Marine Kit - 1 Shipyard Operations

Shipyard Operations Description This shipyard operations activity requires two class periods Students work in groups of 4 Each session can be completed within one class period (55 min.) Students learn about the various departments by building a paper container ship.

Shipyard Operation Schedule Day 1: Shipyard Operations Day 2: Design Calculations

Day 1 Time Topic 00:00 Introduction to Shipyard Operation Activity by the teacher – 10 Min. 00:10 – 00:55 Simulation Activity – 45 Min. Day 2 Time Topic 00:00 Introduction to Shipyard Operation Activity – 15 Min. 00:15 – 00:55 Design Calculations – 40 Min.

Production Layout There are three departments within our shipyard and an external supplier Plasma Cutting Bending Machine Supplier Welding Material Flow Information Flow Our shipyard builds a container ship

Day 1: Activities Instruction manual is provided to guide students in constructing the ship Three departments are involved in this shipyard operation (excluding the Supplier) Teacher serves as the Supplier Plasma Cutting Shop cuts the plates Plate Shop bends the plates to form hull modules Welding & Final Assembly Shop assembles the ship modules

Ship Terminology Starboard Stern Bow Port Bow : Front part of the ship Stern : Rear part of the ship Starboard : Right side of the ship Port : Left side of the ship

Ship Terminology Port Stern Bow Starboard

Activity Involved in the Plasma Cutting Shop Receives steel plates from the supplier Cuts the plates along the solid line Sends the parts to the Plate Shop All the parts are numbered in the order in which they have to be sent to the next department.

Bow – Cut Part from Plasma Shop Cut along solid lines

Fold along dashed lines Mid-Hull – Cut Part Fold along dashed lines

Directions for folding Stern – Cut Part Directions for folding Part Number

Bulk Head – Cut Part

Bow Deck Plate – Cut Part Stern Deck Plate – Cut Part

Mid-Hull Deck Plate – Cut Part

Super Structure – Cut Part

Activity Involved in the Plate Shop Receives steel plates from the Plasma cutting shop Bends the parts along the dotted lines using the instructions given in the instruction sheet Sends the parts to the welding shop

Bow Deck Plate – Bent Part Bow – Bent Part Bow Deck Plate – Bent Part

Mid – Hull Deck Plate – Bent Part Mid – Hull – Bent Part Mid – Hull Deck Plate – Bent Part

Bulk Head – Bent Part Stern – Bent Part

Super Structure – Bent Part Stern Deck Plate – Bent Part Super Structure – Bent Part

Activity Involved in the Welding Shop Receives bent plates from the Plate shop Welds (gluing/taping) the plates along the length of the joints and then assembles the parts All the parts are joined to build the final assembly

Welding and Final Assembly of Bow

Welding and Final Assembly of Mid-Hull

Welding and Final Assembly of Stern

Welding of Super Structure

Final Assembly of the Ship

Day – 2: Design Calculations In the first set of calculations students are required to calculate: Weight of the ship Weight of displaced water Draft of the ship and Kinetic Energy of the ship * The formulae and instructions for calculations are given to the students *

Q 1. Calculation of Weight of the Water Displaced by the ship Weight of displaced water = Weight of loaded Ship = Weight of Ship+ Cargo Weight Step 1: Area of the Plates Step 2: Volume = Area*thickness where A = Area and t = thickness Step 3: Total Weight = Weight of the ship + Weight of the containers Weight of the ship = Sum of weight of each steel part Weight of the containers(1500 TEU containers) (Weight of 1 TEU container=24 tons) A t

Q 2. Calculation of Draft of the Ship

Q 3. Calculation of Kinetic Energy of Ship KE = ½ * m * v2 We know, 1 kg = 9.8 N 1 Ton = 9800 N Weight = m * g Therefore, m = weight/g where g = 9.8m/s2

Sample Student Worksheets

Area Calculations - Bow A1=A3 A4=A6 A2 A5 A1 A4 Area of Bow= A1+ A2+ A3+ A4+ A5+ A6 = __________sq. mm = ___________sq. m

Hull Plate thickness: 5cm and Deck Plate thickness: 2.5cm Part Name Area of paper boat (m2) (1) Area of original ship (m2) (2) = (1) *(400)2 Thickness (m) (1m=100cm) (3) Volume (m3) (4)=(2)*(3) Weight of Each part (kg) (5)=(4)*density of steel (Density of steel=7800kg/cu.m) Bow Bow Bulk Head Bow Deck Plate Mid Hull Mid Hull Bulk Head Mid Hull Deck Plate Stern Stern Bulk Head Stern Deck Plate Super Structure

Calculation’s of Weight of the Ship Part Name Area of paper boat (m2) (1) Area of original ship (m2) (2) = (1) * 400)2 Thickness (m) (1 m =100cm) (3) Volume (m3) (4)=(2)*(3) Weight of Each part (kg) (5)=(4)*density of steel (Density of steel=7800kg/cu.m) Bow Bow Bulk Head Bow Deck Plate Mid Hull Mid Hull Bulk Head Mid Hull Deck Plate Stern Stern Bulk Head Stern Deck Plate Super Structure .0212 .0031 .0082 .0327 .0063 .0153 .0169 .0071 .0092 3392 496 1312 5232 1008 2448 2704 1136 1472 .050 .025 169.6 12.4 32.8 261.6 25.2 61.2 135.2 28.4 73.6 1,322,880 96,720 255,840 2,040,480 196,560 477,360 1054,560 221,520 574,080 Total weight of the Steel Plates =6,336,720 kg

Calculation of Weight of Water Displaced by the Ship Sum of weight of each part = _____________ kg = __________ tons Weight of steel used is approximately 50% of the weight of ship Therefore, the weight of the Ship = ___________ tons Weight of 1 TEU container = 24 tons Weight of 1500 TEU containers = ________________ tons Therefore, weight of water displaced by the ship = Weight of the Ship + Weight of the Containers = ___________________ tons

Q 2. Calculation of Draft of the Ship - Sample For example: The draft for the corresponding weight of water displaced (shown by the arrow) is 4.73 m

Calculation of K.E of the Ship KE = ½ * m * v2 Cruising speed = 26 knots (1 knot = .514 m/s) V = ___________ m/s We know, 1kg = 9.8 N, 1 Ton = 9,800 N So, 48,684 tons = _____________ N Weight = m * g (g= 9.8 m/s) m = _______________ kg KE = _________________ J

Quality Assessment Shipyard Operations will be assessed based on the following quality characteristics Cutting on the solid lines Cutting the corners and intersections properly Gluing the joints properly Hull alignment Bends are straight and creased

Wrap-up Make sure all the items are put back in the kit box and returned to the teacher. Please clean the working area.