Training New Building

Training Material Internal Use Only
Classification Survey during Construction (Hull)

19~21 August 2008
Overview of Lecture
Part 1 Part 2 Part 3
Hull Survey System Record of Inspection Survey on Site
Surveys for CSR-Applied Ships

(for information only)
Part B Plan Approval Manufacturing Welding Hydrostatic test Thickness measurement (Ships in service) 2.1.2 Submission of plans and documents for approval (Chap. 2) 2.1.5 Hydrostatic and watertight tests (Chap. 2) 5.2.6 Thickness measurements (Chap. 5) Part CSR-B 2. Documentation to be submitted (Chap.1, Sec. 2) Sec. 1 Construction (Chap.11) Sec. 2 Welding (Chap.11) Sec. 3 Testing of compartments (Chap.11) Sec. 2 Thickness measurements and acceptance criteria (Chap. 13) Part CSR-T 2 Documentation, plans and data requirements (Sec. 3) 4 Fabrication (Sec. 6) 5 Weld design and dimensions (Sec. 6) 5 Testing procedures (Sec. 11) 1 Allowable thickness diminution for hull structure (Sec. 12)
(CSR will not be further explained in this lecture)
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Part 1
Hull Survey System
Outline of hull survey system Requirements of the rules Plan approval Presence of surveyor Investigation of quality control of shipyard
Hull Survey System

Outline
Project Team Managers in HLD, EQD and SVD General Manager Manager for Hull Surveyor in Charge Direct survey Inspection Record
Rules, Guidance ClassNK Instructions
Indirect survey & QC investigation QC System of Shipyard
Hull Survey System

Precondition (1/3)
The workmanship is to be of the best quality. During construction, the builder is to supervise and inspect in detail every job performed in shed and yard as well. [Rules Part C 1.1.17-1] The requirements concerning presence of surveyor may be modified having regard to the actual status of facilities, technical abilities and quality control at the works, except the case of sea trial. [Rules, Part B, Chapter 2, 2.1.4-4] In case where the works is being in accordance with Rules for Approval of Manufacturers and Service Suppliers, the number of times of the surveyors attendance to the works may be reduced for the purpose of the requirements 2.1.4-4, Part B of the rules. [Guidance, Part B, B2, B2.1.4-5]
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Hull Survey System

Precondition (2/3)
The requirements of this Part are applied to the welding where the manufacturer is to adhere to the requirements specified below. (1) To ensure the quality of the welding under the appropriate facilities and control system, by achieving the process control throughout the welding works. (2) Where deviation from the controls occurs and/or inferior quality of products is identified, the manufacturer is to investigate the substantial cause, to report the result of investigation to the surveyor and to take corrective measures. [Rules, Part M, Chapter 1, 1.1.1-2]
Hull Survey System

Precondition (3/3)
Even if the presence of surveyor will be exempted, the test should be executed and attended by responsible persons of shipyard. The surveyor in charge should seek for an approval of his GM and Manager before he applies an indirect survey and keep the evidence in his inspection record. Tolerance or limit in ClassNK Instructions as well as in shipyards quality standards are ones which will not usually be standard reached under well-controlled situation. Therefore, errors bigger than the standard but within the limit are not always and limit automatically acceptable if they occur frequently.
If the distribution of accuracy is Gaussian, proportion within , 2, 3 is 68.26, 95.44, 99.74% respectively.
New Building and Project Team

Stage
Class entry application Plan approval [Rules Part B 2.1.1] Investigation of QC condition [Rules Part C 1.1.17-1 and Part M 1.1-2(1)] Meeting with persons concerned (owner, shipyard, etc.) * Survey during assembly process and block inspection [Rules Part B 2.1.4] Survey in building berth [Rules Part B 2.1.4] Launching Survey after launching [Rules Part B 2.1.4, 2.3.1 and 2.3.2] Delivery * Meeting shall be held also during survey GM, Manager (H) and surveyors in charge in service site Project team Managers in charge in HLD, EQD and SVD
Work commence Lay down
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Flow of Plan Approval

(1), (2), (3) (1), (2), (3), (4), (5)
Head Office
(1), (2),
(3)
Local Office
(1), (2), (4)
Shipyard
(1) Documents to be approved at Head Office (2) Documents to be examined at Head Office (3) Documents for reference at Head Office (4) Document to be approved at Local Office (5) Documents for reference at Local Office
Note: Regarding plans and document hereafter, ones for application of CSR are excluded)
Presence of Surveyor
Surveyor is to attend to the followings inspection and test in relation to hull and equipment (free quotation from the rules Part B, Chapter 2, 2.1.4-1): Material test prescribed in Part K, L and M Acceptance inspection Block inspection Hydrostatic test, watertight test and non-destructive test Final inspection of hull Performance test Rudder Measurement of principal dimensions Loading computer Marking of Load Lines and ships identification number Sea trial Stability experiments Emergency towing arrangements Fire extinguishing arrangement, including its performance test
Patrol Survey
The purpose of patrol survey is to grasp the actual circumstance of quality control of the shipyard through an investigation of following points during the fabrication (it may be impossible at block inspection) Welding procedure (temporary fitting, edge preparation, position, back gouging, sequence, welders qualification, etc.) Handling of defective work (material, size, accuracy of fitting, record, etc.) Surveyor in charge execute a patrol survey at any time of following occasions, while he follows an application submitted by the shipyard for usual survey To pass through the work shop on his way to and from the place of usual survey, To execute in his spare time of survey, etc. The results of patrol survey should be periodically reported to the General Manager as the monthly report of investigation of QC of the shipyard Surveyor should review his attendance of survey, such as timing and method, according to the results of the investigation of QC of the shipyard
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Background of Patrol Survey

The presence of the surveyor is required at the following stages of the work in relation to hull and equipment (extract): (4) When designated by the society during shop work or subassembly. (17) When deemed necessary by the society. [Rules, Part B, Chapter 2, 2.1.4-1] For the effectiveness of the control of the welding works to be carried out by the manufacturer, the society is to confirm the condition during welding works at an appropriate interval accepted by the surveyor, when deemed necessary. In this case, the manufacturer is to give the convenience to the surveyor and to permit the surveyor to enter all relevant areas of the yard. [Rules, Part M, Chapter 1, 1.3.2-1]
Layout of a Shipyard
Acceptance inspection Block inspection Block assembling, final, fitting, etc. Stability experiments, performance tests Seek for opportunity of patrol survey
Investigation of Quality Control

Investigation of QC condition of shipyard Periodical investigation Annual investigation Occasional investigation Investigation of site execution of shipyard Monthly investigation
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Periodical Investigation
Timing (a) When the shipyard builds a ship being classed with NK for the first time (b) When about 5 years have passed from the previous periodical investigation (c) When the size of ship being classed with NK breaks through 10,000, 30,000 or 100,000 GT for the first time (d) When the shipyard re-starts building a ship being classed with NK after a blanc period of more than 2 years Contents Facilities and features of construction, number of welders, system and details for quality control, etc. (see Record A)
Annual Investigation
Timing When about 1 year has passed from the previous periodical or annual investigation Contents About 20 % of the items for a periodical investigation Record Prepare Record A
Occasional Investigation
Timing (a) When there is a change in the organization of the shipyard or in the layout of shipyard having influence on quality control (b) When the surveyor attending regular survey finds out a serious deficiency which may affect quality of ships (prepare Form S) (c) When the shipyard builds a ship using special production procedure (e.g. LNG carrier, low temperature LPG carrier, etc.) or special material (e.g. stainless steel, clad steel, etc.) (d) When the society deems necessary Contents The items that the society deems necessary relating to (a) to (d)
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Monthly Investigation
Timing Notwithstanding its naming, the investigation should be done during daily survey. Report may be done 1 or 2 monthly. Contents Identification of steel, welding procedure, control of welding materials, observance of the quality standard, etc. are to be investigated at each stage such as in-shop fabrication, panel fabrication, block assembly and block loading Record Prepare Record B
Vertical Inspection of Welding Work

(for shipyard) Approval of welding procedure Welders qualification (for each ship) Approval of welding application plan and NDT plan (for each welding work) Material control Edge preparation Fitting accuracy after tack welding Misalignment between important members Fitting of backing material and run-off-tab Consideration for welding environment Pre-heating etc. Welding sequence Execution of welding Back chipping Removing jigs etc. Investigation of QC condition, etc. Examination of document (during welding work) Designated survey [Rules Part B and M] Patrol survey (after welding work) Visual inspection Non-destructive inspection
Part 2
Record of Inspection
Form IR(H) Form IR (H-A948) Form IR(H) Attachment
Process control record
Form IR
QC control record
Record A
Record B
Deficiency record
Form S
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Part 3
1. 2. 3. 4. 5.
Survey on Site
11. 12. 13. 14. 15. 16. 17. Paint Markings Piping Fire protection Closing appliances Protection of crew Bottom inspection before Launching 18. Stability experiments 19. Navigation bridge visibility 20. Sea trial 21. Documents to be maintained on board
Acceptance inspection Welding Shop Work and Sub-Assembly Block inspection Block joining on building berth 6. Rudder 7. Final inspection of hull compartment 8. Tightness/ Hydrostatic test 9. NDT of welded joints 10. Measurement of principal dimensions
1. Acceptance Inspection
Object of inspection Material and equipment manufactured by subcontractors outside the shipyard, such as rolled steel, steel casting and forging, welding materials, construction materials for fire protection, anchors, anchor chains, ropes, scuttles, hatch tarpaulins, hull blocks (*), steel hatch covers, watertight doors, steering gears, etc. Purpose of inspection To confirm that they have been inspected by the society, and that they have not been damaged during transportation
* For hull blocks manufactured by subcontractors, see 4. below
Makers and Acceptance Inspection
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Stamps and Certificate
The surveyor should confirm not only the stamp but also if the article is suitable for the intended ship; in this case ships Equipment Number.
Rolled Steel
Collation of plate and mill sheet Verification of control by the shipyard (checking-off of already used plate) should be done at least once before launching As to checking-up of mill sheet and actual usage of plate, see 4 Block inspection below
Cast/ Forged Steel

