Preface

This project report is prepared during the summer industrial training

undertaken at HINDUSTAN SHIPYARD LTD., Visakhapatnam” as partial
fulfillment of the degree in “B.Tech Mechanical Engineering“at GMR Institute of
Technology,Rajam.

Theory of project is important,but without practical knowledge it becomes futile

particularly for the engineering students.The knowledge of engineering is incomplete
without the practical applications of the theories studied.This training provides a golden
opportunity to all the students,especially engineering students who are not familiar with
the functioning and working of project construction undertaken at “HINDUSTAN
SHIPYARD LTD.,Visakhapatnam”.

Acknowledgement
Industrial training at HSL had been a great learning experience for me. The theoretical
knowledge I gained during my four years study at GMRIT,Rajam had been
complemented effectively due to the guidance and support provided by HSL
employees.The factors that need to be taken into considerations while designing a
ship cannot be fully covered theoretically. This practical knowledge can only be
guided by handling those cases yourself or by witnessing the process under
guidance.

The shipbuilding process at HSL is a holistic one.HSL has been catering to Indian and
international clients with ease.The reason for the title of one of the largest government
shipbuilding company in india was plainly visible.

We would like to thanks the Chairman and Managing Director L.V SARAT BABU
Sir for creating such opportunities for the students pursuing education in india.

I would like to acknowledge Mr.Krishna Mohan, Manager,Training department,for

allowing me to complete my training at HSL uner knowledgeable training guides
who were happy to pass on their wisdom guided over experience.Also I am very
thankful to all those guides and department engineers whom I visited to get the details
related to my research.The process of teaching and giving practical experience
soon
CONTENTS:
 INTRODUCTION
 HULL SHOP
 PRE-FABRICATION
 ERECTION
 ENGINEERING
 CONCLUSION
 INTRODUCTION

ABOUT HINDUSTAN SHIPYARD LIMITED

History of Hindustan Shipyard Ltd:

 In 1919 the SCINDIA steam navigation company was founded by eminent two
persons i.e. Sri Walchand Hirachand and Sri Narottam Marojee.
 In 1929, they have revised again their ideas to build a ship building company at
Visakhapatnam or Calcutta.
 In 1940, they have commissioned Sir Alexandra Gibbs & partners, London
for the recommendation of the project site.
 Sir Alexandra Gibbs recommended 55 acres of site inside the Visakhapatnam
inside the harbor due its following advantages such as protection from natural
calamities like cyclone & tsunamis etc.
 The geographical location of this site is as follows ,17’’41’ North latitude,83’’17’ East
longitude.
 In 1941, on 21st June foundation stone for the company was laid by Dr.
Rajendra Prasad.
 In 1942 company has laid the keel for the first vessel on 22nd June and August.
These 2 vessels are based on the UK design.
 In 1948 on 14th march first vessel named ‘JALA USHA’ was launched by Sir
Pandit Jawaharlal Nehru & second vessel named ‘JALA PRABHA’ was
launched on 20th November by Sir SardarVallabhai Patel with remote control.
 In 1950 government has entered into the ship building industry and

formed ÉASTERN SHIPPING CORPORATION’ a joint venture with scindia.

In this government has 74% of shares & 26% of shares with scindia
and and named the company as ‘HINDUSTAN SHIPYARD LIMITED’.
 In 1958 government has alliances with ACL consultant which has suggested
switching from steam ship construction to modern diesel motor ships and old
riveting methods to modern welding methods.
 In 1948 on 14th march first vessel named ‘JALA USHA’ was launched by Sir
Pandit Jawaharlal Nehru & second vessel named ‘JALA PRABHA’ was
launched on 20th November by Sir SardarVallabhai Patel with remote control.
 In 1961 during month of July government has fully owned the 100% shares of
the company.
 In 1967 construction of dry dock has started and completed in 1971.
 In 1975 wet basin is commissioned
 In 1985 inauguration of off shore platform and modernization of yard is carried
at an estimation of 80 crores.
 In 1987 the covered building dock of capacity 70000 DWT is completed. The
first oil rig ship ‘SAGAR BUSHAN’ is handed over to owner i.e. ONGC.
 In 1988 the company is diversified into fabrication of steel structures.
 In 1992 the first of its kind a 42750 DWT vessel is floated from building dock.
 1993 the oil is flown out from the platform built by HSL in Godavari basin. On
28th June they constructed 100th vessel named ‘M.V.LOK PRATAP’ is
floated.
 In 1996 an ISO-9001 certificate is awarded by Lloyd’s registry of quality
assurance London.
 In 1999 first largest 1200 passenger cum 160 tones cargo vessel is built and
handed over to Andaman and Nicobar administration.
 In 2000 on 15th September largest ship ‘M.V.TAMILNADU’ OF 42750 DWT is
floated.
 In 2005, submarine retrofit is started for ‘INS SINDUKURI’.
 In 2007, vessels of 36000 DWT named ‘GOOD PROVIDENCE’ and ‘GOOD
PRINCE’ were handed over to the owner i.e. Good Marine
Limited(G.M.L).
 Presently bulk carrier of 53,000 DWT vessel is being erected in building dock.
 HULL SHOP
BASIC INFORMATION
The work in modern hull shop is mainly comprised of construction of blocks, from
plates, and attaching longitudinal and transverse stiffeners. This is accomplished
mainly by welding. The blocks can be the various positions for the ship, namely
superstructures, bulkheads in the midship, and fore and aft regions. After the
construction of these blocks, they are transported to the dry dock with the help of
cranes. The Crane Capacity available for Fabrication Shop-50 MT, Machine Shop-75
MT and for assembly Shop-100 MT.

This is the first department in the production process of a ship. The various jobs
involved in hull shop are
1.Preparation of steel plates and sections
2.Marking
3. Gas cutting
4. Forming

PREPARATION OF STEEL PLATES AND SECTIONS:

Good surface preparation is essential to successful painting, the primary cause of many
paint failures being the inadequacy of the initial material preparation. It is particularly
important before painting new steel that any mill scale should be removed. Mill scale
is a thin layer of iron oxide which is bluish black or reddish brown in color,
depending on how the plates come from steel mills and which forms on steel surface
during hot rolling of the plates and sections. Mill scale resists the corrosion but the
complete plate is not protected by mill scale and will not remain intact, so, mill scale
cannot be relyed upon for steel plates for protection from corrosion. The steel plates
can be thoroughly cleaned before they are painted, by chipping, scraping and brushing
which are sufficient to protect the steel plates with out corrosion. In practice the mill
scale is removed by of the following methods.
MARKING OF PLATES:

The marking of structural elements of ship can be done in three ways.

a. Marking from the mould loft data provided on the moulds and mockups (used prior
to 1972).

b. Marking from drawings.

c. Marking from templates lifted at site on ships.

Marking from the mould loft data is the simplest of all the three and was used up to
1971-72 in shipyard. The mould loft data does not include the edge preparation of the
plates but contains all the reference lines such as the buttock lines /water lines /frame
lines and length of the plate, width of the plate etc. For the edge preparation of the
structural members in the hull shop makers are to refer the drawings.
Marking of the plates from the markers drawing is used directly for producing
components which bear no relation to the lines of the hull parts such as manhole
covers, tanks, ventilation trunks, piping etc. Marking from templates lifted at site on
the ship is used mainly for ship repairs. In ship construction it was a practice earlier
to lift the bilge strake after aligning the side shell and double bottom to allow for the
inaccuracies of the alignment of the panels of the ships at building berth or building dock.

Nesting and Nesting Plan

To minimize the amount of scrap raw material produced during cutting, companies use
proprietary nesting software. The software analyses the parts (shapes) to be produced
at a particular time. Using algorithms, it then determines how to lay these parts out in
such a way as to produce the required quantities of parts, while minimizing the amount
of raw material wasted.v After nesting plan is prepared in a design department, the
drawing (or the plan) is sent to plate preparation shop where it is fed to CNC cutting
machines based on Oxy-Acetylene or Plasma. Plates of the standard sizes,
after being surface-treated, undergo nesting. It is a process in which the plate is
scanned, and by the use of algorithms, the shapes to be cut out of the plate are marked
on the plate by the computer controlled marker. This algorithm makes sure minimum
scrap metal is produced from each plate.
Such a plan is called Nesting Plan.

