Lecture Note of Design Theories of Ship and Offshore Plant Design Theories of Ship and Offshore Plant Part I. Ship Design Ch. 1 Introduction to Ship Design Fall 2016 Myung-Il Roh Department of Naval Architecture and Ocean Engineering Seoul National University 1 Contents Ch. 1 Introduction to Ship Design Ch. 2 Introduction to Offshore Plant Design Ch. 3 Hull Form Design Ch. 4 General Arrangement Design Ch. 5 Naval Architectural Calculation Ch. 6 Structural Design Ch. 7 Outfitting Design 2 1
Ch. 1 Introduction to Ship Design 1. Basic Functions of a Ship 2. Main Terminology 3. Comparisons of a Ship with Other Structures 4. Construction Procedure of a Ship 3 1. Basic Functions of a Ship 4 2
Basic Requirements of a Ship (1) Ship should float and be stable in sea water. Weight of the ship is equal to the buoyancy* in static equilibrium. Ship stability Density of steel = 7.85 ton/m 3 about 0.5 ton/m 3 Wood 10 ton = 10 ton 1.025 ton/m 3 (2) Ship should transport cargoes. Ship compartment design The inner space should be large enough for storing the cargoes. (3) Ship should move fast to the destination and be possible to control itself. Hull form design, Ship hydrodynamics, Propeller design, Ship maneuverability and control Shape: It should be made to keep low resistance (ex. streamlined shape). Propulsion equipment: Diesel engine, Helical propeller Steering equipment: Steering gear, Rudder (4) Ship should be strong enough in all her life. It is made of the welded structure of steel plate (about 10~30mm thickness) and stiffeners. Ship structural mechanics, Structural design & analysis * Archimedes Principle: The buoyancy of the floating body is equal to the weigh of displaced fluid of the immersed portion of the volume of the ship. 5 Basic Functions of a Ship Floating in the water Static equilibrium Containing cargoes like a strong bowl Welded structure of plates (thickness of about 20 ~ 30mm), stiffeners, and brackets A VLCC has the lightweight of about 45,000 ton and can carry crude oil of about 300,000 ton. Going fast on the water Hull form: Streamlined shape having small resistance Propulsion: Diesel engine, Helical propeller The speed of ship is represented with knot(s). 1 knot is a speed which can go 1 nautical mile (1,852 m) in 1 hour. A ship has less motion for being comfortable and safe of passengers and cargo. Maneuvering equipment: Rudder 6 3
How does a ship float? (1/3) The force that enables a ship to float Buoyant Force It is directed upward. It has a magnitude equal to the weight of the fluid which is displaced by the ship. Ship Water tank Ship Water 7 How does a ship float? (2/3) Archimedes Principle The magnitude of the buoyant force acting on a floating body in the fluid is equal to the weight of the fluid which is displaced by the floating body. The direction of the buoyant force is opposite to the gravitational force. Buoyant force of a floating body = the weight of the fluid which is displaced by the floating body ( Displacement ) Archimedes Principle Equilibrium State ( Floating Condition ) Buoyant force of the floating body = Weight of the floating body W = -W = - gv Displacement = Weight G: Center of gravity B: Center of buoyancy W: Weight, : Displacement : Density of fluid V: Submerged volume of the floating body (Displacement volume, ) G B 8 4