Object of inspection: Stems, stern frames, rudder stocks, rudder fittings, rudder coupling bolts, rudder pintles, rudder horns, shaft brackets and valves required to be made of cast steel by the rules Manner of inspection: Verification of inspection report by the shipyard, copy of certificate issued by NK (when applicable) and rubbed copy of stamp and marking on the article. Surveyors attendance at the inspection is not necessary except for valves. In principle, mark shift during machining of material which has been already inspected is not necessary. When important members such as stern frame, rudder stock, etc. are machined, the report of in-house inspection results should be submitted, and process should be attended if deemed necessary.
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Steel without NK Certificate

Procedure of material test
Identify the material as NK material, like as KD36 Confirm mill sheet or certificate (for chemical composition and mechanical property) Carry out visual inspection and measure dimensions for cast steel and forged steel Carry out mechanical test by sampling Put stamp [NK] and issue certificate
Sampling test
Rolled steel: Tensile test, and impact test if deemed necessary Cast steel and forged steel: NDT, mechanical test as appropriate to the material (tensile, hardness, impact, etc.)
Testing machine
The machine used for mechanical test must be certified by NK or appropriate body
Welding Material
Object of inspection: Welding rods, wire for semi-automatic welding, core wire and flux for automatic welding Manner of inspection: Verification of brand to confirm that they are of type approved by NK. Reference should be made to the approved welding procedures applicable to the ship in question. Actual status and control condition of facilities for drying welding materials are to be investigated at the initial stage of construction
Material for Fire Protection

Object of inspection: Non-combustible materials, A, B and C class divisions, flame retardant base materials, materials for primary deck covering, fire retardant veneers, fire retardant coatings, fire retardant surface floorings, fire dampers Manners of inspection Referring the list of brand attached to the approved drawings, materials should be confirmed and the results of the inspection should be recorded The surveyor in charge should attend the site execution at least once in order to confirm the appropriate use of materials, and the results of the inspection should be recorded
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Other Materials and Equipment

Anchors, anchor chains and ropes Collate NK stamp and certificate Verify if the type, diameter, length, weight and other particulars are appropriate as equipment for the ship in question Scuttles After installing scuttles on the ship, the correct application of the scuttles is to be checked at an appropriate opportunity such as tightness test Hatch tarpaulins NK stamp and certificate are to be collated at an appropriate opportunity Hull blocks Inquire the shipyard for any damage during transportation, inspect them if necessary Others Collation of rubbed copy of stamp and certificate. If articles are subject to test, the original should be confirmed at such opportunity
2. Welding
Welding procedure qualification (general) Welder qualification Welding procedure specification (individual application of approved welding procedure qualification to a ship) Kind of members within 0.6 L amidships for on-site welding procedure The welding procedure applicable to the locations above, and welding position Execution of welding and control Control of welding consumables A proper welding shall be done by qualified welder with approved materials in accordance with approved procedure.
Welding procedure qualification and welder qualification approved by other IACS member society may be accepted. In such case, a stamp for reference is to be put and copy of the document sent to EQD.
Kind of Welding Process

Manual welding Stick welding Gravity arc welding TIG welding
Semi-automatic welding
MAG welding CO2 MIG welding Self-shielded arc welding
Automatic welding
Submerged arc welding Electro-gas welding Statistics in 2001 (Japanese shipbuilders) CO2 semi-automatic 60% Automatic 30% Gravity 5% Manual (stick) 5%
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Welding Procedure Qualification

Kind of weld joints Kinds of base metal (grade, maximum thickness) Kinds of welding consumables (grade, shielding gas, backing, etc.) Kind of joints (butt, fillet) Position of welding Shape and size of edge preparation according to the thickness of the base metal (including the standards of accuracy for angle, gap, misalignment), number and arrangement of electrode, length or throat thickness, sequence of layer, conditions (current, voltage, speed, etc.) Pre-heating, temperature control Heat treatment after welding Other necessary items for the welding procedure
Qualification Test of Welding Procedure

Butt Welding -1/2
Finished inspection Welded surface is to be regular and uniform and is to be free from injurious defects, such as cracks, undercuts, overlaps, etc. Tensile test The ultimate tensile strength is not to be less than the minimum ultimate tensile strength specified for the base metal Bend Test There is to be no crack nor any other defect greater than 3mm in length in any direction on the surface of bent specimen

Butt Welding -2/2
Impact test The minimum absorbed energy of three specimens are to be in accordance with the Rules (The percent brittle fracture of the specimens is to be measured) Macro-structure inspection The etched section is to show no crack, poor penetration, lack of fusion and other injurious defects Non-destructive test Internal inspection (X-ray, US) and surface inspection (MP, liquid penetrant) are to show no crack and other injurious defects
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Fillet Welding
Finished inspection Fillet welding is to have a regular and uniform surface, and is to be free from cracks, undercuts, overlaps, and other injurious defects Macro-structure inspection Welded joint is to be free from excessive difference between upper and lower fillet length, cracks and other injurious defects Fracture test The remaining test assemblies after the macro-structure specimen has been removed are to be broken by pressing as shown in the sketch. There is to be no cracks, blow holes, poor penetrations and other injurious defects in the fractured surface Non-destructive inspection Surface inspection (MP, liquid penetrant) is to show no crack and other injurious defects.
Welder Qualification Certificate

(valid for 3 years)
Position Flat Plate Vertical Horizontal Overhead All positions Pipe
Kind of qualification Mild steel
Class F V H O Z P
Symbol CS SU AL 9N M S T G A N
Fixed pipe
Grade 1 2 3
Thickness (mm) 5 or below 19 or below No restriction

Welding procedure Materials
Stainless steel Alminium alloy 9% Ni steel Manual arc welding Semi-automatic welding TIG welding Gas welding
Each welder intended to engage in the automatic welding operation is to be of a well experienced welder for the specific welding work concerned
Use of backing
With backing Without backing
Welding Position at Qualification Test
Pipe
Plate The specimens are to show neither crack nor serious defect greater than 3mm in length in any direction on the outside surface due to the bending
The test assemblies are not to be changed their up-and-down or right-and-left position throughout the welding operation. The welding in vertical position is to be done upward procedure. The welding is to be carried out only on one side and back welding is not to be carried out unless specified otherwise. In general, the test assemblies for plates are to be so restrained or prestrained that the warping due to the welding does not exceed an angular distortion of 5 degrees. The test assemblies are not to be subjected to peening or heat treatment throughout the period before, during and after the welding.
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Qualifications of Welder
A welder of Class Z is regarded to be qualified for all the Classes of F, V, H and O within the same Grade. Any welder who intends to be qualified for Classes V, H, O and P of each Grade and each Kind is to have qualification of Class F of the corresponding Kind and Grade. A welder of any Class of any Grade of Kind N may be regarded as the welder of the same Class of the same Grade of Kind A. If a welder having Class Z of any Grade passes the qualification test on any one welding position of Classes V, H and O (which is specified by the surveyor) and belonging to the same Kind and Grade, his qualifications can be continued. If a welder having Classes other than Class Z passes the qualification test for the Classes (except Class F), he can continue his qualifications including Class F. If a welder having Class P and Classes V, H or O, or Z passes the qualification test for the Class P, he can continue his qualification for plate without test.
Welding Consumables
Drying Control
Type of welding rods Non low-hydrogen Low-hydrogen Maximum period for weathering (hours) Type of steel MS HT Control target 8 4 Allowable limit 24 6 Standard drying conditions 70~150, 30~60 min. 300~350, 30~60 min.
Welding material Bonded flux Molded flux
Type of steel
Welding method
Maximum period for weathering (hours) Control target Allowable limit
Standard drying conditions
Submerged arc welding MS & HT Shielded arc welding CO2 gas arc welding Submerged arc welding 5 10 200~350,60 min.
Welding work outdoors is forbidden when it rains. When such a situation is unavoidable, a rain shelter or covering should be arranged, and special care must be taken to ensure the dryness of the groove of joints and other welding materials
Welding of Rolled Steel

Restriction
Object for control Arc strike Minimum length of short bead Temporary fitting, repair of scar Repair of welding Highest atmosphere temperature requiring preheating Lowest temperature of pre-heating -5 20 5 50 30mm MS HT* Conventional Forbidden 50mm 10mm** 30mm 0 20 TMCP type
Pre-heating (submerged arc welding)
* For KA40, KD40 and KE40, use the values for conventional HT, even if it is TMCP type. ** It is recommendable to be 30mm or more for KE32 and KE36
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3. Shop Work and Sub-Assembly
Patrol survey (investigation of quality control) Quality standard
Patrol Survey
during Shop Work and Sub-Assembly
Identification of steels Confirmation of proper use of steels according to the approved drawings Accuracy of edge preparation Proper fitting of strong back, temporary tack-welding, run-off tab, etc. Accurate fitting of members and corrective measures for defects Proper welding sequence Adequate welding method (including back gouging conditions) conforming to approved welding procedure specification Strict enforcement of rules for arc striking and short bead especially for high tensile steel and Grade E mild steel Qualification of welders
Agreed Rules and Quality Standard

