1. Marine Kit - 1 Shipyard Operations

2. 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.

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

4. 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.

5. 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

6. 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

7. 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

8. Ship Terminology
Port
Stern
Bow
Starboard

9. 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.

10. Bow – Cut Part from Plasma Shop
Cut along solid lines

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

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

13. Bulk Head – Cut Part

14. Bow Deck Plate – Cut Part
Stern Deck Plate – Cut Part

15. Mid-Hull Deck Plate – Cut Part

16. Super Structure – Cut Part

17. 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

18. Bow Deck Plate – Bent Part
Bow – Bent Part
Bow Deck Plate – Bent Part

19. Mid – Hull Deck Plate – Bent Part
Mid – Hull – Bent Part
Mid – Hull Deck Plate – Bent Part

20. Bulk Head – Bent Part
Stern – Bent Part

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

22. 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

23. Welding and Final Assembly of Bow

24. Welding and Final Assembly of Mid-Hull

25. Welding and Final Assembly of Stern

26. Welding of Super Structure

27. Final Assembly of the Ship

28. 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 *

29. 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

30. Q 2. Calculation of Draft of the Ship

31. 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

32. Sample Student Worksheets

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

34. 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

35. 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

36. 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

37. 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

38. 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

39. 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

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