How does a ship float? (3/3) Displacement( ) = Buoyant Force = Weight(W) L B T C T: Draft W LWT B DWT C B : Block coefficient : Density of sea water LWT: Lightweight DWT: Deadweight Weight = Ship weight (Lightweight) + Cargo weight(deadweight) Ship Ship Water 9 2. Main Terminology 10 5
Principal Dimensions (1/2) Loa W.L. B.L. W.L. B.L. A.P. Lbp Lwl LOA (Length Over All) [m]: Maximum Length of Ship F.P. LBP (Length Between Perpendiculars (A.P. ~ F.P.)) [m] A.P.: After perpendicular (normally, center line of the rudder stock) F.P.: Inter-section line between designed draft and fore side of the stem, which is perpendicular to the baseline Lf (Freeboard Length) [m]: Basis of freeboard assignment, damage stability calculation 96% of Lwl at 0.85D or Lbp at 0.85D, whichever is greater Rule Length (Scantling Length) [m]: Basis of structural design and equipment selection Intermediate one among (0.96 Lwl at Ts, 0.97 Lwl at Ts, Lbp at Ts) 11 Principal Dimensions (2/2) B (Breadth) [m]: Maximum breadth of the ship, measured amidships -B molded : excluding shell plate thickness -B extreme : including shell plate thickness Air Draft D (Depth) [m]: Distance from the baseline to the deck side line -D molded : excluding keel plate thickness -D extreme : including keel plate thickness Depth Draft Td (Designed Draft) [m]: Main operating draft - In general, basis of ship s deadweight and speed/power performance Ts (Scantling Draft) [m]: Basis of structural design B.L. Breadth B.L. Air Draft [m]: Distance (height above waterline only or including operating draft) restricted by the port facilities, navigating route, etc. - Air draft from baseline to the top of the mast - Air draft from waterline to the top of the mast - Air draft from waterline to the top of hatch cover - 12 6
What is a Hull form? Hull form Outer shape of the hull that is streamlined in order to satisfy requirements of a ship owner such as a deadweight, ship speed, and so on Like a skin of human Hull form design Design task that designs the hull form Hull form of the VLCC(Very Large Crude oil Carrier) Wireframe model Surface model 13 Hull Form Coefficients (1/2) C B (Block Coefficient) = Displacement / (L x B x T x Density) where, density of sea water = 1.025 [Mg/m 3 ] A M : Maximum transverse underwater area C M (Midship Section Coefficient) = A M / (B x T) C P (Prismatic Coefficient) = Displacement / (A M x L x Density) T B 14 7
Hull Form Coefficients (2/2) A WP : Area of the water plane C WP (Water Plane Area Coefficient) = A WP / (L x B) 15 Lines of a 320K VLCC Body Plan Water Plan Sheer Plan 16 8
What is a Compartment? Compartment Space to load cargos in the ship It is divided by a bulkhead which is a diaphragm or peritoneum of human. Compartment design (General arrangement design) Compartment modeling + Ship calculation Compartment modeling Design task that divides the interior parts of a hull form into a number of compartments Ship calculation (Naval architecture calculation) Design task that evaluates whether the ship satisfies the required cargo capacity by a ship owner and, at the