Ships owner
Rules etc.: Rules, quality standard (JSQS, SRQS, etc.)
Specification: Conformance to NK Rules, quality standard of the ship builder
ClassNK
Rules etc.: Rules, quality standard (see below)
Ship builder
For the allowable criteria of accuracy, refer to the shipyards standard recognized by the society, if available. In principle, such standard should be equivalent or superior to JSQS or SRQS If such standard is not available, refer to JSQS or SRQS JSQS: Japanese Shipbuilding Quality Standard SRQS: IACS Shipbuilding and Repair Quality Standard JSQS SRQS
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Appropriate Arrangement of Material
(1) Are the steel plates per approved plan ? (2) Are the material and size reasonable comparing to mill sheets ? (3) Is the actual block per this plan ?
Cutting
Accuracy for gas cutting
Allowable depth of gas notch in edge preparation is: For a butt welding within 0.6L amidships2mm or less Elsewhere 3mm or less
Gas Notch at Free Edge
No notch is allowed at those locations. The notch shall be welded up avoiding a short bead, and ground smoothly. Allowable depth of notch at other locations of free edge, is 1mm.
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Size of Bracket
Depth of longer arm 150 200 250 1,000 1,050 1,100 1,150 Thickness Plane 6.5 7.0 8.0 ---11.5 12.0 12.5 12.5 95 100 105 110 Flanged 6.5 6.5 Breadth of flange 30 30
Mechanical Flanging
Accuracy of Processing
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Edge Preparation for Butt Welding

Same thickness
Different thickness
Part C 1.2.3-2 requires this tapering not more than 1/3 when there is the difference in the thickness over 4mm
Joint with Cast / Forged Steel
Lap Joint
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Kinds and Sizes of Fillet Weld

Thickness of members Up to 5 6 7~8 9~11 12~14 15~17 18~21 22~26 26~40 Continuous fillet weld Size of fillet f F1 3 4 5 6 7 8 9 10 11 F2 3 4 5 6 7 8 Size of fillet f 3 4 5 6 7 8 9 10 11 75 200 350 Intermittent fillet weld Length of fillet w 60 Pitch p F3 150 F4 250
Lap joint
Tee joint
1. The size f for Tee joints is in general to be determined according to the web thickness of stiffener to deck plate, inner bottom plate, bulkhead plate, shell plate and face plate, and the thickness of the thinner plate in case of connection of other members 2. Lap joint is to have the fillet size of F1according to the thickness of the thinner plate 3. Intermittent fillet weld is to be staggered and w at ends is to be welded on both sides
Intermittent weld
Application of Fillet Weld

Example (Double Bottom Construction)
F3 (F2 for two frame spaces at the end of floor)
F4
F2 F3 F4 F4 F3 F3 (F2 for two frame spaces at the end of floor)
F2 (F1 for water/ oil tight boundary)
Deep / Full Penetration
Usually, edge preparation is not required for fillet weld, except at intersection of important members. Instead, size of fillet shall be increased according to the thickness of the member.
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Slot Weld
Precaution before Welding
Cleanliness in groove
Jig for positioning
Tack Weld
Butt joint
Fillet joint
Tack weld should be shifted from the ends of welding Avoid short bead
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Positioning of Important Members
Securing jig (strong back, bridge) should be used for important members in place of tack weld
Run-Off Tab
Tabs should be provided at both ends of butt welding, because defects are likely to occur here. Tabs are cut after completion of welding, to inspect for defects.
Appropriate Gap for One-side Welding
If the gap is too small, penetration may be insufficient
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Welding Sequence (1/8)

Both-Sides Welding
V groove X groove + cross welding
Finish both sides first
Then connect two strips Plates are relatively thicker, and cracks are likely to occur at the intersection of welding
Welding Sequence (2/8)

T-Shaped Joint
If seam is not withheld, (1) Butt joint will be deformed due to heat (2) End of butt joint overlaps on the seam, and defect is likely to occur
Welding Procedure (3/8)

Joint of Internal Members
(1) A scallop is provided to pass the weld of face plate (a scallop in highstress zone should be closed later) (2) Usually, thicker plate shall be welded first (to avoid deformation due to the heat)
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Shell Plate with Internal Member
Shell plate, Face plate of internal member, Web plate of internal member, Fillet welding between shell plate and web plate

Collar Plate

Closing Round Hole
Thickness 25mm
Thickness > 25mm
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Closing Access Hole

Partial Renewal of Plate
Diameter of stop hole is 20~30 mm, depending on the thickness
CO2 Semi-Automatic Welding

Defect in the First Pass
Caused by inappropriate groove, gap, current, speed, etc.
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Defects at Butt Joint (1/3)
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Defects at Fillet Joint (1/2)
Defects at Fillet Joint (2/2)
In downward pass of welding in the vertical direction, the throat thickness of the bead tends to become too small, if welding rod motion is incorrect.
Foul Welding
Not only too broad bead, but also too narrow bead is doubtful
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Treatment of Mal-Fabrication
Shortage of Size at Fillet Joint
only at compression part
Treatment of Mal-Fabrication
Shortage of Size at Butt Joint
Damage Due to Misalignment

Bending rigidity Axial rigidity
Allowable limit of misalignment is, according to JSQS, 1/3 (important members) or 1/2 (others) of the thickness.
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Reconditioning of Misalignment
Butt joint
Cross joint (fillet joint)
4. Block Inspection
Scope of survey Block plan Confirmation of steel (see 3. above) Confirmation of structure, accuracy and welding Others
Scope of Survey
The scope of the survey covers blocks below the uppermost continuous deck, blocks for superstructures and deckhouses on the first tier above the uppermost continuous deck, and other blocks deemed necessary by the surveyor. [ClassNK Instructions A20, 0144-5)
The requirements are prescribed for the superstructures/ deckhouses up to the third tier above the freeboard deck. [free quotation from Rules, Part C, Chapter 18 & 19]
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Structure, Accuracy and Welding (1/2)

Confirmation of shape, scantling and missing members: Shape and scantling, including thickness, of members Especially primary members such as web frames and girders Missing members Collar plates, carlings, stiffeners, small brackets, etc. If abnormality such as imbalance of structure and discontinuity of strength are found, even if they are per drawings, surveyor is to discuss with the shipyard and have them corrected If the plate thickness is smaller beyond the negative tolerance, it should be regarded as an error, and countermeasures including replacement is necessary Confirmation of assembly accuracy: Misalignment at cross joint (fillet welding) Especially counter members to primary members Misalignment at butt joint Distortion of members
Structure, Accuracy and Welding (2/2)

Confirmation of welding and remaining works: Missing welding and back gouging of critical points Defects such as under cut, blow hole, lack of leg length (90 % specified in the drawings), distortion at welding joint, etc. Inspection around blocks : Finished surface of edge preparation and treatment of craters Sufficient penetration of automatic welding Scallops on internal members at welding line of plates Others: Penetration of internal members through water-/ oil tight bulkhead Properly arranged cut water weld Blocks forming deep tank Air holes and drain holes Quality standard: See 3. above
Sub-Blocks of Side Shell Construction
Tightness of welding joints on the boundary may be locally tested in this stage (explained in Chapter 11), to start painting
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Block Joining
Inspection of this joint only is enough at this stage, because each block has been already inspected
Continuity of Structure (1/3)
It is not so easy to find such problem, when different blocks or compartments are involved
Members should be extended and lapped each other because a steep knuckle can not transfer the load (maximum angle is about 30 for practice)
-30/88-
If surveyor is not well about the construction, he may overlook this inconvenience
Accuracy of Processing
Deformation of face plate a : a = 2 (5)+ b/100 mm ( ): limit
Deformation of stiffener : where 1,000 mm = 5(8) mm where > 1,000 mm = 3(6) + 2 / 1,000 mm
End Connection of Stiffener
Usually, lug and bracket connection are adopted for stiffeners of tank boundary that bears big lateral load, while snip connection for wall of accommodation, etc.
Lug
Bracket (lap)
Clip
Bracket (butt)
Snip
Distribution of bending moment will be significantly affected by the end connection
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Girder under Main Engine
Normally, such important girder shall be designed as continuous member.
Edge of Block Joint (1/2)
Edge of Block Joint (2/2)
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Continuous Welding
High stress zone
Cut-Water Weld
Water or oil penetrates from an accidental defect and travels through the gap to other compartments
Air Holes and Drain Holes
If those holes are not provided, air/water cannot go out during charging/discharging.
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Special Block (1/3)

Stern Frame
Check point: Welding between steel plate and cast/ forged steel Slot welding Tightness test Centering
Stern frame for A type rudder
Special Block (2/3)

Shoe Piece
Slot welding Tightness test
Special Block
Hatch Cover
Check point: Dimensions L & B 5mm, Height 3mm (standard) Distortion 1 2 5mm (standard) Gasket and equipment Tightness (if applicable) Note: The standard is for pontoon hatch covers for container carrier
-34/88-
Blocks Manufactured by Subcontractors