Plate Straightening Machine

Plate straightening machines is also referred to plate rolling machine. It is also used for
rolling steel plates to the curvature required. By adjusting the height of the top roller and
the center distance of the bottom rollers, large or small radius bends can be made.
Blockhead flanging is also possible when the machine is fitted with a flanging bar and
bottom block. Control of machine is by manuals setting and operations carried out from
a console located nearby. Arrangements are made for removing the rolled plate by
realizing the top roller and bearing. The plates on the machines are handled by jib cranes
mounted on frame of the rolled machines. Plate Straightening Machine 4.3 Shot
Blasting In this process, the plate is passed through an enclosed chamber within which,
steel shots are blasted at high velocity on the steel plate. Each shot incident on the plate
scrapes away the mill scale. It is very important to control some of the parameters of
this process, in order to ensure that the amount of material scraped is neither less nor
more than desired. The incident mass, size and velocity of the shots are pre- decided to
ensure that the mill scale is completely removed, but at the same time the scraping
should not be such that it removes steel from the surface. The plate feed speed is
controlled based Figure 6 Shot Blasting 16 on the thickness of mill scale layer. Too
much feed rate might result in insufficient
removal, and excessively less feed rate might result in removal of steel. Shot blasting
has certain disadvantages too. The incidence of high velocity shots exert stress on the
surface of the plate. If stress levels are more than the yield strength of the material of
plate, then it enters into the plastic region. A unique behavior is observed at this stage.
To explain that, let’s revisit the basics of the stress strain curve of steel. When steel is
subjected to stress levels within the proportional limit, removal of the load does not
leave any deformation in the specimen. But if the stress levels go up to the plastic
region, there is certain amount of permanent deformation even after the removal of
stress. So, when subjected to stress again, the material would actually have less
capacity to yield that before. In other words, its reserved plasticity has now reduced.
Figure 7 Stress-Strain Curve of Steel It is the above phenomenon that takes place in
case of shot blasting. This reduction of plasticity is also called cold hardening.
However, this effect can be prevented by controlling the parameters of the blasting
chamber. Once the plate is completely free of mill scale, the supervisor checks the
roughness of the plate surface. In case the plate it too rough, it would be unfavorable for
proper welding. And if too smooth, it would not provide enough surface roughness for
proper adhesion of paint
.

PLATE CUTTING
The surface treated plates are to be cut into desired shapes and sizes, in order to be
developed to the required three-dimensional shape or be used as straight plates for
other structural components. Now, it is very important for a shipyard to increase its
production, as a result of which wastage of material is prevented to the maximum
extent possible.

Manual gas Cutting:

In this type of cutting, a preheating flame heats the material and after which the ferric
oxide is blown away by a powerful blast of oxygen. The cutting by the oxy-acetylene
flame is only possible whose melting points are higher than the boiling points.
Combustible gases used for preheating are acetylene, propane, pyrogas and coal gas.
The oxygen that assists the combustion and forces the iron oxide should contain at
least 99% of oxygen to ensure a smooth cut. Care should be taken to use correct
nozzle size for the thickness to the blowpipe type. The nozzle of the cutting torch
should be cleaned regularly as it becomes clogged with metallic particles during its use.
Cast iron having a melting point of 1100-1200C and a boiling point of 1250 is difficult to
cut. If the carbon content in the cast iron is about 3.4%, it cannot be cut at all.

The accuracy of the cut is largely dependent on the uniformity with which the
workman moves the torch. Oxygen and acetylene gases are usually piped through
distinguished mains to various parts of the shipyard. Oxygen and acetylene are
supplied in cylinders where it is not possible.
CNC Plasma Cutting Machine

The CNC system is especially suited for the control of flame or plasma cutting
machines or similar application, also the punching on the plate can be done with the help
of this machine. The CNC stands for Computerized Numerical Control. Direct
programming is made easy by means of keyboard and computer screen. Subroutines,
macros, and parametric programming result in short but powerful programs.
Alternatively, remote programming is possible with the program being stored on
convectional paper (or optionally on cassettes). The third possibility is the creation of
program on a computer. The program data can be then transferred into the control via,
direct or indirect data link. In all cases, programs can be edited on the machine. The
control comprises of an operator front panel and a card rack, which are connected by
multi way cables and are intended for corporation in the machine builders control
cabinet. Each plug-in card has one or a few specific tasks, which make for easy
troubleshooting specially in connection with the status messages and the diagnostic
display on the screen. During operation, the screen shows the current absolute position
of both axes, the current active block, the active auxiliary function and text messages,
which are controlled in the program.
PLASMA
When a gas is heated to a high temperature, its molecular state Figure 8 CNC
- Plasma Machine 18 changes to the atomic, further healthy splits these atoms to the
ionic state capable of conducting electricity. The forth state of matter is called
“PLASMA” [the outer 3 being solid, liquid and gaseous].
Temperature at the core of this plasma exceeds 30000’c. The aura around the sun is an
example of plasma. Gas mixtures like argon and hydrogen used in producing gas
plasma are both expensive a hazardous so compressed air is used. A plasma jet is
obtained by passing a gas through a constricted electric are and letting it escape
through the office in the nozzle at high velocity. Plasma is used in cutting as well as
welding.

Advantages of Plasma Cutting

1) It cuts carbon steel up to 10 times faster than oxy-fuel cutting, with equal quality
more economically.

2) Plasma cutting being primarily a melting process can cut any metal.

3) Arc plasma torches give the highest temperature available from many
practicable sources. The energy seems to be unlimited in this method.
CNC Oxy-Acetylene Cutting Machine
Oxy-Acetylene cutting uses a combination of oxygen and acetylene to cut
metals. A variety of different fuels other than acetylene may be utilized, although the
most common is acetylene. Other gases utilized include natural gas, propane, hydrogen,
propylene, liquified petroleum gas (LPG), and combinations of these gases. Oxy-fuel
cutting begins by using a torch to heat a metal to its kindling temperature. This is the
lowest temperature at which the metal in question will spontaneously ignite. At this
point, a stream of oxygen is trained onto the metal, in turn burning it into a metal oxide.
This new metal oxide then flows out and away from the intact material being utilized.
Any leftover slag can be wiped or tapped away. It’s actually the heat produced by the
metal oxide and its contact with the rest of the material which actively continues the
cutting process. The torch itself only heats the metal to begin the process. Popular
alternatives to oxy-fuel cutting include plasma cutting as explained earlier and waterjet
cutting. With plasma cutting, the plasma torch blows an inert gas at high speeds and
through an electrical arc, turning some of the gas into plasma and providing the means
for cutting. With a waterjet cutter, a mixture of water and abrasive is utilized to cut the
metal. This method provides no heat or heat affected zone as one of its key benefits.
Figure 10 Plasma Cutting Schematic In both types of machines program that is nesting
plan drawing is sent via wi-fi to the machine which is interpreted by the built-in
software in the machine.
Marking on the plate is done using Zinc Oxide with the help machine.
FORMING OF PLATES:
The forming of plates can be done in
1.cold
2. hot
3. line heating

The effect of cold forming of bilge plates is out side fibers strain up to 1%elongation and can be
neglected. Cold forming of pipes, tubes from thick plates such as heavy masts out side fiber of
strake which will have more than 1% elongation is take into consideration in a highly stressed
area in a ship for cold forming conventional rolling machine and presses are used for rolling and
bending of plates. Rolling machines are provided with feature for corrugating the plates and for
flanging off the plates. The radius of flange of plate is depending on the radius of knife-edge
used. Generally the radius will be 2 ½ times the thickness of the plate. The rolling of plates
requires “edge nipping’’. The rolling machines have adequate bending rolls for rolling shell
plates etc. and they are hydraulically operated. Two lower rollers are provided and are
made to revolve in same direction, so that the plate will kept between them. A slight larger
diameter top roll may be adjusted for larger and two lower rolls have adjustable centers.
The 2000 tons rolling machine in hull shop can be used to roll the plates into semicircular
shapes up to 45mm thickness and length of plates can be around 14mm. Some of these
rolling machine are supplied with the accessories to allow them to under take heavy flange
work for corrugated bulkhead. Rolled plates are shaped in rolling machine. The fore and aft
curvatures in forward and after parts of ship are obtained by pressing rolled plates by the
presses.
Press
320-ton press used for the plates having thickness 14 mm to 16mm 250- ton press
used to give double curvature to required plates 400-ton frame bender800-ton
pressRolling and bending machine 2000 ton 500-
ton pressGilton and shearing machine: Blade angle is 5°Max. thickness to be cut:
15mm