same time, the international regulations related to stability, such as MARPOL and SOLAS, or not Compartment of the VLCC 17 G/A of a 320K VLCC Principal Dimensions LOA 332.0 m LBP 320.0 m B 60.0 m D 30.5 m Td / Ts 21.0 / 22.5 m Deadweight at Ts 320,000 ton Service speed at Td 16.0 knots at NCR with 15% sea margin * Reference: DSME Capacities Cargo tank 357,000 m 3 Water ballast 101,500 m 3 Main Engine SULZER 7RTA84T-D MCR 39,060 PS x 76.0 rpm NCR 35,150 PS x 73.4 rpm No. of cargo segregation Three (3) Cruising range 26,500 N/M 18 9
What is a Hull Structure? Hull structure Frame of a ship comprising of a number of hull structural parts such as plates, stiffeners, brackets, and so on Like a skeleton of human Hull structural design Design task that determines the specifications of the hull structural parts such as the size, material, and so on Hull structure of the VLCC 19 Structural Drawing of a 320K VLCC Web Frame Drawing Midship Section (Ordinary Frame Section) Drawing 20 10
What is a Outfitting? Outfitting All equipment and instrument to be required for showing all function of the ship Hull outfitting: Propeller, rudder, anchor/mooring equipment, etc. Machinery outfitting: Equipment, pipes, ducts, etc. in the engine room Accommodation outfitting: Deck house (accommodation), voyage equipment, etc. Electric outfitting: Power, lighting, cables, and so on Like internal organs or blood vessels of human Pipe model of the VLCC Outfitting design Design task that determines the types, numbers, and specifications of outfitting 21 P&ID of a 320K VLCC P&ID: Piping & Instrumentation Diagram, Non-scaled drawing representing the relationship between equipment 22 11
Criteria for the Size of a Ship Displacement Weight of water displaced by the ship s submerged part Equal to total weight of ship Used when representing the size of naval ships Deadweight Total weight of cargo. Actually, Cargo payload + Consumables (F.O., D.O., L.O., F.W., etc.) + DWT Constant Used when representing the size of commercial ships (tanker, bulk carrier, ore carrier, etc.) Tonnage Total volume of ship Basis for statics, tax, etc. Used when representing the size of passenger ships * F.O.: Fuel Oil, D.O.: Diesel Oil, L.O.: Lubricating Oil, F.W.: Fresh Water 23 Weight and COG (Center Of Gravity) Displacement [ton] Weight of water displaced by the ship s submerged part Deadweight (DWT) [ton]: Cargo payload + Consumables (F.O., D.O., L.O., F.W., etc.) + DWT Constant = Displacement - Lightweight Cargo Payload [ton]: Weight of loaded cargo at the loaded draft DWT Constant [ton]: Operational liquid in the machinery and pipes, provisions for crew, etc. Lightweight (LWT) [ton]: Total of hull steel weight and weight of equipment on board Trim: difference between draft at A.P. and F.P. Trim = {Displacement x (LCB - LCG)} / (MTC x 100) LCB: Longitudinal Center of Buoyancy LCG: Longitudinal Center of Gravity * F.O.: Fuel Oil, D.O.: Diesel Oil, L.O.: Lubricating Oil, F.W.: Fresh Water 24 12