Delivery of block
Shipyard
Application/ Notification
In , and , offices A and B are in same/different country -/ Application
Subcontractor
-/ Report
Request of survey Report on results
NK Office A
NK Office B
Upon delivery of the block, the surveyor in office A is to ask the shipyard for report on any damage during transportation and inspect it, if any
5. Block Joining on Building Berth

Patrol survey: Correct sequence of block loading Appropriate fitting accuracy of members in adjacent blocks and appropriate measures for defects (including marking of reference line) Condition and accuracy of joints just before welding (including back gouging condition) Proper fitting of strong back, temporary tack welding, run-off-tab, etc. Proper welding sequence Adequate welding method (including back gouging condition) conforming to approved welding procedure specification Strict enforcement of rules for arc striking and short bead especially for high tensile steel and Grade E mild steel Qualification of welders
Positioning of Block
A line just on the correct location will be hidden by the block
Reference marking
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Serious Accident Originated in Field Joint
A crack generated at poor penetration of one-side welding of hatch side box girder, and propagated into the Second Deck
6. Rudder
Confirmation of material and welding procedure Internal/ External inspection Fitting of sleeve, pintle, bush, etc. Coupling (rudder plate and rudder stock) Alignment (centering of rudder and stern frame) Installation of rudder Measurement of clearance Swing test
Material and Construction of Rudder

Confirmation of material and welding procedure Material of rudder stock, pintles, rudder plates, frames, coupling bolts, etc. Material of sleeve and bush Adoption of welding procedure Internal inspection Scantling and arrangement of rudder plates, frames, main pieces, etc. Welding condition No gap between rudder plate and strap for slot welding Dimension and pitch of slots Confirmation of internal coating Drain plug on the bottom External inspection Slot welding Pressure of tightness test (see 8. above)
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Alignment of Stern Frame and Rudder

Rudder carrier Material of rudder carrier and bearing Completion of all the construction works in the vicinity of deck Finished surface, dimension and install angle of rudder carrier and liner plate Arrangement and dimension of reamer bolts or stoppers Alignment of rudder Fore/ aft direction, athwart ship direction Alignment of stern frame Completion of construction works and hydrostatic test in the vicinity Measurement of pre-alignment prior to boring Fixing of rudder carrier Final boring
Installation of Rudder
Coupling of rudder plate and rudder stock Fitting condition of coupling bolts Locking of nut Portable box Jumping stopper Measurement of clearance Lubrication of rudder carrier bearing Swing test (only for confirmation that the rudder does not come into contact with any part of the hull)
Kind of Rudder
Rules Part C
Type A Type B
Type C
Type D
Type E
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Construction of Type A Rudder
Fore and Aft Edge of Rudder
Shift the joint from the center
Fitting of Rudder Plate by Slot Weld

The stud bolts are not necessary if the rudder plate is well formed
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Crack at Slot Weld
Pintle and Sleeve
Shrinkage fitting
Hydrostatic test of sleeve
Confirmation of contact by hammering
Colour Check of Pintle

Put red lead on the tapered part
Insert the pintle into the gudgeon
Confirm the contact by the color remained on the gudgeon Standard is 65%, and the contact must be uniform
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Water Seal and Nut Stopper

If water soaks
Rust of pintle Rust of pintle and slackness of sleeve
Centering of Rudder
Allowable error is 0.5mm (standard is 0.3mm)
Centering of Stern Frame
Centering shall be carried out after hydrostatic test of aft construction is finished (to avoid its effect).
Allowable error is also 0.5mm (standard is 0.3mm)
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Sequence of Rudder Fitting
Various Coupling of Rudder
Horizontal coupling
Vertical (scarf) coupling
Cone coupling
Sleeve coupling
Locking of Nut
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Stuffing Box
Jumping Stopper
Bush Retainer
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Portable Box
(Note) This slide illustrates the procedure to lift the rudder
Accident Due to Poor Weld
Even if the portable box only is missing, the reduction of area affects the performance of rudder, and generates unbalanced force
Rudder Carrier
Inside
Rudder lifted
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Measurement of Clearance
To be measured at top, middle and bottom, and averaged.

Metalic bearing where d bu d bu + 1.0(mm) 1,000 is inner diameter of the bush clearance 1.5 2.0(mm )
Non metalic bearing
Note: Clearances at shoe piece, rudder horn, packing gland of stuffing box and jumping stopper are also to be measured as applicable
7. Final Inspection of Hull Compartment

Structure and members: Missing members Balance of structure and continuity of strength Assembly accuracy: Misalignment Distortion of members Welding works (after block joining) Missing work Defects Others Arrangement of various pipes and equipment Reinforcement of the deck under the seat/ bed of auxiliary machinery and equipment Finishing of free edge of important members Disposition of jig Treatment of fault
Misalignment at Various Locations
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Re-conditioning of Misalignment
Increase fillet size by 10 %
Prevention of Misalignment (1/2)

Avoid lap joint, or provide the same joint at both sides
Prevention of Misalignment (2/2)
Fit a part of members of adjacent block
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Deformation at Various Locations
Absence of Work at Various Locations
Finish of Free Edge
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Local Reinforcement
(1) Compensation for cuttingoff to pass other members
(2) Reinforcement for big load
Disposition of Jig Piece
Serious Accident Originated in Secondary Member (1/2)
Actual work Drawing
A crack generated at poor welding of half-round-bar of hatch coaming propagated into Upper Deck
-47/88-
Serious Accident Originated in Secondary Member (2/2)

Other possible triggers
Partial Renewal of Plate

Due to Mal-fabrication, Defect, etc.
Breadth of replacement Shell plate, strength deck, decks of refrigerating cargo hold High stress zone 1,600 mm or more Elsewhere 800 mm or more Other members 300 mm or more Where the new welding line is not on the existing butt or seam, sufficient radius (more than 300mm for important members) should be provided Edge preparation should be inspected for full length Rolling direction of the new plate should be arranged to ships longitudinal direction
Closing Hole by Insert/ Doubler/ Spigot
Insert
Doubler
Spigot
Longitudinal member: Enlarge the hole to 75 mm (if applicable) and close it by spigot, or Enlarge the hole to 300 mm (if applicable) and close it by insert Other members: Enlarge the hole to 200 mm (if applicable) and close it by insert or doubler Remarks Welding sequence, grinding of bead, NDT
-48/88-
Block Inspection vs Final Inspection

Block Inspection Easy inspection (staging, position, physical strength, safety, etc.) Small unit fits to elaborate inspection Some parts are impossible to inspect at the final inspection Easy repair, when necessary Absence of members Balance of structure Discontinuity of strength Some parts are impossible to inspect at earlier stage This table lists up the advantages of one, and they are disadvantages for another. Therefore, both inspections complement each other. Final Inspection
8. Tightness / Hydrostatic Test

Approval of test procedure Hydrostatic test Head, deformation, leakage Airtight test Detector, pressure, leakage Hose test Pressure, sequence, leakage
Kinds of Tightness Test

Hose test Hydrostatic test Tightness test Airtight test Hydropneumatic test Other test Note: Weathertight and Watertight Weathertight means that in any sea condition water will not penetrate into the ship Watertight means capable of preventing the passage of water through the structure under a head of water for which the surrounding structure is designed Internal pressure External pressure Whole Vacuum test Air hose test Local Air injection test
-49/88-
Double Bottom Tank
Hydrostatic test with a head of water to the top of air pipe
Deep Tank
Deep tank is a tank designed for carriage of water, fuel oil and other liquids, forming a part of the hull, regardless of shape and location.
LWL
H H2/3 2.45m
Hydrostatic test with a head of water to ; (a) load water line, (b) top of overflow pipe, (c) level of 2.45m above the tank top, or, (d) level of 2/3H above the tank top, where H is the distance between the tank top and upper end of D Whichever is the greatest
(Note) Alternative method of hydrostatic test for a big deep tank
COT and Cofferdam of Tanker

2.45m
0.6m
Hydrostatic test with a head of water to; (a) level of 2.45m above the deck at side, or (b) level of 0.6m above the top of hatch, Whichever is the greater
(Note) Alternative method of hydrostatic test for a big tank
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APT and FPT
LWL
LWL 2/3D
APT (a) below LWL: hydrostatic test with a head of water to LWL (b) above LWL: hose test with pressure of 0.2MPa
FPT (a) below LWL: hydrostatic test with a head of water to LWL or to the draught of 2/3D whichever is the greater (b) above LWL: hose test with pressure of 0.2MPa
Double Plate Rudder

1.5D or 2d, whichever is the smaller
(a) hydrostatic test with head of 1.5D or 2d whichever is the smaller, or (b) airtight test with pressure of 0.05MPa
Hose Test
Pressure (in nozzle): 0.2MPa Diameter of nozzle: 12mm or more Maximum distance: 1.5m
Hose test is applicable to shell plating, water-tight deck, water-tight bulkhead, shaft tunnel, hatchway, etc. For shell plating of fully welded construction being inspected from both sides visually, the hose test may be omitted at the discretion of the surveyor.
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Ballast Hold of Bulk Carrier
Notwithstanding the requirements for deep tanks, ballast hold of bulk carrier may be tested as follows: Hydrostatic test is to be carried out with a head of water to the level of the top of the hatch coaming Hose test for weathertight steel hatch cover is to be carried out
Procedure of Hose Test
(1) Dry-up the surface before the test (2) Apply water jet from lower part to upper (3) The speed must be restrained
Hydrostatic Test and Airtight Test
As the ratio of compression of air is very high, special attention should be paid during its release (leakage, over pressure, exhaust)
Structural test is indispensable when following data are insufficient; Reliable direct calculation or model test, Experience of sister ships
-52/88-
Airtight Test in Place of Hydrostatic Test