HOT FORMING:
The curved plates or sections which cannot be cold formed by mechanical devices
may be hot formed by furnacing. The floor area in front of furnace is made of
perforated cast iron blocks. The perforated holes are used to place drift pins, dogs
for holding down, guide bars and heated members. Earlier for bending of frames
furnace is used. The furnaces are generally operated by oil or gas. The length of
frame is taken on a neutral axis with bending allowance and heated in furnace. The hot
frame is bent with aid of hydraulic squeezers from a pin fitted to one of the holes of
bending floor. During this the frame is hammered to secure a flat shape of the web
and to prevent lengthwise bulging, when the frames are bent in hot. Then it changes to
actual shape when it cools down. The frame is checked with wooden template in
cold. The bending of frames in hot is superseded by cold frame bending machine,
whichtakes less time, and pair of frames, port and starboard side, can be done
simultaneously.
Types of Plates being processed by PP Shop
Plate preparation shop mainly handles three grades of plates. These are DMR, IS and
Aluminum plates. Aluminum plates are used lighter construction like superstructure of
ship while mild steel plates are used in shell plating and framing of ship. Every kind of
plate differs in the tensile strength. Yield strength - The stress a material can withstand
without permanent deformation. This is not a sharply defined point. Yield strength is the
stress which will cause a permanent deformation of 0.2% of the original dimension.
Ultimate strength - The maximum stress a material can withstand. Breaking strength -
The stress coordinate on the stress-strain curve at the point of rupture.
WELDING

Welding is a process of joining two similar or dissimilar metals by heating them to a

suitable temperature,with or without the applications of pressure and with or without
use filler metal.

Different types of welding used in plumbing department are: -

1. Tungsten inert gas welding(TIG)

2. Metal inert gas welding(MIG)
3. Submerged arc welding
4. Shielded metal arc welding(SMAW)

Tungsten Inert Gas Welding (TIG)

Tungsten Inert Gas (TIG) or Gas Tungsten Arc (GTA) welding is the arc welding
process in which arc is generated between non consumable tungsten electrode and
work piece. The tungsten electrode and the weld pool are shielded by an inert gas
normally argon and helium

Principle:
TIG welding works on same principle of arc welding. In a TIG welding process, a high
intense arc is produced between tungsten electrode and work piece. In this welding
mostly work piece is connected to the positive terminal and electrode is connected to
negative terminal. This arc produces heat energy which is further used to join metal
plate by fusion welding. A shielding gas is also used which protect the weld surface
from oxidization.
Power Source:
The first unit of equipment’s is power source. A high current power source needed
for TIG welding. It uses both AC and DC power source. Mostly DC current is
used for stainless steel, Mild Steel, Copper, Titanium, Nickel alloy, etc. and AC current
is used for aluminum, aluminum alloy and magnesium. Power source consist a
transformer, a rectifier and electronic controls. Mostly 10 – 35 V is required at 5-300
A current for proper arc generation.

TIG Torch:
It is a most important part of TIG welding. This torch has three main parts, tungsten
electrode, collets and nozzle. This torch is either water cooled or air cooled. In this
torch, collet is used to hold the tungsten electrode. These are available in varying
diameter according to diameter of tungsten electrode. The nozzle allows the arc and
shielded gases to flow into welding zone. The nozzle cross section is small which
gives high intense arc. There are passes of shielded gases at nozzle. The nozzle of TIG
needs to replace in regular interval because it wear out due to presence of intense spark.

Shielding Gas Supply System:

Normally argon or other inert gases are used as shielded gas. The main purpose
of shielded gas to protects the weld from oxidization. Shielded gas does not allow
coming oxygen or other air into welded zone. The selection of inert gas is depends
upon metal to be welded. There is a system which regulates the flow of shielded gas
into welded zone.

Filler Material:
Mostly for welding thin sheets no filler material is used. But for thick weld, filler
material is used. Filler material is used in form of rods which are directly feed into
weld zone manually.
 Working:

 First, a low voltage high current supply supplied by the power source to the welding
electrode or tungsten electrode. Mostly, the electrode is connected to the negative
terminal of power source and work piece to positive terminal.
 This current supplied form a spark between tungsten electrode and work piece.
Tungsten is a non –consumable electrode, which give a highly intense arc. This arc
produced heat which melts the base metals to form welding joint.
 The shielded gases like argon, helium is supplied through pressure valve and
regulating valve to the welding torch. These gases form a shield which does not allow
any oxygen and other reactive gases into the weld zone. These gases also create
plasma which increases heat capacity of electric arc thus increases welding ability.
For welding thin material no filler metal is required but for making thick joint some filler
material used in form of rods which fed manually by the welder into welding zone.

Application:
 Mostly used to weld aluminum and aluminum alloys.
 It is used to weld stainless steel, carbon base alloy, copper base alloy, nickel base alloy
etc.
 It is used to welding dissimilar metals.
 It is mostly used in aerospace industries.

Advantages and Disadvantages:

Advantages:
 TIG provides stronger joint compare to shield arc welding.
 The joint is more corrosion resistant and ductile.
 Wide verity of joint design can form.
 It doesn’t required flux.
 It can be easily automated.
 This welding is well suited for thin sheets.
 It provides good surface finish because negligible metal splatter or weld sparks that
damage the surface.
 Flawless joint can be created due to non-consumable electrode.
 More control on welding parameter compare to other welding.
 Both AC and DC current can be used as power supply.

Disadvantages:
 Metal thickness to be weld is limited about 5 mm.
 It required high skill labor.
 Initial or setup cost is high compare to arc welding.
 It is a slow welding process.
Shielded Metal Arc Welding (SMAW)
This method is also known as Manual Metal Arc Welding or Stick Welding. An arc
welding process in which coalescence of metals is produced by heat. The heat comes
from an electric arc that is maintained between the tip of a covered electrode and the
surface of the base metal in the joint being welded. In the SMAW process, welding is
done by setting up an electrical circuit using a welding machine to produce the
electricity, a welding cable with an electrode holder to hold the electrode and a
ground cable
with a clamp to fasten to the work-piece to complete the circuit. The weld is made by
touching the electrode to the work-piece closing the electrical circuit and causing the
electrode to melt and form the weld. It uses a metallic consumable electrode of a proper
composition for generating arc between itself and the parent work piece. The
molten electrode metal fills the weld gap and joins the work pieces.
This is the most popular welding process capable to produce a great variety of welds.
The electrodes are coated with a shielding flux of a suitable composition. The
flux melts together with the electrode metallic core, forming a gas and a slag,
shielding the arc and the weld pool. The flux cleans the metal surface, supplies some
alloying elements to the weld, protects the molten metal from oxidation and stabilizes
the arc.
the slag is after solidification
The consumable electrode provides:
1) Gas protection to shield the arc and prevent atmospheric contamination of the molten
filler metal.
2) Adding elements to change the mechanical properties and prevents excessive grain
growth in the welded
metal.
3) Enhance the mechanical properties and surface cleanliness of the weld metal.
This welding method is used for maintenance and repair industries, naval industry,
pipelines, offshore
platforms, construction of steel structures, weld carbon steel, low and high alloy steel,
stainless steels, cast
iron, aluminum, nickel and cooper alloys.
Advantages of Shielded Metal Arc Welding (SMAW):
 Simple, portable and inexpensive equipment;
 Wide variety of metals, welding positions and electrodes are applicable;
 Suitable for outdoor applications.

Disadvantages of Shielded Metal Arc Welding (SMAW):

 The process is discontinuous due to limited length of the electrodes;
 Weld may contain slag inclusions;
 Fumes make difficult the process control.
Metal inert gas welding(MIG)
Metal inert gas welding by definition, is an arc welding process which produces the
coalescence of metals by heating them with an arc between a continuously fed filler
metal electrode and the work. The process uses shielding from an externally
supplied gas to protect the molten weld pool. Gas metal arc welding (GMAW),
sometimes referred to by its subtypes metal inert gas (MIG) welding or metal
active gas (MAG) welding, is a semi- automatic or automatic arc welding process in
which a continuous and consumable wire electrode and a shielding gas are fed through
a welding gun.