Tonnage Tonnage: normally, 100 ft 3 (=2.83 m 3 ) = 1 ton Basis of various fee and tax GT (Gross Tonnage): Total sum of the volumes of every enclosed space NT (Net Tonnage): Total sum of the volumes of every cargo space GT and NT should be calculated in accordance with IMO 1969 Tonnage Measurement Regulation. CGT (Compensated Gross Tonnage) Panama and Suez canal have their own tonnage regulations. 25 Speed and Power (1/2) MCR (Maximum Continuous Rating) [PS x rpm] NMCR (Nominal MCR) DMCR (Derated MCR) / SMCR (Selected MCR) NCR (Normal Continuous Rating) [PS x rpm] Trial Power [PS x rpm]: Required power without sea margin at the service speed (BHP) Sea Margin [%]: Power reserve for the influence of storm seas and wind including the effects of fouling and corrosion. Service Speed [knots]: Speed at NCR power with the specific sea margin (e.g., 15%) 26 13
Speed and Power (2/2) DHP: Delivered Horse Power Power actually delivered to the propeller with some power loss in the stern tube bearing and in any shaft tunnel bearings between the stern tube and the site of the torsion-meter EHP: Effective Horse Power Required power to maintain intended speed of the ship D : Quasi-propulsive coefficient = EHP / DHP RPM margin To provide a sufficient torque reserve whenever full power must be attained under unfavorable weather conditions To compensate for the expected future drop in revolutions for constant-power operation 27 Unit (1/2) LT (Long Ton, British) = 1.016 [ton], ST (Short Ton, American) = 0.907 [ton], MT (Metric Ton, Standard) = 1.0 [ton] Density [ton/m 3 or Mg/m 3 ] e.g., density of sea water = 1.025 [ton/m 3 ], density of fresh water = 1.0 [ton/m 3 ], density of steel = 7.8 [ton/m 3 ] 1 [knots] = 1 [NM/hr] = 1.852 [km/hr] = 0.5144 [m/sec] 1 [PS] = 75 [kgf m/s] = 75 10-3 [Mg] 9.81 [m/s 2 ] [m/s] = 0.73575 [kw] (Pferdestarke, German translation of horsepower) NMCR of B&W6S60MC: 12,240 [kw] = 16,680 [PS] 1 [BHP] = 76 [kgf m/s] = 76 10-3 [Mg] 9.81 [m/s 2 ] [m/s] = 0.74556 [KW] (British horsepower) 28 14
Unit (2/2) SG (Specific Gravity) No dimension SG of material = density of material / density of water e.g., SG of sea water = 1.025, SG of fresh water = 1.0, SG of steel = 7.8 SF (Stowage Factor) [ft 3 /LT] e.g., SF = 15 [ft 3 /LT] SG = 2.4 [ton/m 3 ] API (American Petroleum Institute) = (141.5 / SG) - 131.5 e.g., API 40 SG = 0.8251 1 [barrel] = 0.159 [m 3 ] e.g., 1 [mil. barrels] = 159,000 [m 3 ] 29 3. Comparisons of a Ship with Other Structures 30 15
Features of a Ship Comparison with Other Structures (Building, Automobile, Airplane) Objective Moving or fixed External force acting on the structure Design concept Production method 31 Hull Form Design vs. Car Exterior Design Hull form design A hull form is related to the resistance and propulsion performance of a ship. Order production: new design for each order Large structure of about 100~400 m length The performance like speed and deadweight is most important. Car exterior design A exterior is related to the air resistance and esthetic design of a car. Mass production: one time design for each model The performance and esthetic design are simultaneously important. 32 16
Procedure of Car Exterior Design Idea Sketch & Rendering Tape Drawing Clay Modeling Stylist Digital Modeling (Reverse Engineering) Measuring Engineer Hull From Design 33 Procedure of Hull Form Design Wireframes of Hull Form Fairing Hull Form Surface General Arrangement and Hull Structure Design feedback offset feedback Basis Ship Variation Model Test Naval Architectural Calculation/CAE CFD Hull Form Design * CFD: Computational Fluid Dynamics, CAE: Computer-Aided Engineering 34 17