Conditions Watertight test may be replaced by airtight test at the discretion of the society, provided that certain tanks designated by the society are to be subjected to hydrostatic test afloat Timing of airtight test Airtight test is to be carried out, prior to the application of a protective coating, on all fillet welds, penetration welds and erection welds on tank boundaries Regarding other welds on tank boundaries, airtight test after coating is acceptable, provided that visual inspection on the welds was carefully done before coating to the satisfaction of the surveyor (up to the quality control operations in the shipyard) Execution of airtight test An air pressure of 0.015MPa is to be applied during the test Prior to examination, air pressure in the tank is to be raised to 0.02MPa and kept at this level for about 1 hour to reach stabilized state and then lowered to the test pressure Welds are to be coated with an efficient indicating liquid A U-tube, having cross section larger than that of pipe supplying air, and filled with water up to a height corresponding to the test pressure is to be fitted to verify the test pressure The test pressure is also to be verified by means of one master pressure gauge or other equivalent means
Hydrostatic Test at Sea

Where it is impracticable to carry out the hydrostatic test on the berth with the specified test head, the test may be carried out in such a manner; Hydrostatic test for each compartment on berth under the water head to the level of ballast water line After that, hydrostatic test for each compartment under the water head specified above, when ship is afloat When hydrostatic test for certain compartments is replaced by air test on berth; Some of them including FPT, APT, all COT adjacent to cofferdam and pump room and ones selected by the surveyor are to be subject to hydrostatic test in afloat condition under the water head as specified above All ballast tanks other than the above selected ones are to be subject to the hydrostatic test during sea trial with the head of water to the top of the air pipe
Test Plan
Start
Building berth
Hydrostatic Test with Full Head
Hydrostatic Test with Partial Head Specified tanks Hydrostatic Test with Full Head
Airtight Test Ballast tanks Others
Afloat
Hydrostatic Test to Air Pipe Top
End
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Check Point for Possible Leakage
Vacuum Test
Test is meaningless when the gauge doesnt go down due to leakage of the box
The speed to shift the box should be restrained
Air Injection Test
This test may be done during in-shop fabrication or block inspection, in accordance with the approved procedure If the gauge doesnt go up, the tunnel is stuffed by any reason. The test becomes meaningless in such case.
-54/88-
9. NDT of Welded Joints

Radiographic (X-ray) test and ultrasonic test Members and spots to be tested (approval of NDT plan) Examination of X-ray films
Condition for Adopting Ultrasonic Test
The Society has approved the consistence of results of manufacturers ultrasonic test for at least 3 ships at 1/10 points to be subjected to radiographic test For strength deck, side shell plating and bottom shell plating, the number of inspection replaced by ultrasonic test is to be not more than 1/2. Furthermore, the intersections of butt welds are to be excluded. For internal members, all spots may be replaced by ultrasonic test, except the intersections of weld lines of plate members. The surveyor is to attend during ultrasonic test, in principle
NDT
Members and Number
Number of inspection for each member subject to inspection Members subject to inspection Hull within 0.6L amidships Butt joints Strength deck Side shell plating Bottom shell plating Other member Plates Plates Girders Frames 6L/10 (*) 3L/40 (*) 2L/40 3L/40 Seam joints 2L/10 L/40 L/40 Hull without 0.6L amidships Butt or seam joints 2L/10
* One-third thereof is to be the intersections of weld lines In addition, parts of start/ interrupted/ end points of automatic welded joint, welded joints of hatch corner, connection of stern frame or rudder horn made of casting steel to rolled steels for hull, welded joints of insert plate for working holes and welded joints in the vicinity of parts where stress is concentrated shall be tested.
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X-Ray Photos of Defect (1/3)
Blow hole
Pipe
Slag inclusion
Incomplete infusion
Incomplete penetration
Longitudinal crack
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Incomplete Infusion and Penetration

Incomplete fusion: boundary of welds do not melt each other
Incomplete penetration: empty part in a full penetrate welding (Note) A fillet welding is not always a full penetrate welding
NDT
Classification of Defects
Classification of defects Type 1 Type 2 Type 3 A B Kind of defects Round blow holes and similar defects Incomplete fusion, elongated slag inclusion, pipe and similar defects Incomplete penetration Cracks and similar defects
Any defect of Type 3 is to be judged unacceptable regardless of the size
NDT
Allowable Limit (Radiography)
Allowable limit of defect of Type 1
Thickness of base metal t (mm) Test field of vision Size of defect Maximum size of defect (mm) Sum of size of defect (mm) t 10 5 5 10 < t 25 5 t/2 25 < t 50 t/5 t/2 50 < t 100 10 25 10mm x 10mm 10mm x 20mm
Allowable limit of defect of Type 2

Thickness of base metal t (mm) Classification of defect Size of defect Maximum size of defect (mm) Sum of size of defect (mm) t 50 t/2 2t 50 < t 100 25 100 t 50 t/2 t 50 < t 100 25 50
Defect of Type 2-A
Defect of Type 2-B
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NDT
Expansion of Scope
The first test Accepted Rejected Plate: 2 parts within the weld lines where the faulty welds are found Girder or frame: 2 welding joints for each member, where the same welding procedure with the faulty welds is applied to the same block joints Automatic welding: Full length or all number of the welded joints Accepted Rejected Plate: Full length Girder or frame: All number Accepted Rejected Failed Passed
Treatment after Rejection

Repair is to be carried out after the surveyors judgement All length or all number of welded joints may be repaired The rejected welds (at the first and second test) are to be repaired Repair process and additional NDT in other welded joints are to be carried out according to the surveyors direction taking account of the condition of faulty welds (kind, size and distribution of defects, etc.) Where the rejected welds are more than 10% of the number of inspection, the results of investigation on the substantial cause and measures to improve the quality are to be submitted to the surveyor Surveyor in charge prepares Form S (Deficiency Record)
10. Measurement of Principal Dimensions

Flatness of keel Length Breadth Depth Tools and accuracy Position of measurement Record of weather, temperature and time during the measurement
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Standard for Error (JSQS)
Flatness of keel:
Length:
50 mm (per 100 m)
Length between aft edge of boss and main engine: 25 mm
Breadth and Depth:
Measurement of L, Flatness of Keel

The base line is defined at first
Slit gauge
Point of FP
Measurement of Breadth and Depth
Erect a pole at middle of L along the side shell Shift the height of the lower face of keel to the pole using a water level Measure the height from the deck line to the lower face of keel using a mould Measure the breadth at upper deck or bottom
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11. Paint
Approved corrosion prevention scheme Ballast tank (full coating) Cargo hold/ tank Exemption from coating for bulk carriers Restriction of kind of paint for COT of tankers Oil tank (no need of coating) Cathodic protection Paint for fire protection (see 14. below)
Specification of Coating
Surface preparation
Remove mill scale, rust, other foreign object on the surface of steel plate, as well as apply certain roughness for better adhesiveness with coating
Various paint
Below water line: Corrosion by sea water, stain by marine creature Above water line: Impact of waves, alternation of dry/wetness due to wave splash and sunshine Shop primer Paint for accommodation Anti corrosive paint Paint for E/R, work shop Anti fouling paint Paint for cargo hold Boot top paint Paint for fresh water tank Top side paint Paint for ballast tank Paint for exposed deck etc.
Shop Primer
Temporary protection of the surface between surface preparation and coating, as well as improvement of adhesiveness with coating Wash primer Short/Long period of exposure. Long one is usually applied. Good for 3 months. Zinc-epoxy primer Weak points are noxious smoke during gas cutting and low weldability due to zinc. Good for 6 months. (Non-zinc) epoxy primer Pigment other than zinc is used. Durability is between wash primer and zinc epoxy primer. Non-organic zinc shop primer Chemical adhesion to steel plate is excellent and good for 8 months. But same problem as zincky primers.
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Timing of Coating
Hydrostatic/watertight tests are to be carried out after all work in connection with water-tightness are completed but before painting except shop primer. However, the tests may be carried out after the protective coating has been applied, provided that following conditions are satisfied prior to the application of the protective coating: All the welds are completed and carefully examined visually to the satisfaction of the surveyor An airtight test is carried out
Exemption from Coating (1/3)

Cargo Hold of Bulk Carrier
If thickness is increased in accordance with the Rules

Cargo Hold of Chip Carrier
Coating may be exempted
Resin contained in the chip prevents corrosion Inside of deck does not touch the chip, therefore coating should not be omitted
-61/88-

Oil Tank
(Note) Inside of oil tanks need not be coated as exception, but coating of ballast tanks adjacent to oil tank with heating facility is likely to deteriorate
Cathodic Protection
Anodic protection system Zinc, aluminum, magnesium, etc. are used as sacrificial anode that has lower electric potential than the metal to be protected. This system is adopted as a back-up for protective coating for shell plate and ballast tank. Duration is usually designed as 2~4 years. Impressed current cathodic protection system The electric potential of the target is maintained by direct current supplied by the system
Metal Copper Low carbon steel Zinc Electric potential in sea water -0.36V -0.61V -1.03V
12. Markings
Load lines Position of each mark and line Accuracy (0.5 mm) Permanent marking (welding of thin steel plate or punching Color (in contrast with the color of the shell) Draught scale Ships identification number (SOLAS XI/3.4) CC mark (TM69)
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Load Line Mark and Lines