Principle:
Mig works on same principle of TIG or arc welding. It works on basic principle of heat
generation due to electric arc. This heat is further used to melt consumable
electrode and base plates metal which solidify together and makes a strong joint. The
shielded gases are also supplied through nozzle which protect the weld zone from
other reactive gases. This gives good surface finish and a stronger joint.
Power Source:
In this type of welding process, a DC power supply is used with reverse polarity.
Reverse polarity means the electrode or in case of MIG welding electrode wire is
connected positive terminal and work piece to negetive terminal. It is due to principle
of electric circuit which state that 70% of heat is always on positive side. So reverse
polarity ensures that the maximum amount of heat liberate at tool side which melt the
filler metal in proper way. Straight polarity can cause unstable arc that result into
large spatter. The power source consist a power supply, a transformer, a rectifier
which change AC into DC and some electronic controls which control the current
supply according to weld requirement.

Wire Feeder System:

We know that MIG welding needs continuous consumable electrode supply for welding
two plates. This consumable electrode used in form of wire. These wire is
continuously supplied by wire feed mechanism or system. It controls the speed of
the wire and also pushes the wire form welding torch to welding area. These are
available in different shapes and sizes. It consist a wire pool holder, a driving motor, a
set of driving rollers and wire feed controls. The wire feed speed is directly control
the current supply through power supply. If the wire feeding speed is high, it required
more current in welding zone to produce proper heat for melting of it.

Welding Torch:
This torch is slightly different as used in TIG welding. In this torch there is a
mechanism which hold the wire and supply it continuously with the help of wire feed.
The front end of the torch is fitted with a nozzle. The nozzle is used to supply inert
gases. These gases form a shielding area around the weld zone and protect it from
oxidization. The welding torch is air cooled or water cooled according to the
requirement. For high current supplied, the torch is water cooled and for low supply it
is air cooled.

Shielding Gases:
The primary function of shielding gases is to protect weld area from other reactive
gases like oxygen etc. which can affect the strength of welding joint. These shielding
gases are also form plasma which helps in welding. The choice of gas is depend
on the welding material. Mostly argon, helium and other inert gases are used as
shielding gases.
 Regulators:
As the name implies, they are used to regulate the flow of inert gases from the
cylinder. The inert gases are filled into cylinder at high pressure. These gases cannot
be used at this pressure so a regulator is used between the gases supply which lower
down the gases pressure according to welding requirements.

Working:
 First, a high voltage current is change into DC current supply with high current at
low voltage. This current passes though welding electrode.
 A consumable wire is used as electrode. The electrode is connected to the negative
terminal and work piece from positive terminal.
 A fine intense arc will generate between electrode and work piece due to power supply.
This arc used to produce heat which melts the electrode and the base metal. Mostly
electrode is made by the base metal.
 This arc is well shielded by shielding gases. These gases protect the weld form
other reactive gases which can damage the strength of welding joint.
 This electrode travels continuously on welding area for making proper weld joint. The
angle of the direction of travel should be kept between 10-15 degree. For fillet joints the
angle should be 45 degree.

Applications:
 MIG is best suited for fabrication of sheet metal.
 Generally all available metals can be weld through this process.
 It can be used for deep groove welding.
 Advantages and Disadvantages:
Advantages:
 It provide higher deposition rate.
 It is faster comparing to arc welding because it supply filler material continuously.
 It produce clean weld with better quality.
 There is no slag formation.
 Minimize weld defects.
 This welding produces very little slag.
 It can be used to make deep groove weld.
 It can be easily automated.

Disadvantages:
 It cannot be used for welding in difficult to reach portions.
 Higher initial or setup cost.
 It cannot be used for outdoor work because wind can cause damage of gas shield.
 It required high skilled labor.
 ENGINEERING
Machines used in engineering department
1.lathe machine

2.Drilling machine

LATHE MACHINE:
A lathe is a tool that rotates the work piece about an axis of rotation to perform
various operations such as cutting, sanding, knurling, drilling, deformation, facing,
and turning, with tools that are applied to the work piece to create an object with
symmetry about that axis.

Lathes are used in woodturning, metalworking, metal spinning, thermal spraying,

parts reclamation, and glass-working. Lathes can be used to shape pottery, the best-
known design being the potter's wheel. Most suitably equipped metalworking
lathes can also be used to produce most solids of revolution, plane surfaces and screw
threads or helices. Ornamental lathes can produce three-dimensional solids of
incredible complexity. The workpiece is usually held in place by either one or two
centers, at least one of which can typically be moved horizontally to accommodate
varying workpiece lengths. Other work-holding methods include clamping the work
about the axis of rotation using a chuck or collet, or to a faceplate, using clamps or
dogs
 Types of chucks
1. Four jaws independent chuck
2. Three jaws universal chuck
3. Combination chuck
4. Magnetic Chuck
5. Collet chuck
6. Air or hydraulic operated chuck
7. Drill Chuck

Four-Jaw Independent Chuck

Here all the four jaws are opened independently. Here four screws are used in place of
scroll disk, Hence it is called as four jaw independent chuck. Each jaw made of tough
steel has three inner and one outer gripping surface. The outer gripping surface is used
for holding larger sizes of the workpiece by reversing the jaw. Concentric circles
inscribed on the face of the chuck facilitate quick centering of the workpiece. This type
of chuck is particularly used in the setting up of heavy and irregular shaped articles.
The diameter of the body specifies the size of the chuck.
Universal or Three Jaw Chuck

A three-jaw chuck is shown in the figure. This is the most commonly used types of
chuck in the lathe machine. The three jaws are generally made of high-quality steel
and are arrogated at an angle of 120° to each other.

During the operation, the jaw teeth are made to mesh with scrawl spiral teeth (Bevel
teeth). The meshing causes a moment of all three jaws either towards or away from
the chuck center, depending upon the direction of rotation of the bevel pinion. The
pinion is operated by square end key called “chuck key”.

The chuck suitable for holding round, or hexagonal, and other similar shaped work
pieces. In three jaw chuck, the job is centered automatically and quickly. But it has the
less gripping capacity as only three jaws are used and centering accuracy is soon lost
due to wear.

Difference between Three jaws and Four-jaw chucks

1. The jaws on the three jaw chuck move all at the equal time. On four jaws chuck,
jaws move separately.

The depth of cut is relatively less in three jaw chuck. In four jaw chuck, the higher depth of cut can
be produced.

2. The three Jaw chuck has one hole for the chuck key to tighten or loosen the jaws’ grip.
Four-Jaw chuck has four holes for the chuck key to controlling each jaw at one time.
 3. In three jaw chuck, the work pieces cannot be set for eccentric turning. But in four
jaw chuck, the work pieces can be set for eccentric turning.

4. In three jaw chuck centering accuracy is lower. But in four jaw chuck
centering accuracy better than a three jaw chuck.

5. Three jaw chuck has less gripping power than four jaw chuck.

6. In three jaw chuck, heavier work pieces cannot be turned. In four chuck heavier
work pieces can be turned.

Cutting tools used in lathe machines

1. Turning tool.
2. Chamfering tool.
3. Thread cutting tool.
4. Internal thread cutting tool.
5. Facing tool.
6. Grooving tool.
7. Forming tool.
8. Boring tool.
9. Parting-off tool.
10. Counter boring tool

Turning Tool

There are mainly two classes of turning tool:

1. Rough turning tool.

2. Finish turning tool.

Rough Turning tool

The main function of a rough turning tool is to remove the maximum amount of metal in a
minimum time that the tool, work, and the machine will permit. The cutting angle is so
ground that it can withstand maximum cutting pressure.

Turning tool is used to remove the very small amount of metal. A tool angle is so ground that
it can produce a very smooth and accurate surface.

Facing tool

A facing tool removes metal by its side cutting edges. So no top rake in necessary in a facing
tool. The figure shows H.S.S. facing tool intended for finishing opration.

The tool has 2° side cutting edge angle and 34° end cutting edge angle can be accommodated
in the space between the end of the work and 60° dead centre leaving a clearance of 2° on both
sides.

Chamfering Tool

Straight turning tools are also used as a chamfering tool when the cutting edges are set at an
angle of the chamfer.
 Where a large number of chamfer works are to be performed a special chamfering tool with its
side cutting edge angle ground to the angle of the chamfer is used.

Thread Cutting Tool

External Thread Cutting Tool

Metric, B.S.W or American “V” thread are formed by a single point thread cutting tool. Its
cutting edges sharpened to the shape and size of the thread to be cut.

The shape of the tool is determined by the included angle at the nose of the tool which should
correspond to the angle of the thread. It may be 60° for metric threads or 55° for B.S.W threads. It
included angle at the nose of the tool which should correspond to the angle of the thread. It may
be 60° for metric threads or 55°
for B.S.W threads. The size or cross-section of the cutting edges of the tool depends upon the
pitch of the thread. Below figure illustrates an H.S.S. thread cutting tool.