4. Construction Procedure of a Ship 35 Construction Procedures of a Ship (Overview) Deadweight 300,000 ton VLCC (Very Large Crude oil Carrier) 5 key events of construction procedures Contract Steel Cutting (S/C) * Deadweight 300,000 ton VLCC, L: 320.0 m, B: 58.0 m, D: 31.2 m, 3 soccer fields can be located on the deck. * 63 building in Seoul, 249.0 m from the ground Keel Laying (K/L) Launching (L/C) Delivery (D/L) Contract Initial design K/L Detailed design S/C Production design L/C D/L -6-4 -2 0 +3 +6 +8 * Reference: DSME Design (Initial/Detailed/Production) Construction period of 300K VLCC (on December 2006) Key Event Duration Steel Cutting Assembly Outfitting Contract -6 months S/C or W/C* Base date K/L +3 months L/C +6 months D/L +8 months Total 14 months * W/C: Work Commence. Starting date when Design S/C is Painting Erection Launching Theories made. of Ship and Offshore Plant, Fall 2016, Myung-Il Roh 36 18
Construction Procedures of a Ship (Detailed) : 5 key events of construction procedures Ship Owner, Classification Society Survey Classification Society, Customs Design Department Design S/C Assembly Contract Marketing Department Production Planning Production Planning Department (Plan) (BOM/POR) Material Procurement Receiving Inspection Material Issuing Procurement Department Pre-outfitting K/L Erection Outfitting Production Department L/C Outfitting Quay Outfitting & Production Department Trial See Trial Department /QA,QC D/L A/S Ship Warranty Department * S/C: Steel Cutting, K/L: Keel Laying, L/C: Launching, D/L: Delivery * BOM: Bill Of Material, POR: Purchase Order Request, QA: Quality Assurance, QC: Quality Control 37 Construction Procedures of a Ship (Detailed) Contract Steel Cutting (S/C) Keel Laying (K/L) Launching (L/C) Delivery (D/L) Design Assembly Assembly Quay Work Piling Up and Preprocess Pre-Outfitting and Pre-Painting A/S Pre-Erection 38 19
Design 39 Initial Design 설계조립강재적치및선행의장및전처리도장 - 재화중량 300,000톤대형유조선의선형모델링결과 계약강재절단용골배치진수인도 탑재 안벽작업 * 재화중량 300,000 톤대형유조선의주요치수 Lbp: 320.0m, B: 58.0m, D: 31.2m, Td: 20.8m, Ts: 20.8m, Cb: 0.8086 선형 선주의요구조건, 즉재화중량 (deadweight) 과계획속력및기타조건을모두만족시키는동시에유체특성이우수하며일반배치 (general arrangement) 가 compact 하도록선체를유선형형상으로깎고다듬어만든선박의외곽모양 Design * 서정우 Theories, 강성찬 of, 임중현 Ship and, 이규열 Offshore, 이상욱 Plant,, 조두연 Fall, 노명일 2016,, Myung-Il 조선전용 Roh CAD 시스템 : EzSHIP, 2003년도한국CAD/CAM학회학술발표회, pp.23-28, 서울, 2003.2.7 40 20
Initial Design 설계조립강재적치및선행의장및전처리도장 - 재화중량 300,000톤대형유조선의구획모델링결과 계약강재절단용골배치진수인도 탑재 안벽작업 * 재화중량 300,000 톤대형유조선의주요치수 Lbp: 320.0m, B: 58.0m, D: 31.2m, Td: 20.8m, Ts: 20.8m, Cb: 0.8086 구획 선체내부에화물, 연료등을실을수있으며선박관련규약 (Rule) 의요구사항을만족하는적재공간 * Kyu-Yeul Lee, Sang-Uk Lee, Doo-Yeoun Cho, Myung-Il Roh, Seong-Chan Kang, Jung-Woo Seo, An Innovative Compartment Modeling and Ship Calculation System, Design International Theories Marine of Ship Design and Offshore Conference(IMDC) Plant, Fall 2003, 2016, pp.683-694, Myung-Il Athens, Roh Greece, 2003.5.7 41 Initial Design (Hull Structure) 설계조립강재적치및선행의장및전처리도장 - 재화중량 300,000톤대형유조선의선체모델링결과 계약강재절단용골배치진수인도 탑재 안벽작업 구조 구조적안전성을가지기위한선박내부의뼈대 화물창내부의모습 선체중앙부를확대한모습 * 재화중량 300,000 톤대형유조선의주요치수 Lbp: 320.0m, B: 58.0m, D: 31.2m, Td: 20.8m, Ts: 20.8m, Cb: 0.8086 * Myung-Il Roh, Kyu-Yeul Lee, An Initial Hull Structural Modeling System for Computer-Aided Process Planning in Shipbuilding, Design Advances Theories in Engineering of Ship and Software, Offshore Vol. Plant, 37, No. Fall 7, 2016, pp.457-476, Myung-Il 2006.7 Roh 42 21