Note: This marking is one on the starboard side
Deck line Load lines
Load line mark (ring and horizontal line)
Measurement of Load Lines
Allowable error is 0.5mm
Draught Scale
Marked at fore, aft and midship on both port/ starboard side, every 20 cm. The height the letter is 10 cm. The lower edge of the letter coincides with the draught line represented by it. (standard 1 mm, limit 2 mm)
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Ships Identification Number

(SOLAS XI/3.4)
Stern, both sides of hull at midship, both sides or front of superstructure
Aftermost bulkhead or hatchway in the machinery space
CC (Cargo Compartment) Mark
Characters CC should be permanently marked at the compartments included in the calculation of net tonnage. Location of the marking is in principle as follows:
Cargo ship: Tanker: PCC: LPG carrier: Outside of hatch coaming Outside of cargo hatch Outside of entrance to the hold Coaming of tank on upper deck
13. Piping
Pipes and valves Pressure test Air pipe Sounding pipe Scupper and sanitary pipe Bilge and ballast line
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Material of Pipe
Steel pipe
Carbon steel pipe for pressure piping (STPG) is the most commonly used for ship
Cast steel pipe

Corrosion-resistant. Large scale and thick ones are used for cargo oil line and ballast line of tankers
Stainless steel pipe

For piping, where less-maintenance and corrosion-resistance are required
Copper and copper alloy pipe

Easy for bending and corrosion-resistant. For deck steam line
Other material
Synthetic resin, PVC, etc.
Pressure Test
Object of test Pipes in Group I and II Steam pipes, feed water pipes, compressed air pipes and fuel oil pipes with the design pressure exceeding 0.35MPa (e.g. F.O. pipes and heating pipes) Cargo oil pipes, crude oil washing pipes for oil tanker Check point Hydrostatic test with pressure of 1.5 time (1.25 time for cargo oil pipes) the design pressure. The test may be replaced by airtight test by prior consultation. Test pressure is to be checked by JIS/ISO pressure gauge properly calibrated Welding of pipe is to be executed by qualified welders. Joints of pipes in Group I & II with a diameter of 50A or more is to be of butt welding type Others Penetration of air pipes, sounding pipes, etc. is to be confirmed at the time of pressure test of tanks Not applicable to the pipes with opening end
Insufficient Pipe Support
-65/88-
Protective Arrangement of Pipes
Kind of Air Pipe Head

Manual closing type Self closing type
Ball float type
Gooseneck type
Mushroom type
(Note) Head of air pipe located on the exposed deck of a ship, whose keel is laid on or after 1/1/2005, should be of self closing type
Disc float type
Hinged Steel Cover of Air Pipe Head
Direct clamping may hider sometimes sufficient passage of air during ballast operation To prevent negative pressure of tank, air passage hole of about 10 mm in diameter may be drilled in the cover plate
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Number and Sectional Area of Air Pipe
1. Tanks having top plates not less than 7m either in length or in width are to be provided with two or more pipes arranged with a suitable distance 2. However, tanks having inclined top plate may be provided with one air pipe located at the highest part of the top plate
Height of Air Pipe

On Freeboard Deck On Superstructure Deck
(1) Air pipes for water tank should open above Bulkhead Deck (2) Air pipes for oil tank should open at weather part (with wire gauze)
Note: The height is specified by ILLC, not for positions I and II but for kind of deck
Check Point of Air Pipe

Drain free under any trim condition of the ship (see the slide just before) Name plate at upper end Protection for mechanical damage Thermal insulation in refrigerated compartments Closing appliance The openings should be provided with a permanently attached effective closing appliance (wooden plug and canvas are not regarded as effective at Position I and II) For ships intended to carry timber deck cargo, the closing appliance is to be of an automatic type Detachable and corrosion-resistant gauze wire net at the open end of air pipe to fuel oil tank, cargo oil tank and adjacent cofferdam (If gauze wire net is found to air pipe to ballast tank, it should be removed)
-67/88-
Kind and Position of Sounding Pipe
In principle, the pipes are to be led to positions above the bulkhead deck which at all times readily accessible, and are to be provided with effective closing appliance at their upper ends Requirements for air pipes concerning name plate, protection and insulation are applicable to sounding pipes Self-closing device is required for sounding pipes which open in E/R
Construction of Sounding Pipe

Striking plate
Additional holes are drilled on the pipe for viscous liquid
Cap of Sounding Pipe
Cap should be permanently attached by chains or other means, to prevent loss
Head of short sounding pipe in E/R (With self-closing cock for confirmation of absence of oil before opening the cap)
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Arrangement of Deck Scupper
Square gunwale
Round gunwale
Standard of is 25m (20m, when B exceeds 48m)
Other Scupper Pipes

Car carrier Scupper line from car space to E/R bilge well automatic closing valves Bilge from living quarters should not be led to car space Scupper line from car space to bilge well of another car space (different fire protection compartment) automatic closing valves of vertical nonreturn valves Refrigerated compartment Water seal is arranged to prevent a back flow of the atmosphere
Scupper from Living Quarters
Example of bad piping
The scupper piping within superstructure is not to be connected to the scupper piping on the weather deck In general, different systems of overboard discharge are not to be connected each other, unless specially approved by the society. In general, scupper piping should not pass through fresh water or potable water tank
-69/88-
Discharge from Enclosed Spaces (1/3)

Inboard discharge Principle (1) To be led directly to inboard bilge wells (2) One ANRV with positive means of closing it from a position above the freeboard deck, and one open/close indicator General (3) One ANRV, one stop valve controlled from above the freeboard deck, and one open/close indicator (4) One ANRV, and one positive closing valve operated in manned engine room (*) Overboard discharge Height between inboard end and tropical LWL exceeds 0.01Lf Height between inboard end and tropical LWL exceeds 0.02Lf Inboard end is always closed, except when discharging, during navigation Penetration of shell plating (5) Each one ANRV above/below tropical load line (6) Two ANRV below tropical load line, and one stop valve between the two ANRV (*) (7) One ANRV (*) (8) One stop valve (9) If pipe penetrates shell plating at either more than 450mm below the freeboard deck or below 600mm above the load line, one ANRV is to be provided at the shell plating
* Not applicable to scupper pipes from spaces below the freeboard deck

Cases (1)(4)
(1) (2)
(3)
(4)

Cases (5)(8)
(5) (6)
(7)
(8)
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Reinforcement of Distance Piece
Bilge Line System (1/2)

Manifold System or Independent System
If the pipes pass in cargo holds, they must be protected against cargo damage
Bilge Line System (2/2)

Main Line System or Xmas Tree System
-71/88-
Bilge Suction for Long Hold
(Bend type)
In ships having only one hold exceeding 33 m in length, bilge suctions are to be provided in suitable positions in the after half-length and in the forward half-length of the hold Slip-on joints are not to be used in pipe lines in cargo holds deep tanks, and other spaces which are not easily accessible, unless approved by the society.
Bilge Well
Bilge hat for small compartment
In either case, a should be less than d0/2, and b more than 460 mm Capacity of the well should be 0.17 m3 or more (reasonable capacity, in case of hat)
Non-Return Valve for Bilge Line
The same is applicable for bilge line in side tanks and bilge hopper tanks
-72/88-
Cargo / Ballast Hold
This slide shows the arrangement for cargo mode. For ballast mode, a blank flange should be fitted to the hold bilge line
14. Fire Protection
Fire protection materials Inspection at intermediate stage Inspection of fire protection, detection and extinction and means of escape
Fire Protection Materials

Non-combustible material A and B class division Fire retardant base material (for divisions, groundsills) Fire retardant veneers Fire retardant surface floorings Primary deck covering Classes A and B mean equivalent Fire retardant coating performance as the division where Door (A and B class) they are installed. (Class B of side scuttle is a category of strength) Side scuttle (B class) In addition to confirmation of the certificate including its validity and label on the articles, proper use of the articles should be confirmed according to the approved drawings
-73/88-
Inspection at Intermediate Stage

Following parts are to be inspected before ceiling, paneling and lining. Treatment at intersection of bulkhead or deck, and extension of insulation Construction of bulkhead or deck at penetration of pipe, duct or electric cable Arrangement and construction of ventilation duct including damper Arrangement and construction of draught stop behind ceiling, paneling and lining Non-combustible materials (especially for Method IC)
Inspection of Fire Protection

Cargo Ships Other than Tankers
For cargo ships applying Method IIC or Method III, arrangement of automatic sprinkler system (Method II only), fire detecting and fire alarming equipment In ro/ro cargo spaces Mechanical ventilation systems and their closing appliances Materials and arrangement of ventilation ducts Arrangement of scupper pipes Means of escape In Cargo spaces of ships carrying dangerous goods Exclusion of source of ignition Installation of mechanical ventilation systems Installation of explosion-proof mechanical ventilation systems Prevention of ingress of bilge into engine room (from cargo spaces) Insulation of boundaries between cargo spaces and machinery space of Category A
Inspection of Fire Protection

