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1、April 2008,Classification Survey during Construction(Hull),Part 1Hull Survey SystemPart 2Survey on Site,Hull Survey SystemOutline,QC System of Shipyard,General Manager,Manager for Hull,Surveyorin Charge,Managers in HLD,EQD and SVD,Project Team,Rules,GuidanceClassNK Instructions,Indirect survey&QC in
2、vestigation,Directsurvey,InspectionRecord,New Building and Project TeamStage,Plan approval Rules Part B 2.1.1,Investigation of QC condition Rules Part C 1.1.17-1 and Part M 1.1-2(1),Meeting with persons concerned(owner,shipyard,etc.)*,Survey during assembly process and block inspection Rules Part B
3、2.1.4,Survey in building berth Rules Part B 2.1.4,Survey after launching Rules Part B 2.1.4,2.3.1 and 2.3.2,Managers in charge in HLD,EQD and SVD,GM,Manager(H)and surveyors in charge in service site,Project team,Class entryapplication,Workcommence,Lay down,Launching,Delivery,*Meeting to be held any
4、time during each stage,Flow of Plan/Drawing Approval,Local Office,Head Office,Shipyard,(1),(2),(3),(1)Plan/Drawing approved by HO（Examined and approved by HO and return to shipyard）(2)Plan/Drawing examined by HO（Examined by HO and return to shipyard with stamp of EXAMINED）(3)Plan/Drawing reference f
5、or HO（Reference for HO and return to local office except calculation sheet）(4)Plan/Drawing approved by local office（Examined and approved by local office and return to shipyard）(5)Plan/drawing reference for local office（Reference for local office and no return to shipyard）,(1),(2),(3),(4),(5),(1),(2
6、),(3),(1),(2),(4),Management of Survey Attendance and Investigation of Quality Management,Survey attendance Management of daily surveyInvestigation of Quality Management system of shipyard Periodical Investigation Annual Investigation Occasional InvestigationSite Execution Investigation Monthly Inve
7、stigationPatrol Survey,Form IR,Form IR(H),Form IR(H-A948),Form IR(H)Attachment,Form B,Record A,Form S,Periodical Investigation,Timing(a)When the shipyard builds a ship being classed with NK for thefirst time(b)When about 5 years have passed from the previous periodicalinvestigation(c)When the size o
8、f ship being classed with NK breaks through10,000,30,000 or 100,000 GT for the first time(d)When the shipyard re-starts building a ship being classed withNK after a blanc period of more than 2 years ContentsFacilities and features of construction,number of welders,system and details for quality cont
9、rol,etc.(see Record A)RecordRecord A to be prepared,Annual Investigation,TimingWhen about 1 year passed from the last periodical investigation or annual investigationContentsAbout 20%of the contents for periodical investigationRecorsRecord A to be prepared,Occasional Investigation,Timing When organi
10、zation or layout of shipyard which have influence on quality control is changed When a serious deficiency is found during regular survey(Form S to be prepared)When shipyard builds a ship by using special production process or special material for the first time When deemed necessary by the societyCo
11、ntentsItems deemed necessary in relation to the above,Monthly Investigation,TimingNotwithstanding its naming,the investigation should be done during daily survey.Report may be done 1 or 2 monthly.ContentsIdentification of steel,welding procedure,control of welding materials,observance of the quality
12、 standard,etc.are to be investigated at each stage such as in-shop fabrication,panel fabrication,block assembly and block loadingRecordRecord B to be prepared,Patrol Survey,The purpose of“patrol survey”is to grasp the actual circumstance of quality control of the shipyard through an investigation of
13、 following points during the fabrication(it may be impossible at block inspection)Welding procedure(temporary fitting,edge preparation,position,backgouging,sequence,welders qualification,etc.)Handling of defective work(material,size,accuracy of fitting,record,etc.)Surveyor in charge execute a patrol
14、 survey at any time of following occasions,while he follows an application submitted by the shipyard for usual survey To pass through the work shop on his way to and from the place of usualsurvey,To execute in his spare time of survey,etc.The results of patrol survey should be periodically reported
15、to the General Manager as the monthly report of investigation of QC of the shipyardSurveyor should review his attendance of survey,such as timing and method,according to the results of the investigation of QC of the shipyard,Background of Patrol Survey,The presence of the surveyor is required at the
16、 following stages of the work in relation to hull and equipment(extract):(4)When designated by the society during shop work or sub-assembly.(17)When deemed necessary by the society.Rules,Part B,Chapter 2,2.1.4-1For the effectiveness of the control of the welding works to be carried out by the manufa
17、cturer,the society is to confirm the condition during welding works at an appropriate interval accepted by the surveyor,when deemed necessary.In this case,the manufacturer is to give the convenience to the surveyor and to permit the surveyor to enter all relevant areas of the yard.Rules,Part M,Chapt