Initial Design (Hull Structure) 설계조립탑재안벽작업강재적치및선행의장및전처리도장 - 재화중량 300,000톤대형유조선의구조해석모델생성결과 계약강재절단용골배치진수인도 전선구조해석모델 (global structural analysis model) 선체구조해석 선체가구조적안전성을가지는지를평가하는작업 화물창구조해석모델 (hold structural analysis model) * Myung-Il Roh, Kyu-Yeul Lee, Woo-Young Choi, Seong-Jin Yoo, Improvement of Ship Design Practice Using a 3D CAD Model of a Hull Structure, Design Robotics Theories and Computer-Integrated of Ship and Offshore Manufacturing Plant, Fall 2016, Journal(SCIE/IF:0.699), Myung-Il Roh 2006.10.16[Article in Press, e-journal Available] 43 Initial Design (Pipe Outfitting) 설계조립탑재안벽작업강재적치및선행의장및전처리도장 - 배관계통도 (P&ID: Piping and Instrument Diagram) 작성 계약강재절단용골배치진수인도 P&ID: Pipe and Instrument Diagram, 시스템간의연결관계를나타낸 Non-scaled drawing Sea water cooling system Outlet Ejector Fresh water cooler CW022-500A: 응축기 (condenser) 로부터나온고온의해수를 5 o C 이하로감압한후선측외부로배출하기위한직경 500mm의배관route Ejector( 압력조절기 ) Fresh Water Generator Cooling sea water pump Sea chest Design * Sea Theories water cooling of Ship and system: Offshore 선체Plant, 내각종 Fall 2016, 기기들을 Myung-Il 냉각하기 Roh 위한 fresh water cooler 자체를해수를이용하여냉각해주는배관시스템 Topology data 44 22
Detail/Production Design (Hull Structure) - Result of Detailed/Production Design 계약 강재절단 용골배치 진수 인도 설계 조립 탑재 안벽작업 강재적치및 선행의장및 전처리 도장 Detailed design: 선박의상세성능을결정하는단계로서 System 별상세도면을작성 Production design: 선박의생산을위한구획 / 블록별건조도면을작성 Example of a detailed structural drawing of the fore body Example of a cutting drawing Example of a nesting drawing 45 Detailed Design (Pipe Outfitting) 설계조립강재적치및선행의장및전처리도장 - 재화중량 300,000톤대형유조선의배관모델링결과 계약강재절단용골배치진수인도 탑재 안벽작업 z x Section view y z Plan view x y z x ISO view y * Myung-Il Roh, Kyu-Yeul Lee, Woo-Young Choi, Rapid Generation of the Piping Model Having the Relationship with a Hull Structure in Shipbuilding, Design Advances Theories in Engineering of Ship and Software(SCIE/IF:0.371), Offshore Plant, Fall 2016, 2006.12.1 Myung-Il [Article Roh in Press, e-journal Available Now] 46 23
Block Division (Production Planning) 계약 강재절단 용골배치 진수 인도 설계 조립 탑재 안벽작업 강재적치및전처리 선행의장및도장 Block division drawing of a deadweight 300,000 ton VLCC * Deadweight 300,000 ton VLCC, L: 320.0 m, B: 58.0 m, D: 31.2 m, 3 soccer fields can be located on the deck. * 63 building in Seoul, 249.0 m from the ground Block seam Building block * Block seam: Joint line or welding line between adjacent blocks 47 Piling Up and Preprocess of Steel Material 48 24