Tankers
Arrangement of machinery spaces of Category A Arrangement and separation of accommodation spaces, main cargo control stations, control and service spaces including insulation Construction and arrangement of coaming to prevent oil from flowing into accommodation space Insulation of exterior boundaries of superstructures and deckhouses enclosing accommodation spaces and service spaces Arrangement of entrances, air inlets and openings of superstructures and deckhouses Construction and arrangement of scuttle on the sides of superstructures and deckhouses Skylights of cargo pump rooms Protection of cargo tanks
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Class of Division
Class Construction Formed by bulkheads and decks Constructed of steel or equivalent material Suitably stiffened Insulated with approved non-combustible material Formed by bulkheads, decks, ceiling or linings Constructed of approved non-combustible materials and all materials entering into the construction and erection of B class divisions shall be non-combustible Constructed of approved non-combustible materials Rise of temperature of unexposed side Average: 140 Any point: 180 Time: 0, 15, 30, 60 minutes Average: 140 Any point: 225 Time: 0, 15 minutes Passage of smoke and flame Prevent the passage of smoke and flame for 1 hour
Prevent the passage of flame for 30 minutes -
Non-combustible material is a material which neither burns nor gives off flammable vapours in sufficient quantity for self-ignition when heated to approximately 750
Fire Integrity of Bulkheads

(Cargo Ships other than Tankers)
Spaces (1) Control stations (2) Corridors (3) Accommodation spaces (4) Stairways (5) Service spaces (low risk) (6) Machinery spaces of category A (7) Other machinery spaces (8) Cargo spaces (9) Service spaces (high risk) (10) Open decks (11) Ro-ro cargo spaces (1) A-0 (2) A-0 C (3) A-60 B-0 C (4) A-0 B-0 A-0 B-0 A-0 B-0 A-0 (5) (6) (7) (8) (9) A-15 A-60 A-15 A-60 A-60 B-0 A-60 A-0 A-0 A-0 B-0 B-0 A-0 C A-60 A-60 A-60 * A-0 A-0 A-0 A-0 A-0 A-0 A-0 A-0 A-0 A-0 * A-0 A-0 A-0 A-60 A-0 A-0 A-0 (10) * * * * * * * * * (11) A-60 A-30 A-30 A-30 A-0 A-60 A-0 A-0 A-30 A-0 *
* Where an asterisk appears in the table, the division is required to be of steel or other equivalent material but is not required to be of A class standard
Fire Integrity of Decks

(Cargo Ships other than Tankers)
Space above (1) (2) (3) (4) (5) (6) (7) (8) (9) A-0 A-0 A-0 A-0 A-0 A-60 A-0 A-0 A-0 A-0 * * A-0 * A-60 A-0 A-0 A-0 A-60 A-0 * A-0 * A-60 A-0 A-0 A-0 A-0 A-0 A-0 * A-0 A-60 A-0 A-0 A-0 A-15 A-0 A-0 A-0 * A-60 A-0 A-0 A-0 A-60 A-60 A-60 A-60 A-60 * A-60 A-30 A-60 A-15 A-0 A-0 A-0 A-0 A-0 * A-0 A-0 A-60 A-0 A-0 A-0 A-0 A-0 A-0 * A-0 A-60 A-0 A-0 A-0 A-0 A-60 A-0 A-0 A-0 * * * * * * * * * A-60 A-30 A-30 A-30 A-0 A-60 A-0 A-0 A-30 (10) * * * * * * * * * * (11) A-60 A-30 A-30 A-30 A-0 A-60 A-0 A-0 A-30 * *
(1) Control stations (2) Corridor (3) Accommodation spaces (4) Stairways (5) Service spaces (low risk) (6) Machinery spaces of category A (7) Other machinery spaces (8) Cargo spaces (9) Service spaces (high risk) (10) Open decks (11) Ro-ro cargo spaces
Space below
* Where an asterisk appears in the table, the division is required to be of steel or other equivalent material but is not required to be of A class standard
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Protection in Accommodation Area (1/3) Method IC (Cargo Ships including Tankers)

All the internal divisions are of class B or C Without automatic sprinkler, fire detection and fire alarm system in accommodation and service spaces
For tankers, only this method is applicable.
Protection in Accommodation Area (2/3)

Method IIC (Cargo Ships other than Tankers)
Automatic sprinkler, fire detection and fire alarm system is required in all spaces in which fire might be expected to originate No restriction on the type of internal divisions unless otherwise required
Protection in Accommodation Area (3/3)

Method IIIC (Cargo Ships other than Tankers)
Automatic sprinkler is exempted from Method IIC Area of any accommodation spaces bounded by class A or B division shall not exceed 50 m2
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Space for Emergency Fire Pump

to be extended by 450 mm
No direct access is permitted between machinery space of category A and the space for emergency fire pump When this is impracticable, the access may be by means of an airlock with the door of the machinery space being of A60 class standard
Materials of Overboard Fittings
Materials readily rendered ineffective by heat, such as PVC, FRP, aluminium alloys, lead, copper and copper alloys, should not be used for overboard scuppers and sanitary discharges at following parts: (1) The parts below the freeboard deck (2) The parts in the space having the open end (3) The parts in the spaces directly above the freeboard deck
Prevention of Heat Transmission
Extend the insulation at least 450mm (principle)
If the pipe is made of material having low-heat conductivity character and a diameter of less than 150mm, the insulation may be terminated at the end of penetration piece or sleeve
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Penetration of Electric Cables

Class A division
Class B division
Working Drawing
Type approval of Fire Protection Material
The on-site survey is to confirm that the execution of works is in accordance with the approved drawing
Inspection at Intermediate Stage
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Division and Penetration
A-60 Class
A-0 Class
Cables penetrating A-0 Class Division
Route of Escape in Machinery Space
15. & 16 ILLC Matters
Refer to a separate topic Load Lines and Stability for following topics: 15. Closing appliances 16. Protection of crew
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17. Bottom Inspection before Launching

Shell plating: Any deformation (damage occurred after block inspection etc.) especially around block joints and blocks of building berth Any notches around the openings of shell plate, such as sea chest (including air holes and drain holes), rudder trunk, etc. Welding and shapes of penetration part of distant piece Any discharge pipe around lifeboat launching area (if any, cover and stopping device of discharge water should be provided) Any undercut or notch after removal of jigs and eye pieces for lifting or staging Closing of bottom plugs, fitting of zinc anodes (only for reference) Rudder and sea chest Bush retainers for rudder, grating for sea chest Results of NDT The results of NDT for welds below the water line Construction and arrangement for in-water survey, if applicable (see next slide)
Construction and Arrangement for In-Water Survey

Approval of the documents and plans for in-water survey Marking of the position of bulkheads and the name of space on bottom shell plate Following items are to be arranged for measuring at afloat condition Clearance of each rudder pintle Clearance between propeller shafts and their bearings (in case of water lubricating type stern tube bearings) Reading of ware down gauge (in case of oil lubricating type stern tube bearings) Confirmation of the position and identification of each propeller blade Open and close of hinged gratings on all sea chests
18. Stability Experiments

Inclining test: to locate the center of gravity of the ship Oscillation test: to determine rolling period of the ship
General stability requirements
Rules Part U assume that rolling angle 1 is proportionate to the root of s, which is functional to T (rolling period)
s T
Rolling angle Stability requirements in wind and waves
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Omission of Stability Experiments

The stability experiments of an individual ship may be dispensed with, provided that available stability data are obtained from stability experiments of a sister ship or other adequate means and special approval is given by the society. Where the stability experiment is dispensed with, light weight measurement is to be carried out, and it is to be confirmed that the deviation of light weight as well as of lightship longitudinal centre of gravity between the ship in question and a lead sister ship (to be modified, if necessary) do not exceed following values. Length for freeboard Light weight Longitudinal centre of gravity Lf < 50m 2% Lf < 160m 50m Lf 160m By linear interpolation 1% 0.5% of Ls
When the society gives a special approval, oscillation test may be dispensed with and rolling period may be determined by an approximate calculation
T= L 2B B 0.373 + 0.023 0.043 wl dm 100 G0M
Inclining Test
Prior to the measurement, the surveyor is to confirm that the ships condition, test circumstances and test devices conform to the requirements in Annex B2.3.2-2 Guidance for Inclining Test of the guidance During the measurement, the surveyor is to confirm that sufficient data is gathered to determine the particulars of stability information of the ship If the ship has not completed construction work, the weights and positions of items which are to be added, removed or relocated should be recorded by the shipyard and confirmed by the surveyor (within 2% of final lightweight) When the test report incorporating the data is submitted, the surveyor is to ensure that the data given in the report is consistent with that gathered during the test Note: 1. Small heel angle may result in deviation over tolerance limit (expected heel 1 to 4) 2. Mooring lines are to be free of transverse tension
Document and Tool Concerning Loading

Stability information ILLC Annex I, II/10 (2): Stability information and loading information shall be carried on board all times together with evidence that the information has been approved by the Administration SOLAS II-1/22: The master shall be supplied with such information satisfactory to the Administration as is necessary to enable him by rapid and simple processes to obtain accurate guidance as to the stability of the ship under varying conditions of service Loading manual ILLC Annex I, II/10 (1): The master of every ship shall be supplied with sufficient information, in approved form, to enable him to arrange for the loading and ballasting of his ship in such a way as to avoid the creation of any unacceptable stresses in the ships structure. SOLAS VI/7.2: To enable the master to prevent excessive stresses in the ships structure, the ship shall be provided with a booklet, which shall be written in a language with which the ships officers responsible for cargo operations are familiar. Loading instrument (SOLAS XII/11): Bulk carriers of 150 m in length and upwards shall be fitted with a loading instrument capable of providing information on hull girder shear forces and bending moments.
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Draught and Specific Gravity
Measured at fore, aft and midship on both port/starboard sides
Measured around the depth of center of buoyancy
Hydrostatic Curves
Measured draught W KM
Calculation of KG
The length of the pendulum should be so arranged to obtain a swing of about 100 mm, in order to improve the accuracy (This requires the length of 5.7 m to detect an angle of 1. It may be almost impracticable for big ships.)
tan = r / p wa W GM wa GM = W tan KG = KM GM tan =