Boring Tool

A boring tool is similar to a left-hand external turning tool so far its cutting edge is concerned.
The tool may be a bit type inserted in a boring bar or holder, or forged type having a tool shank.
The figure shows an H.S.S. tool bit inserted in a boring bar. A boring bar is made of mild
steel with slots or holes cut into it to accommodate the tool bit which is locked by an
Allen screw. The amount of projection of the cutting edge of the tool from the center of
the bar
DRILLING MACHINE

This article is all about drilling machine, Parts of drilling machine, Types of drilling machine,
Tools and operations of the drilling machine .The drilling machine is defined as a machine which
is used to make a circular hole, a tool used to drill the holes of different size and other related
operations using a drill bit. The drilling machine is one of the most important machines in a
workshop. As regards its importance it is second only to the lathe machines. Holes were drilled
by the Egyptians in 1200 B.C. about 3000 years ago by bow drills. The bow drill is the mother of
present-day metal cutting drilling machine.

In drilling, machine holes may be drilled quickly and at a low cost. The hole is generated by the
rotating edge of a cutting tool known as the drill which applies a large force on the work
clamped on the table. As the machine use vertical pressure to originate a hole it is loosely
called a “drill press”
 Main Parts of Drilling Machine
The schematic diagram of the drilling machine is shown in the figure. The main parts
of drilling machines are

1. Base
2. Column
3. Table
4. Radial Arm
5. Drill head
6. Spindle speed and Feed mechanism.

Base

The base is that part of the machine on which the verticle column is mounted. The base is
made of casting. A base supports the column and worktable with other attachments.
The top of the base is round column section type upright drilling machined and has T-
slots on it so that large workpieces and work holding devices may be set up and bolted
to it. The base of the machine may be mounted on a bench or on the floor.

Column

The Column is the verticle member of the machine which supports the table and the
head containing all the driving mechanism. It is a cylindrical casting mounted vertically
at one end of the base and supports the radial arm, which slides up and down. An
electric motor at the top of column helps in the vertical adjustment of the arm by rotating
a screw passing through a nut attached to the arm.

Table
The table is mounted on the column and is provided with T-slots for clamping the work directly
on its face. A table is round or rectangular in shape. Radial Arm

It is mounted on the column and extends horizontally over the base. It has guide
ways on which drill head slides. The radial arm moves around the column.
 Drill head

It is mounted on the redial arm and drives the drill spindle. In some of the drill machines,
the drill head may be adjusted up or down for accommodating different heights of the
work in addition to the table adjustment. It encloses all the mechanism for driving the
drill at the different speed and feeds. In lighter machines, the driving motor is mounted at
the rear end of the head counterbalancing the weight of the drill spindle.

Spindle speed and feed mechanism

The motor at the top of the drill head drives the horizontal spindle and the motion is
transmitted to the drill head through a group of bevel gears. With another group of gears,
different spindle speed and feed are obtained.The main advantage of this type of drilling
machine is that holes of variable sizes at any point and at any angles can be drilled on the
large-sized workpiece without moving the workpiece.

 Multiple speed of the spindle may be obtained as follows:

 By step cone pulley drive
 By step cone pulley drive with one or more back gears
 gearing.

Types of Drilling Machine

1. There are 8 different types of the drilling machine. Portable drilling machine
2. sensitive drilling machine
1. Bench mounting sensitive drilling machine
2. Floor column upright drilling machine
3. Upright drilling machine
1. Round column upright drilling machine
2. Box column upright drilling machine
4. Radial drilling machine
1. Plain drilling machine
2. Universal drilling machine
3. semi-universal drilling machine
5. gang drilling machine
6. Multiple spindle machine
7. Automatic drilling machine
8. Deep hole drilling machine
1. Vertical deep hole drilling machine
2. Horizontal deep hole drilling machine

Portable Drilling Machine

This types of drilling machines are commonly used in all the workshop. Used to drill
small sized holes. It is operated by holding in a hand. The workpiece where the hole is to
be drilled is held in a vice.

Sensitive Drilling Machine

This types of drilling machine are used to drill small holes at high speeds in lighter jobs
or work pieces. The machine may be mounted on the bench or floor & the drilling work
is started with the drill fed into the workpiece by purely hand control Hand feed permits
the operator to sense the progress of the drill into the workpiece, so that if there is any
drill worn out or jams it may be released immediately to prevent the drill bit from
breaking Since the operator senses the cutting action at any instant it is called as the
sensitive drilling machine. These machines are capable of drilling small holes of
diameter as small as 0.35 mm to 15 mm. These machines run at the higher speed as
high as 2000 rpm.
Radial Drilling Machine

This type of drilling machines is designed for medium to large and heavy work pieces.
The machine is having a vertical column mounted on the large base. The column is
supported by radial arm which can be raised or lowered to accommodate work pieces
of different heights. The arm can swing horizontally to any position around the column
over the work. The drill head mechanism for rotating the spindle and feeding the drill is
mounted on the radial arm can be moved horizontally to and fro from the column then it
is clamped at any desired position.

These three movements in a radial-drilling machine when combined together permit the
drill to be located at any desired position. When two or more holes are to be drilled in a
work piece, the position of the arm and drill head is altered so that drill spindle can be
moved from one hole to another without altering the setting of the work. If the work
piece is too big it can be clamped directly on the base.

Types of Radial Drilling Machine

The radial drilling machines are of three types, these are:

(a) Plain Radial Drilling Machine. In this type the arm is having vertical and horizontal
movement of the drill head along the arm and circular movement of the arm in
horizontal plane about the vertical column.

(b) Semi Universal Radial Drilling Machine. In this type of radial drilling machine, in
addition to the above three movements the drill head can be swung about the
horizontal axis perpendicular to the arm. This permits to drill a hole at an angle to the
horizontal plane.

(c) Universal Radial Drilling Machine. In this drilling machine in addition to above four
movements, the arm holding the drill head can be rotated on the horizontal axis. All
these movements in radial drilling machine enable to drill on a work piece at any

desired place at any angle.

 PRE –FABRICATION

Introduction to Pre-Fabrication

‘Prefabrication is a manufacturing process, generally taking place at a specialized facility, in which

various materials are joined to form a component part of the final installation’.

Prefabrication is defined as “1. To fabricate or construct beforehand. 2. To

manufacture in standardized parts or section ready for rapid assembly and erection.”

Instead of starting in the dry dock and building the ship from the ground up, sub-
assemblies are fabricated away from the final assembly site. The process of
constructing a ship relies heavily on prefabrication to speed up the fabrication process.
The ship is considered in 4 main stages “part, block, mega block, ship’, each of these
stages has a series of distinct tasks that are performed and the breakdown of the ship
into sub-assemblies enables many operations to run simultaneously. The dry dock
can be considered the site, but only a fraction of the total work occurs within the
dry dock, allowing many operations to be done simultaneously, which speeds up the
process.

To join these plates as per the grooves and edge preparation which are out at hull
shop from previous stage the welding will be carried out in the form of grooves as
per the required welding process (SAW, MIG, and MAG) and procedures by
qualified welders with suitable selected electrodes and welding equipment.

Pre fabrication shops are existing adjacent hull shop at the east side which consists
of four areas A1, A2, A3 and A4 in two huge buildings consisting all required
facilities and infrastructure arrangement to construct and fabricate blocks up to 150
tones in weight.

All the welders of the pre fabrication as well as other departments of shipyard are
well qualified in all positions of welding as per the classification society rules and
as stipulated in international welding practice and rules. It is observed that the quality
control department plays their role during the above process of welding and
inspect at every stage to correct them in time.

Once the welding inspection is completed for a block it will be programmed

for third party classification surveyors’ inspection along the with the owners’
representative inspection by Quality Control department. If any
defect/problem is identified during their survey, the same will be attended and
rectified. Finally QC will make arrangements for final inspection to clear the product at
fabrication level to send them to next stage of work at Hull berth and erection
departments.

During the inspection stages of above fit-ups and welding if any unsolved problem is
identified the same will be recorded in NCRR (Non Conformity Report and
Reservation) format number QA – R – 01 and circulate to all the concerned design
office and classification societies to resolve them further rectification.

All the butt joints of the block will be radio graphed randomly before the blocks are sent
to Hull berth. Radiographs will be shown to classification society surveyors and owner’s
representatives for their approvals.

