 12m flat stiffened panels Single-side plate welding Panel cutting, layout & marking Stiffener fitting Stiffener welding Three manual stations at end of line for installation of web frames, bulkheads, etc. Single-Side Plate Welding Panel Cutting Stiffener Fitting Gantry 7

Block Assembly Shop (30m x 130m) Cranes (2) 40T bridge cranes

for setting of web frames, bulkheads, etc.

form configuration Supports accurate assembly of complex

8 Block Assembly Shop (30m x 130m) Cranes (2) 40T bridge cranes each with two 40T trolleys for block turnover (2) 15T cranes for setting of web frames, bulkheads, etc. Pin Jigs Telescoping pipes adjusted to height to match hull form configuration Supports accurate assembly of complex curved hull blocks Chip Barge Construction in Block Assembly Pin Jig Upright and Base Pipes 8

positions Steel grit vacuum and elevator recovery system

Repair Building shell relocated to new foundation New

Accommodates vessels up to 75m in length and 22m in height

9 Blast and Paint Shops (New Const. 30m x 60m & Repair 28m x 76m) New Construction Two blast positions Steel grit vacuum and elevator recovery system Dedicated dust collection system Four paint positions Repair Building shell relocated to new foundation New cladding, ventilation and blasting equipment installed Accommodates vessels up to 75m in length and 22m in height Exhaust Ventilation System Repair B&P Building Relocation New Construction Paint Dust Collection System 9

Installation of outfit components on a structural

10 Pre-Outfitting Shop (New Const. 30m x 180m) Block outfitting Installation of outfit components on structural hull blocks 5 bays each 16m x 28m 10 block outfitting positions Module construction Installation of outfit components on a structural framework Two bays each 16m X 28m Block Outfitting Pre-Outfitting Shop Module Construction 10

11 Pre-Erection and Erection (76m x 230m) 300T Goliath Crane Schedule Order Feb 28, 2013 Design Mar-June Manufacture June-Dec Erection Mar-Apr, 2014 Test Aug Capabilities 300T block lift 200T block turnovers Crane specifications Two trolleys 2 x 100 T 1 x 150 T Hook height 70 m Bridge span 76 m Travel speed 30 m/min Hoist speed 12 m/min 11

12 Pre-Erection and Erection cont. (76m x 230m) SPMTs 32 axles & 2 power units Grandblock and vessel moves to 960T Rolling Mobile Shelters (3) 30.5 m x 29m x 20m Loadout Pier Provides level vessel transfer to floating drydock Careen Drydock Capable of launching Panamax vessels up to ~200m 12

Lecture 3-2: Hull production Steel processing methods

Kul-24.4130 Shipyard engineering Lecture 3-2: Hull production Steel processing methods Applied Mechanics Marine Technology Lecture in course contents Production planning Introduction Shipbuilding process