This value, obtained as for light weight condition, is the basis of calculation for all the loading conditions
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19. Navigation Bridge Visibility

SOLAS V/22
View of sea surface Blind sectors Horizontal field of vision
Terminology
Main steering position
Conning position (5m to each side)
Wheel house
Bridge wings
Bridge
View of Sea Surface
2L or 500m, whichever is less

10
10
It must be satisfied even in trimmed condition
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Blind Sectors
3 2
1 1, 2, 3... < 10 1+2+3+... < 20 1, 2,> 5 1
Horizontal Field of Vision
22.5
45
At conning position
45 60
At each bridge wing (The ships side is to be visible from the bridge wing.)
60
At main steering position
Bridge Front Window
Horizontal forward must be seen even the ship makes pitching. The height of eye may be reduced up to 1600mm when approved by the administration
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20. Sea Trial

Speed test Astern test Steering test, main/auxiliary steering gears change-over test Turning test Performance test of windlass Confirmation of no abnormality for the operating condition of machinery and behaviors of the ship during the trial Performance test of automatic and remote control systems for main propulsion machinery or CPP, boilers and electric generating sets The accumulation test of boilers Measurement of the torsional vibration for the shafting system Other tests deemed necessary by the Society. (e.g. initial turning test, zigzag test, etc. for hull part)
Regarded as belonging to hull part
One Day of a Sea Trial
Progressive speed trial Continuous running test Crash astern & ahead Boiler accumulation test test (engine side) Zigzag test Main steering gear test Ship inertia test (different Turning test from stopping test)
Crash astern & ahead test (bridge side) Aux. steering gear test Windlass performance test
Speed Test
To confirm speed of ship defined in 2.1.8 of Part A of the Rules where test is carried out in full load condition speed at MCO (maximum continuous output) of the main engine where test is carried out in other condition speed at MCR (maximum continuous revolution, corresponding to MCO) of the main engine In addition, speed at 25%, 50%, 75%, normal continuous cruise power run (85%) and 100% of the engine is also to be confirmed The speed against ground is measured by running between two mileposts erected ashore, or by GPS (accuracy is 10m) or DGPS (accuracy is 5m) Measurement is taken on going and returning, in order to cancel the effect of current
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Astern Test
An order for full astern* is issued while the ship is running ahead at the maximum speed. The test is continued until the speed against the water reaches 0** (Rudder is to be kept at the mid position during the test) Speed, heading angle and trace of running are to be measured at a constant interval (it is to be confirmed that machinery installations have normal functions while the ship is running astern) Track reach, Stopping distance and lateral deviation are to be measured
Note: * The rate of main engine is to be kept more than 70% of MCR ** Continuous running of engine in astern is required for more than 30 minutes for machinery part
Steering Test
Main steering gear: While ship is running ahead at maximum speed, put the rudder over from 35 on one side to 35 on the other side put the rudder from 35 on either side to 30 on the other side in not more than 28 seconds Aux. steering gear: While ship is running ahead at max (half of maximum speed, 7kt) put the rudder over from 15 on one side to 15 on the other side in not more than 60 seconds Hydraulic Change-over test cylinder During those, the power units, hydraulic fluid recharging system, emergency power supply, operation of controls, means of communication between bridge and engine room/ steering gear compartment, indicators for the alarm, rudder angle indicator, etc. are to be also tested.
Pump
Plunger Cross head Connecting rod Rudder stock
Turning Test
The ship is steered to 35 while running ahead at the maximum speed, and the rudder angle is to be kept until the ship turns to 360 (turn to right and left) Ships speed and/or turning rate are measured at the heading angle reached at 0, 5, 15, 30, 60, 90, 120, 150, 180, 210, 240, 270, 300, 330, 360 and the elapsed time reached to each heading angle is also to be measured
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Performance Test of Windlass

Loading test: Hoist up anchor chains from the state in which 82.5 m (3 lengths) of chain are submerged and freely suspended at commencement of lifting, in accordance with the manner specified below hoisting up 2 lengths of chain by one side (average speed not less than 0.15m/sec) hoisting up 2 lengths of chain by the other side (ditto) hoisting up one length of chain together by both sides regardless of the time Cable lifter braking test: The brake is to be tested with the anchor dropping at every about length of chain to confirm safe paying out and holding of the anchor chain by the brake Driving lever Clutch handle Chain wheel Brake
Zigzag Test, Initial Turning Test

The initial turning test: The ship is steered to the 10 rudder angle, while running ahead at the maximum speed, and this rudder angle is to be kept until the ship turns to 10 from the original course. This test may be conducted at the 10/10 zigzag test. The zigzag test: While the ship is running ahead at the test speed
steered to to p (s) side when the ships heading reaches to , the ship is steered to to s (p) side when the ships heading reaches to , the ship is steered again to to the p (s) side The test is continued until the ships heading reaches to the original course shall be taken as 10 and 20
21. Documents to Be Maintained on Board

At the completion of a classification survey, the surveyor confirms the following drawings, plans, manuals, lists, etc., as applicable, of finished version are on board. Finished plans General arrangement Midship section, scantling plans (construction profile), deck plans, shell expansion, transverse bulkheads, plans for rudder and rudder stock, and plans for cargo hatch covers Bilge, ballast and cargo piping diagrams Fire protection plans Fire extinguishing applications arrangement Plans and data showing the navigation bridge visibility Manuals and lists (see following slide) Ship construction file (see following slide) Note 1: Other than those required by Parts CSR-B, CSR-T, N, S, P Note 2: Certificates shall be also confirmed
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Manuals and Lists

Documents approved by the Society Operating and maintenance manuals for the door and inner door Damage control plans Loading manuals Ship structure access manuals Stability information booklets Cargo securing manuals (Japanese ships only) Coating technical file Plans and documents for in-water survey Other documents Towing and mooring fitting arrangement plans Operation manuals for the emergency towing arrangement Booklets for the damage control
Operation manuals for the loading computer Plans for means of access Operation manuals for stability computer Operating and maintenance instructions for ship machinery and equipment Manuals for water level detection and alarm systems Maintenance records of batteries Instruction manuals for the cargo tank venting systems Fire control plans, fire safety operational booklets, training manuals and maintenance plans Operation manuals for the helicopter facilities Instruction manuals for the inert gas systems
Ship Construction File

Ship Construction File required to be maintained on board for ships engaged in international voyage, contains the necessary documents from the following drawings, plans, manuals and documents (duplicate documents to previous slides are not necessary) Finished plans of hull structural drawings Operating and maintenance manuals for the door and inner door Damage control plans Loading manuals Stability information booklets Ship structure access manuals Copies of certificates of forgings and castings welded into the hull structures Plans showing locations, sizes and details of equipment forming part of the watertight and weather-tight integrity of the ship including piping Corrosion prevention scheme Plans and documents for in-water survey Docking plan including locations and other necessary information of all penetrations Test plans, test records , measurement records, etc.
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What are the main components of a ship's hull survey system?

What are the main components of a ship's hull survey system?

What are some of the preconditions for a shipyard's quality control system?

What are some of the preconditions for a shipyard's quality control system?

Training Material Internal Use Only

Classification Survey during Construction (Hull)

Part 1 Part 2 Part 3

Hull Survey System Record of Inspection Survey on Site

Surveys for CSR-Applied Ships

(CSR will not be further explained in this lecture)

Classification Survey during Construction (Hull)

Hull Survey System

Hull Survey System

Rules, Guidance ClassNK Instructions

Indirect survey & QC investigation QC System of Shipyard

Hull Survey System

Classification Survey during Construction (Hull)

Hull Survey System

Hull Survey System

New Building and Project Team

Work commence Lay down

Classification Survey during Construction (Hull)

Flow of Plan Approval

Classification Survey during Construction (Hull)

Background of Patrol Survey

Investigation of Quality Control

Classification Survey during Construction (Hull)

Classification Survey during Construction (Hull)

Vertical Inspection of Welding Work

Process control record

Classification Survey during Construction (Hull)

* For hull blocks manufactured by subcontractors, see 4. below

Makers and Acceptance Inspection

Classification Survey during Construction (Hull)

Stamps and Certificate

Cast/ Forged Steel

Classification Survey during Construction (Hull)

Steel without NK Certificate

Material for Fire Protection

Classification Survey during Construction (Hull)

Other Materials and Equipment

Kind of Welding Process

MAG welding CO2 MIG welding Self-shielded arc welding

Classification Survey during Construction (Hull)

Welding Procedure Qualification

Qualification Test of Welding Procedure

Qualification Test of Welding Procedure

Classification Survey during Construction (Hull)

Qualification Test of Welding Procedure

Welder Qualification Certificate

Thickness (mm) 5 or below 19 or below No restriction

With backing Without backing

Welding Position at Qualification Test

Classification Survey during Construction (Hull)

Welding material Bonded flux Molded flux

Maximum period for weathering (hours) Control target Allowable limit

Standard drying conditions

Welding of Rolled Steel

Pre-heating (submerged arc welding)

Classification Survey during Construction (Hull)