After of all works including Q.C inspections survey by classification societies and
owner’s representatives, the blocks will be sent for the surface cleaning by mechanical
cleaning and sand blasting methods and painted with coats of as per the painting
scheme before they are handed over to next production department i.e. Hull
berth/Erection department.

PROCESS CHART

1. Drawn from hull shop

2. Laying of combining plates
3. Tacking
4. Inspection
5. Welding
6. Inspection
7. Storage
8. Transportation
 WELDING
Welding is a process of joining two similar or dissimilar metals by heating them to a
suitable temperature ,with or without the applications of pressure and with or without
use filler metal.

Fusion welding:
In the fusion welding or no pressure welding, the material at the joint is heated to a
molten state and allowed to solidify. This includes gas welding, arc welding etc.

Cold welding:
In this welding the joints are produced without the application of heat, but by applying
pressure which results in inter-surface molecular fusion of the parts to be joined. This
process is mainly used for welding nonferrous sheet metal, particularly aluminum and
its alloys.
Arc welding
Principle of Arc Welding

Arc welding is a welding process that is used to join metal to metal by

using electricity to create enough heat to melt metal, and the melted metals when cool
result in a binding of the metals. It is a type of welding that uses
a welding power supply to create an electric arc between a metal stick ("electrode")
and the base material to melt the metals at the point of contact. Arc welders can use
either direct (DC) or alternating (AC) current, and consumable or non-consumable
electrodes.
The welding area is usually protected by some type of shielding gas, vapor, or slag.
Arc welding processes may be manual, semi-automatic, or fully automated. First
developed in the late part of the 19th century, arc welding became commercially
important in shipbuilding during the Second World War. Today it remains an
important process for the fabrication of steel structures and vehicles.
Meaning of Electric Arc Welding:

The arc welding is a fusion welding process in which the heat required to fuse the
metal is obtained from an electric arc between the base metal and an electrode.

The electric arc is produced when two conductors are touches together and then
separated by a small gap of 2 to 4 mm, such that the current continues to flow, through
the air. The temperature produced by the electric arc is about 4000°C to 6000°C.

metal

electrode is used which supplies the filler metal. The electrode may be flux coated or
bare. In case of bare electrode, extra flux material is supplied. Both direct current (D.C.)
and alternating current (A.C.) are used for arc welding.

The alternating current for arc is obtained from a step down transformer. The
transformer receives current from the main supply at 220 to 440 volts and step down
to required voltage i.e., 80 to 100 volts. The direct current for arc is usually obtained from
a generator driven by either an electric motor, or patrol or diesel engine.

An open circuit voltage (for striking of arc) in case of D.C. welding is 60 to 80 volts
while a closed circuit voltage (for maintaining the arc) is 15 to 25 volts.

Procedure of Electric Arc Welding:

First of all, metal pieces to be weld are thoroughly cleaned to remove the dust, dirt,
grease, oil, etc. Then the work piece should be firmly held in suitable fixtures. Insert
a suitable electrode in the electrode holder at an angle of 60 to 80° with the work
piece.
Select the proper current and polarity. The spot are marked by the arc at the places
where welding is to be done. The welding is done by making contact of the electrode
with the work and then separating the electrode to a proper distance to produce an arc.
When the arc is obtained, intense heat so produced, melts the work below the arc, and
forming a molten metal pool. A small depression is formed in the work and the molten
metal is deposited around the edge of this depression. It is called arc crator. The slag is
brushed off easily after the joint has cooled.
After welding is over, the electrode holder should be taken out quickly to break the arc
and the supply of current is switched off.
 Electric Current for Welding:

Both D.C. (direct current) and A.C. (alternating current) are used to produce an arc in
electric arc welding. Both have their own advantages and applications.

The D.C. welding machine obtains their power from an A.C. motor or diesel/petrol
generator or from a solid state rectifier.

The capacities of D.C. machine are: Current:

Up to 600 amperes.

Open Circuit Voltage:

50 to 90 volts, (to produce arc).

Closed Circuit Voltage:

18 to 25 volts, (to maintain arc).

The A.C. welding machine has a step down transformer which receives current from main A.C.
supply. This transformer step down the voltage from 220 V-440V to normal open circuit
voltage of 80 to 100 volts. range available up to 400 amperes in the steps of 50 ampere.

capacities of A.C. welding machine are:

Up to 400 ampere in steps of 50 ampere.

Input Voltage:
220V- 440V

Actual Required Voltage:

80 – 100 volts.

Frequency:
50/60 HZ.
Significance of Polarity:
When D.C. current is used for welding, the following two types of polarity are available:
(i) Straight or positive polarity.

(ii) Reverse or negative polarity.

When the work is made positive and electrode as negative then polarity is called
straight or positive polarity, as shown in Fig. 7.16 (a).

(a) Straight polarity.

(b) Reverse polarity

 .

Equipments Required for Electric Arc Welding:

The various equipments required for electric arc welding are:
1. Welding Machine:
The welding machine used can be A.C. or D.C. welding machine. The A.C. welding
machine has a step-down transformer to reduce the input voltage of 220- 440V to 80-
100V. The D.C. welding machine consists of an A.C. motor- generator set or
diesel/petrol engine-generator set or a transformer- rectifier welding set.

A.C. machine usually works with 50 hertz or 60 hertz power supply. The efficiency of
A.C. welding transformer varies from 80% to 85%. The energy consumed per Kg. of
deposited metal is 3 to 4 kWh for A.C. welding while 6 to 10 kWh for D.C. welding. A.C.
welding machine usually work with low power factor of 0.3 to 0.4, while motor in D.C.
welding has a power factor of 0.6 to 0.7. The following table 7.9 shows the voltage and
current used for welding machine.

Electrode Holders:
The function of electrode holder is to hold the electrode at desired angle. These are
available in different sizes, according to the ampere rating from 50 to 500 amperes.

Cables or Leads:
The function of cables or leads is to carry the current from machine to the work.
These are flexible and made of copper or aluminum. The cables are made of 900 to
2000 very fine wires twisted together so as to provide flexibility and greater strength.

The wires are insulated by a rubber covering, a reinforced fibre covering and further
with a heavy rubber coating.

Cable Connectors and Lugs:

The functions of cable connectors are to make a connection between machine
switches and welding electrode holder. Mechanical type connectors are used; as they
can he assembled and removed very easily. Connectors are designed according to the
current capacity of the cables used.

Chipping Hammer:
The function of chipping hammer is to remove the slag after the weld metal has
solidified. It has chisel shape and is pointed at one end.
Wire Brush, Power Wire Wheel:
The function of wire brush is to remove the slag particles after chipping by
chipping hammer. Sometimes, if available a power wire wheel is used in place
manual wire brush.

Protective Clothing:
The functions of protective clothings used are to protect the hands and clothes of the
welder from the heat, spark, ultraviolet and infrared rays. Protective clothing used are
leather apron, cap, leather hand gloves, leather sleeves, etc. The high ankle leather shoes
must be wear by the welder.

Screen or Face Shield:

The function of screen and face shield is to protect the eyes and face of the welder from
the harmful ultraviolet and infrared radiations produced during welding. The shielding
may be achieved from head helmet or hand helmet.
Edge Preparation of a Joint:
The efficiency and quality of welded joint also depends upon the correct preparation
of the edges of the plates to be welded. It is necessary to remove all scales, rust,
grease, paint, etc. from the surface before welding.

The cleaning of the surface should be carried out mechanically by wire brush or power
wire wheel, and then chemically by carbon tetrachloride. Proper shape to the edges of
the plate should be given to produce a proper joint.
square Butt:
It is used when the thickness of the plate is from 3 to 5 mm. Both the edges to be weld
should be spaced about 2 to 3mm apart as shown in Fig. 7.17 (a).

Single- V-Butt:
It is used when the thickness of the plates is from 8 to 16 mm. Both the edges are
bevelled to form an angle of about 70° to 90°, as shown if Fig. 7.17 (b).

Double-V-Butt:
It is used when the thickness of the plates is more than 16mm and where welding
can be performed on both sides of the plate. Both the edges are bevelled to form a
double-V, as shown in Fig. 7.17 (c).

Single and Double-U Butt:

It is used when the thickness of the plate is more than 20mm. The edge preparation is
difficult but the joints are more satisfactory. It requires less filler metal, as shown in
Fig. 7.17 (d) and (e).

Arc Welding Electrodes:

Arc welding electrodes can be classified into two broad categories:
1. Non-Consumable electrodes.