Piling Up and Preprocess of Steel Material - Piling Up of Steel Material 계약강재절단용골배치진수인도 Steel material consists of plates and section steels which have the shape of bar. Piling up: 제철소에서구매한강재를해상또는육상으로운송하여조선소의야적장에보관하는공정 Grouping: 각호선 ( 선박의 ID) 별사양및가공일정에따라강재의선별작업을실시한뒤강재전처리장으로공급하는공정 Piling up method: Using Pallet 설계 강재적치및전처리 조립 선행의장및도장 탑재 안벽작업 Pallet Types of section steels 49 Piling Up and Preprocess of Steel Material - Preprocess of Steel Material 계약강재절단용골배치진수인도 Shot blasting 과 Shop priming 작업을하여강재표면의녹을제거하여도료의부착을좋게하고추후녹발생을방지하는공정 Shot blasting: 연소재 (shot ball, cut wire) 를강판의표면에고속으로투사하여녹, 흑피 (mill scale) 등을제거하는작업 Shop priming: 가공 / 조립등의공정중녹이발생하지않도록 shot blasting 이완료된강판에방청도료 (shop primer) 를도장하는작업 설계 강재적치및전처리 조립 선행의장및도장 탑재 안벽작업 Shot blasting Shop priming Types of shots * 흑피 (mill scale): 대기속에서금속을가열하였을때 Design 표면에 Theories 생기는 of Ship 금속산화물의 and Offshore 얇은 Plant, 층 Fall. 검은색을 2016, Myung-Il 띔 Roh Shot ball Cut wire 50 25
Piling Up and Preprocess of Steel Material -Marking Marking: 절단, 굽힘및조립작업에필요한선과기호를기입하는작업 계약강재절단용골배치진수인도 설계 강재적치및전처리 조립 선행의장및도장 탑재 안벽작업 최적화기법을이용한 Marking 토치경로생성시스템의예 Before: 84.67m 조립을위한수작업 marking line 의예 After: 39.26m NC(Numerical Control) marking 시어떻게하면 marking 토치의이동궤적을최소로할수있을까? 최적화기법의응용예 * Nesting: 규격강판을가장효율적으로사용하기위하여, 부재조각들을이리저리돌려맞추어서못쓰고잘려나가는강판의잔재를최소화하는작업 어떻게하면자동으로수율 ( 규격강판의면적대비실제사용할수있는강판의면적비율 ) 을최대로하는 nesting 결과를얻을수있을까? 최적화기법의또다른응용예 최적화기법을이용한 Auto-Nesting 시스템의예 51 Steel Cutting (S/C) 52 26
Steel Cutting (S/C) 계약 강재절단 용골배치 진수 인도 설계 조립 탑재 안벽작업 강재적치및 선행의장및 전처리 도장 Cutting: Marking line 을따라강재를잘라원하는형상의부재를얻기위한작업 Steel Cutting (S/C) or Work Commence (W/C): 강재를처음으로절단하는것 ( 착공식이라고함 ) Cutting methods Gas cutting, Plasma cutting, Laser cutting, Edge milling, etc. CNC flame cutting machine 을이용한강재절단모습 CNC plasma cutting machine 을이용한강재절단모습 Edge milling machine을이용한강재절단모습 ( 현대삼호중공업 ) * CNC: Computer Numerical Control * Gas 절단 : 강재를가열하여산화반응이일어나기쉬운온도 ( 약 800~900 도 ) 로만든후고압산소를공급하면발열반응이일어나산화철이생기고, 이를고압산소로불어내어절단 * Plasma 절단 : 기체상태의공기, 수소, 가스등에서전기적인아크방전을일으키면, 그기체가부분적으로 plasma 화되는데, 이것을열물리적인방법으로수축시켜최고온도가 20,000~30,000 도까지이르게하고이를부재에닿게하여국부적으로강재를녹이고고압가스로이를불어내어절단 * Laser 절단 : 빛을증폭시켜고밀도화한후필요한곳에주사함으로써국부적으로강재를녹이고고압가스로이를불어내어절단 * Edge milling: 공업용다이아몬드를이용하여강재를절단 53 Plate Forming 계약 강재절단 용골배치 진수 인도 설계 조립 탑재 안벽작업 강재적치및 선행의장및 전처리 도장 Plate forming: 강재를곡면이나곡선으로굽히는작업 Cold forming: 상온상태에서기계적인힘을가하여재료에소성변형을일으키는것 벤딩롤러 (bending roller) 또는유압 Press 를이용한단순한 1 차곡면 ( 한방향으로곡률이존재 ) 의성형 Step before hot forming Hot forming: 강재를국부적으로가열하였다가냉각시키면그부위가수축하는성질을이용하여굽힘가공을하는것 Line heating 부재에고온의열을가해서영구변형을얻는 2 차곡면 ( 두방향으로곡률이존재 ) 의성형방법 현재세계대부분의조선소에서 2 차곡면의성형방법으로사용하고있으나자동화의어려움때문에전적으로작업자의수작업에의존하고있음 벤딩롤러를이용한냉간가공모습 작업자에의한선상가열모습 54 27
Assembly 55 Assembly - Subassembly/Assembly Sub assembly 블록을구성하는크기가작은부재를제작하는과정 Assembly 소조립블록들을합쳐큰블록을제작하는과정 선박건조물량의약 60% 이상이처리되는공정 블록의형상에따라크게평블록제작공정과곡블록제작공정으로구분됨 Panel block 전체대조립물량의약 80% 를차지 블록및내부재의형상이비교적간단하여자동화시스템이채용되어있음 Matrix(Egg Box) 조립공법, Line welder 조립공법, Slit 조립공법, Piece by piece 조립공법 Curbed block 전체대조립물량의약 20% 를차지 블록의형상이다양하고복잡하여자동화시스템을채용하기가어려움 Line welder 조립공법, Piece by piece 조립공법 Example of sub assembly blocks Example of assembly blocks 계약강재절단용골배치진수인도 설계 강재적치및전처리 조립 선행의장및도장 탑재 안벽작업 평블록 ( 중앙부이중저블록 ) 곡블록 ( 선미부블록 ) 56 28
Pre-Outfitting and Pre-Painting 57 Pre-Outfitting and Pre-Painting Pre-Outfitting 공기후반에오는혼잡을피하기위해의장품 ( 배관, 덕트등 ) 의설치를앞당겨하는작업 블록의장, 유닛 (Unit) 의장, 탑재동시의장으로구분 Pre-Painting 강재전처리과정에서의강재도장 : Shop priming 조립공정에서의블록도장 : 선행도장 선행도장전블록전처리작업을수행함 탑재공정에서의도장 : 탑재도장 탑재블록간접합부위에대한추가전처리및도장작업수행 계약 강재절단 용골배치 진수 인도 설계 조립 탑재 안벽작업 강재적치및 선행의장및 전처리 도장 아중저블록내의선행의장 선행도장모습 탑재블록간접합부위 선박측면 탑재공정에서의도장모습 58 29
Block Preprocess 계약 강재절단 용골배치 진수 인도 설계 조립 탑재 안벽작업 강재적치및 선행의장및 전처리 도장 블록전처리공정 : 선행도장전에조립공정중발생한부재표면의녹을제거하여도료의부착을좋게하는공정 Blasting, Air blowing, Grit recovery 작업으로구성됨 Blasting: 작은철조각 (grit) 을강판에분사하여녹을제거하는작업 Air blowing: Air 를이용, 보강재 (stiffener) 의상면등에쌓인 grit 을바닥으로떨어뜨리는작업 Grit recovery: 바닥에쌓인 grit, 분진등을회수하는작업 1 Block in 2 Blasting 3 Air blowing 4 Grit recovery 5 Block out Pre-Painting VLCC 이중저블록의전처리작업공수 ( 작업면적약 4,000m 2, 표면조도 SA2.5 기준 ) -Blasting: 16명 X 3.5H = 56M/H -Air blowing: 8명 X 1H = 8M/H -Grit recovery: 8 명 X 1.5H = 12M/H 59 Pre-Erection 60 30
Pre-Erection 도크 (dock) 의탑재효율을높이는방안으로고안된조립과탑재의중간공정 도크옆에서두개이상의선각블록및의장품을합쳐하나의큰 PE(Pre- Erection) 블록 을만드는과정 PE(Pre-Erection) 장 골리앗크레인 계약 강재절단 용골배치 진수 인도 설계 조립 탑재 안벽작업 강재적치및 선행의장및 전처리 도장 도크 Dock PE area PE blocks on the PE area 61 Keel Laying (K/L) 62 31
Keel Laying (K/L) 계약 강재절단 용골배치 진수 인도 설계 조립 탑재 안벽작업 강재적치및 선행의장및 전처리 도장 The event when the first block is erected on the dock. That means the starting point of block erection. At this time, put several supports under the ship for supporting ship s weight 도크 Bottom shell Support 63 Erection 64 32
Block Erection Simulation Considering Semi-tandem Construction Method 계약 강재절단 용골배치 진수 인도 설계 조립 탑재 안벽작업 강재적치및 선행의장및 전처리 도장 Semi-tandem Construction Method 도크내에서완전한한척의선박과또다른선박의선미부를함께건조하는방법 Dock gate Sea Dock Floating * Myung-Il Roh, Kyu-Yeul Lee, An Initial Hull Structural Modeling System for Computer-Aided Process Planning in Shipbuilding, Advances in Engineering Software, Vol. 37, No. 7, pp.457-476, 2006.7 400 History of the erection joint length by the semi-tandem construction method Erection joint length Erection JL(m) 350 300 250 200 150 100 50 0 Floating 1 11 21 31 41 51 61 71 81 Erection event(number of erection blocks) 65 Launching (L/C) 66 33
Launching (L/C) 진수란도크내또는육상에서건조한선박을각종검사를거친후처음으로수상에띄우는것을말하며, 진수시기는계약일기준약 12 개월정도임 계약 강재절단 용골배치 진수 인도 설계 조립 탑재 안벽작업 강재적치및 선행의장및 전처리 도장 * Reference: DSME 67 Launching 설계전처리 - Ground Launching Method of HHI and STX 계약강재절단용골배치진수인도 강재적치및 도크가아닌육상에서선박을건조하는방법으로 2004 년 10 월현대중공업이세계최초로성공 Overall procedures of ground launching method 1. 육상에서선박탑재완료 2. 육상건조장옆에두대의바지선을연결하여배치 3. 독일의잠수함원리와스위스가개발한이동시스템원리 ( 레일 ) 를이용하여선박을바지선위로끌어냄 ( Road Out 기술 ) 4. 선박을실은바지선을깊은바다로이동시킴 5. 바지선을수면아래로가라앉힘 6. 선박의진수완료 조립 선행의장및도장 탑재 안벽작업 * Reference: Hyundai Heavy Industries 68 34
Quay Work 69 Quay Work - Outfitting/Painting 계약 강재절단 용골배치 진수 인도 설계 조립 탑재 안벽작업 강재적치및 선행의장및 전처리 도장 After launching the ship, put her on the quay and perform outfitting and painting for the finish. Quay 70 35
Quay Work -Sea Trial 계약 강재절단 용골배치 진수 인도 설계 조립 탑재 안벽작업 강재적치및 선행의장및 전처리 도장 The testing phase of the ship for conducting to measure her performance and general seaworthiness. It is usually the last phase of construction and takes place on open water, and it can last from a few hours to many days. The ship s speed, maneuverability, equipment, and safety features are usually conducted. Typical trials: speed trial, crash stop, endurance, maneuvering trials, seakeeping 71 Delivery (D/L) 72 36
Delivery (D/L) - Naming Ceremony and Delivery 계약 강재절단 용골배치 진수 인도 설계 조립 탑재 안벽작업 강재적치및 선행의장및 전처리 도장 Name the ship and deliver her to a ship owner Naming Ceremony of FPSO (Floating Production Storage Off-loading) 73 37