2. Consumable electrodes.
 There are 4 basic steps to perform an arc welding:

1. Strike the arc. This is the process of creating an electric arc between the electrode
and the workpiece.
2. Moving the arc to create a bead. The bead is the metal from the melting electrode
flowing together with molten metal from the base metal to fill the space between
the pieces being joined by welding.
3. Shape the weld bead. This is done by weaving the arc back and forth across the
weld path either in a zig zag or figure 8 motion so the metal spreads to the width
that you want your finished weld bead to be.
4. Chip and brush the weld between passes. Each time you complete a pass, or trip
from one end to the other of your weld, you need to remove the slag, or the melted
electrode flux material, from the surface of the weld bead so only clean molten metal
will be filling the weld on the subsequent passes
Co2 Welding

Co2 Welding is basically MIG/GMAW Welding. It is a fusion welding process where

joining takes place by an electric arc shielded by co2 gas and electrode is
consumable. From Wikipedia, the free encyclopedia Gas metal arc welding Gas metal
arc welding (GMAW) , sometimes referred to by its sub types metal inert gas (MIG)
welding or metal active gas (MAG) welding , is a semi-automatic or automatic arc
welding process in which a continuous and consumable wire electrode and a shielding
gas are fed through a welding gun. A constant voltage, direct current power source is
most commonly used with GMAW, but constant current systems, as well as
alternating current, can be used. There are four primary methods of metal transfer in
GMAW, called globular, short-circuiting, spray, and pulsed-spray, each of which has
distinct properties and corresponding advantages and limitations .Originally developed
for welding aluminum and other non-ferrous materials in the 1940s, GMAW was
soon applied to steels because it allowed for lower welding time compared to other
welding processes. The cost of inert gas limited its use in steels until several years
later, when the use of semi-inert gases such as carbon dioxide became common
.Further developments during the 1950s and 1960s gave the process more versatility
and as a result, it became a highly used industrial process. Today, GMAW is the most
common industrial welding process, preferred for its versatility, speed and the relative
ease of adapting the process to robotic automation.
The auto mobile industry in particular uses GMAW welding almost exclusively. In CO2
arc welding, the welding wire wound in coil is fed into the welding torch by the feeding
motor automatically. The welding wire that is electrified through the contact tip
becomes the electrode to strike an arc between itself and the base metal. The arc heat
melts the wire and the base metal to join two pieces of base metal. In this case, in order
that the weld metal will not be affected by oxygen and nitrogen in the atmosphere, CO2
gas is supplied from the nozzle of the welding torch to shield the weld pool.
 Sub-Merged Arc Welding

Submerged arc welding is an arc welding process in which heat is generated by an arc
which is produced between bare consumable electrode wire and the workpiece. The
arc and the weld zone are completely covered under a blanket of granular, fusible flux
which melts and provides protection to the weld pool from the atmospheric gases.

The molten flux surrounds the arc thus protecting arc from the atmospheric gases. The
molten flux flows down continuously and fresh flux melts around the arc. The molten
flux reacts with the molten metal forming slag and improves its properties and later
floats on the molten/solidifying metal to protect it from atmospheric gas contamination
and retards cooling rate.

This is a well established and extremely versatile method of welding. Submerged-arc

welding (SAW) involves the formation of an arc between a continuously fed
electrode and the workpiece. A blanket of powdered flux, which generates a protective
gas shield and a slag (and may also be used to add alloying elements to the weld pool),
protects the weld zone. A shielding gas is not required. The arc is submerged beneath
the flux blanket and is not normally visible during welding.

The electrode may be a solid or cored wire or a strip made from sheet or sintered
material. The flux may be made by either fusing constituents to form a glassy slag (which is
then crushed to form a powder) or by agglomerating the constituents using a binder and a
corning process. The chemical nature and size distribution of the flux assists arc stability
and determines the mechanical properties of the weld metal and the shape of the bead.
SAW is usually operated as a mechanised process. Welding current (typically
between 300 and 1000 amperes), arc voltage and travel speed all affect bead shape,
depth of penetration and chemical composition of the deposited weld metal. Since the
operator cannot observe the weld pool, great reliance must be placed on parameter
setting and positioning of the filler wire.

Although SAW is normally operated with a single wire using either AC or DC current,
there are a number of variants including the use of two or more wires, adding chopped
wire to the joint prior to welding, and the use of metal powder additions. Additional
productivity may be gained by feeding a small diameter non-conducting wire into
leading edge of the weld pool. This can increase deposition rates by up to 20%. These
variants are used in specific situations to improve productivity through increasing
deposition rates and/or travel speed. Replacing the wire with a 0.5mm thick strip,
typically 60mm wide, enables the process to be used for surfacing components.

SAW is ideally suited to the longitudinal and circumferential butt welds required for
the manufacture of line pipe and pressure vessels. Welding is normally carried out in
the flat (BS EN ISO 6947 PA) position because of the high fluidity of the weld pool
and molten slag and the need to maintain a flux layer. Fillet joints may also be
produced, welding in either the flat or horizontal-vertical (PB) positions.
Gas cutting
Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding,
or gas welding in the U.S.) and oxy-fuel cutting are processes that use fuel gases (or
liquid fuels such as gasoline) and oxygen to weld or cut metals. French engineers
Edmond and Charles Picard became the first to develop oxygen-acetylene welding
in 1903.[1] Pure oxygen, instead of air, is used to increase the flame temperature to
allow localized melting of the workpiece material (e.g. steel) in a room environment.
During the early 20th century, before the development and availability of coated arc
welding electrodes in the late 1920s that were capable of making sound welds in steel,
oxy-acetylene welding was the only process capable of making welds of exceptionally
high quality in virtually all metals in commercial use at the time. These included not
only carbon steel but also alloy steels, cast iron, aluminum, and magnesium. In recent
decades it has been superseded in almost all industrial uses by various arc
welding methods offering greater speed and, in the case of gas tungsten arc welding, the
capability of welding very reactive metals such as titanium. Oxy
-acetylene welding is still used for metal-based artwork and in smaller home
-based shops, as well as situations where accessing electricity.
In oxy-fuel welding, a welding torch is used to weld metals. Welding metal results
when two pieces are heated to a temperature that produces a shared pool of molten
metal. The molten pool is generally supplied with additional metal called filler. Filler
material depends upon the metals to be welded.
In oxy-fuel cutting, a torch is used to heat metal to its kindling temperature. A stream of
oxygen is then trained on the metal, burning it into a metal oxide
that flows out of the kerf as slag.[5]
Torches that do not mix fuel with oxygen (combining, instead, atmospheric air) are not
considered oxy-fuel torches and can typically be identified by a single tank (oxy-fuel
cutting requires two isolated supplies, fuel and oxygen). Most metals cannot be melted
with a single-tank torch. Consequently, single- tank torches are typically suitable for
soldering and brazing but not for welding.
Pressure regulator
The regulator ensures that pressure of the gas from the tanks matches the required
pressure in the hose. The flow rate is then adjusted by the operator using needle valves
on the torch. Accurate flow control with a needle valve relies on a constant inlet
pressure.
Most regulators have two stages. The first stage is a fixed-pressure regulator, which
releases gas from the cylinder at a constant intermediate pressure, despite the pressure
in the cylinder falling as the gas in it is consumed. This is similar to the first stage of a
scuba-diving regulator. The adjustable second stage of the regulator controls the
pressure reduction from the intermediate pressure to the low outlet pressure. The
regulator has two pressure gauges, one indicating cylinder pressure, the other
indicating hose pressure. The adjustment knob of the regulator is sometimes roughly
calibrated for pressure, but an accurate setting requires observation of the gauge.
Some simpler or cheaper oxygen-fuel regulators have only a single-stage regulator, or
only a single gauge. A single-stage regulator will tend to allow a reduction in outlet
pressure as the cylinder is emptied, requiring manual readjustment. For low-volume
users, this is an acceptable simplification.
Welding regulators, unlike simpler LPG heating regulators, retain their outlet (hose)
pressure gauge and do not rely on the calibration of the adjustment knob. The cheaper
single-stage regulators may sometimes omit the cylinder contents gauge, or replace
the accurate dial gauge with a cheaper and less precise "rising button" gauge.
Gas hoses
The hoses are designed for use in welding and cutting metal. A double-hose or twinned
design can be used, meaning that the oxygen and fuel hoses are joined together. If
separate hoses are used, they should be clipped together at intervals approximately 3
feet (1 m) apart, although that is not recommended for cutting applications, because
beads of molten metal given off by the process can become lodged between the hoses
where they are held together, and burn through, releasing the pressurised gas inside,
which
in the case of fuel gas usually ignites.
The hoses are color-coded for visual identification. The color of the hoses varies
between countries. In the United States, the oxygen hose is green and the fuel hose is
red.[6] In the UK and other countries, the oxygen hose is blue (black hoses may still be
found on old equipment), and the acetylene (fuel) hose is red.[7] If liquefied petroleum gas
(LPG) fuel, such as propane, is used, the fuel hose should be orange, indicating that it is
compatible with LPG. LPG will damage an incompatible hose, including most
acetylene hoses.
The threaded connectors on the hoses are handed to avoid accidental mis- connection:
the thread on the oxygen hose is right-handed (as normal), while the fuel gas hose has a
left-handed thread.[6] The left-handed threads also have an identifying groove cut into
their nuts.
Gas-tight connections between the flexible hoses and rigid fittings are made by using
crimped hose clips or ferrules, often referred to as 'O' clips, over barbed spigots. The
use of worm-drive hose clips or Jubilee clips is specifically forbidden in the UK and
other countries.[8]

Non-return valve
Acetylene is not just flammable; in certain conditions it is explosive. Although it has an
upper flammability limit in air of 81%,[9] acetylene's explosive decomposition behiavour
makes this irrelevant. If a detonation wave enters the acetylene tank, the tank will be
blown apart by the decomposition.
Ordinary check valves that normally prevent back flow cannot stop a detonation
wave because they are not capable of closing before the wave passes around the
gate. For that reason a flashback arrestor is needed. It is designed to operate before the
detonation wave makes it from the hose side to the supply side.
Between the regulator and hose, and ideally between hose and torch on both oxygen
and fuel lines, a flashback arrestor and/or non-return valve (check valve) should be
installed to prevent flame or oxygen-fuel mixture being pushed back into either cylinder
and damaging the equipment or causing a cylinder to explode.
European practice is to fit flashback arrestors at the regulator and check valves at the
torch. US practice is to fit both at the regulator.
The flashback arrestor (not to be confused with a check valve)
prevents shock waves from downstream coming back up the hoses and entering the
cylinder, possibly rupturing it, as there are quantities of fuel/oxygen mixtures inside
parts of the equipment (specifically within the mixer and blowpipe/nozzle) that may
explode if the equipment is incorrectly shut down, and acetylene decomposes at
excessive pressures or temperatures. In case the pressure wave has created a leak
downstream of the flashback arrestor, it will remain switched off until someone resets
it.

Check valve
A check valve lets gas flow in one direction only. It is usually a chamber containing a
ball that is pressed against one end by a spring. Gas flow one way pushes the ball out of
the way, and a lack of flow or a reverse flow allows the spring to push the ball into the
inlet, blocking it. Not to be confused with a flashback arrestor, a check valve is not
designed to block a shock wave. The shock wave could occur while the ball is so far
from the inlet that the wave will get past the ball before it can reach its off position.
Torch
The torch is the tool that the welder holds and manipulates to make the weld. It has a
connection and valve for the fuel gas and a connection and valve for the oxygen, a
handle for the welder to grasp, and a mixing chamber (set at an angle) where the fuel gas
and oxygen mix, with a tip where the flame forms. Two basic types of torches are
positive pressure type and low pressure or injector type.

Welding torch
A welding torch head is used to weld metals those are difficult to weld by using
electrode. It can be identified by having only one or two pipes running to the nozzle, no
oxygen-blast trigger, and two valve knobs at the bottom of the handle letting the
operator adjust the oxygen and fuel flow respectively.

Cutting torch
A cutting torch head is used to cut materials. It is similar to a welding torch, but can be
identified by the oxygen blast trigger or lever.
When cutting, the metal is first heated by the flame until it is cherry red. Once this
temperature is attained, oxygen is supplied to the heated parts by pressing the oxygen-
blast trigger. This oxygen reacts with the metal, forming an oxide and producing heat. It
is the heat that continues the cutting
process. The cutting torch only heats the metal to start the process; further heat is
provided by the burning metal.
The melting point of the iron oxide is around half that of the metal being cut. As the metal
burns, it immediately turns to liquid iron oxide and flows away from the cutting zone.
However, some of the iron oxide remains on the workpiece, forming a hard "slag"
which can be removed by gentle tapping and/or grinding.
Rose bud torch
A rose bud torch is used to heat metals for bending, straightening, etc. where a large area
needs to be heated. It is so-called because the flame at the end looks like a rose bud. A
welding torch can also be used to heat small areas such as rusted nuts and bolts.

Injector torch
A typical oxy-fuel torch, called an equal-pressure torch, merely mixes the two gases.
In an injector torch, high-pressure oxygen comes out of a small nozzle inside the
torch head which drags the fuel gas along with it, using the venturi effect.

Fuels
Oxy-fuel processes may use a variety of fuel gases, the most common being
acetylene. Other gases that may be used are propylene, liquified petroleum gas (LPG),
propane, natural gas, hydrogen, and MAPP gas. Many brands use different kinds of
gases in their mixes.

Acetylene
Acetylene is the primary fuel for oxy-fuel welding and is the fuel of choice for repair
work and general cutting and welding. Acetylene gas is shipped in special cylinders
designed to keep the gas dissolved. The cylinders are packed with porous materials
(e.g. kapok fiber, diatomaceous earth, or (formerly) asbestos), then filled to around 50%
capacity with acetone, as acetylene is soluble in acetone. This method is necessary
because above
207 kPa (30 lbf/in²) (absolute pressure) acetylene is unstable and may
explode.
There is about 1700 kPa (250 psi) pressure in the tank when full. Acetylene when
combined with oxygen burns at 3200 °C to 3500 °C (5800 °F to 6300 °F),
highest among commonly used gaseous fuels. As a fuel acetylene's primary disadvantage, in
comparison to other fuels, is high cost.
As acetylene is unstable at a pressure roughly equivalent to 33 feet/10 meters
underwater, water-submerged cutting and welding is reserved for hydrogen rather
than acetylene.

Gasoline
Oxy-gasoline, also known as oxy-petrol, torches have been found to perform very well,
especially where bottled gas fuel is not available or difficult to transport to the worksite.
Tests showed that an oxy-gasoline torch can cut steel plate up to 0.5 in (13 mm) thick at
the same rate as oxy-acetylene. In plate thicknesses greater than 0.5 in (13 mm) the
cutting rate was better than that of oxy-acetylene; at 4.5 in (110 mm) it was three times
faster.[10]
The gasoline is fed either from a pressurised tank (whose pressure can be hand-
pumped or fed from a gas cylinder).[10] OR from a non pressurised tank with the fuel
being drawn into the torch by venturi action by the pressurised oxygen flow. Another
low cost approach commonly used by jewelry makers in Asia is using air bubbled
through a gasoline container by a foot-operated air pump, and burning the fuel-air
mixture in a specialized welding torch.
Hydrogen
See also: Oxy hydrogen

Hydrogen has a clean flame and is good for use on aluminium. It can be used at a
higher pressure than acetylene and is therefore useful for underwater welding and
cutting. It is a good type of flame to use when heating large amounts of material. The
flame temperature is high, about 2,000 °C for hydrogen gas in air at atmospheric
pressure,[11] and up to 2800 °C when pre- mixed in a 2:1 ratio with pure oxygen (oxy
hydrogen). Hydrogen is not used for welding steels and other ferrous materials,
because it causes hydrogen
embrittlement.
For some oxy hydrogen torches the oxygen and hydrogen are produced by
electrolysis of water in an apparatus which is connected directly to the torch. Types
of this sort of torch:

 The oxygen and the hydrogen are led off the electrolysis cell separately and are
fed into the two gas connections of an ordinary oxy-gas torch. This happens in the
water torch, which is sometimes used in small torches used in making jewelry
and electronics.

 The mixed oxygen and hydrogen are drawn from the electrolysis cell and are led
into a special torch designed to prevent flashback. See oxy hydrogen.
 CONCLUSION
In the present competitive world there has been many competitors in the field of ship
building may have emerged but still HINDUSTAN SHIPYARD LIMITED is as popular
as it was before because of its strict maintenance in the quality and standards of its
products hence ship yard still have many customers and have ample orders. This in
order to meet the demand of its customer’s ship yard has to speed its production by
the more utilization of latest technology.