18、er 1,1.3.2-1,Example of Shipyard Layout,Acceptance InspectionBlock InspectionBlock erection,Fittings,etc.Stability experiment,Function TestsSeek for the opportunity of patrol survey,Vertical Inspection of Welding Work,(for each welding work)Material controlEdge preparationFitting accuracy after tack
19、 weldingMisalignment between important membersFitting of backing material and run-off-tabConsideration for welding environmentPre-heating etc.Welding sequenceExecution of weldingBack chippingRemoving jigs etc.,(for shipyard)Approval of welding procedureWelders qualification,(during welding work)Desi
20、gnated survey Rules Part B and MPatrol survey,(for each ship)Approval of welding application plan and NDT plan,(after welding work)Visual inspectionNon-destructive inspection,Investigation of QC condition,etc.Examination of document,Part 2Survey on Site,1Acceptance inspection2Welding3Shop Work and S
21、ub-Assembly4Block inspection5Block joining on building berth6Rudder7Final inspection of hull compartment8Tightness/Hydrostatic test9NDT of welded joints10Measurement of principal dimensions,11Paint12Markings13Piping14Fire protection15Closing appliances16Stability experiments17Navigation bridge visib
22、ility 18Sea trial,1.Acceptance Inspection,Purpose of inspectionTo confirm that the materials which a shipyard placed an order outside,and was produced at other places have been inspected by the society,and that they have not been damaged during transportationObject of inspectionMaterial and equipmen
23、t manufactured by subcontractors outside the shipyard,such as rolled steel,steel casting and forging,welding materials,construction materials for fire protection,anchors,anchor chains,ropes,scuttles,hatch tarpaulins,hull blocks(*),steel hatch covers,watertight doors,steering gears,etc.Manner of insp
24、ection Verification of issue of certificate to the material carried into shipyard Verification of the material carried into shipyard and content of certificate is corresponding to content demanded by rule Verification of stamped serial number,identification symbol and identification number on the ma
25、terial carried into shipyard iscorresponding to content of certificate,*For hull blocks manufactured by subcontractors,see 4.below,Makers and Acceptance Inspection,Stamps and Certificate,Location of Stamp,Rolled Steel,Mill sheet is necessary for the later follow-up survey,not only collation of the s
26、teel plate at acceptance inspection.,Cast/Forged Steel,Object of inspection:Stems,stern frames,rudder stocks,rudder fittings,rudder coupling bolts,rudder pintles,rudder horns,shaft brackets and valves required to be made of cast steel by the rulesManner of inspection:Verification of inspection repor
27、t by the shipyard,copy of certificate issued by NK(when applicable)and rubbed copy of stamp and marking on the article.Surveyors attendance at the inspection is not necessary except for valves.When important members such as stern frame,rudder stock,etc.are machined,the report of in-house inspection
28、results should be submitted,and process should be attended if deemed necessary.,Welding Material,Object of inspection:Welding rods,wire for semi-automatic welding,core wire and flux for automatic weldingManner of inspection:Verification of brand to confirm that they are of type approved by NK.Refere
29、nce should be made to the approved welding procedures applicable to the ship in question.Actual status and control condition of facilities for drying welding materials are to be investigated at the initial stage of construction,Material for Fire Protection,Object of inspection:Non-combustible materi
30、als,“A”,“B”and“C”class divisions,flame retardant base materials,materials for primary deck covering,fire retardant veneers,fire retardant coatings,fire retardant surface floorings,fire dampersManners of inspectionReferring the list of brand attached to the approved drawings,materials should be confi
31、rmed and the results of the inspection should be recordedThe surveyor in charge should attend the site execution at least once in order to confirm the appropriate use of materials,and the results of the inspection should be recorded,Other Materials and Equipment,Anchors,anchor chains and ropes Colla
32、te NK stamp and certificate Verify if the type,diameter,length,weight and other particulars areappropriate as equipment for the ship in questionScuttlesAfter installing scuttles on the ship,the correct application of the scuttles is to be checked at an appropriate opportunity such as tightness testH
33、atch tarpaulinsNK stamp and certificate are to be collated at an appropriate opportunityHull blocksInquire the shipyard for any damage during transportation,inspect them if necessaryOthersCollation of rubbed copy of stamp and certificate.If articles are subject to test,the original should be confirm
34、ed at such opportunity,2.Welding,Outline（Kind of Welding、Test of weld）Welding Procedure SpecificationWelder qualificationWelding Application PlanWelding Works,A proper welding shall be done by“qualified welder”with“approved materials”in accordance with“approved procedure”.,Kind of Welding ProcessCla
35、ssification by Theory,Arc welding,Inert gas shielded arc weldingSubmerged arc weldingSelf-shielded arc welding,Oxyacetylene welding,Gas welding,Electro-gas weldingElectro-slag weldingPlasma arc welding,Shielded metal arc welding,CO2 arc welding(MAG welding),TIG weldingMIG welding,Test of Weld,Test,D
36、estructive test,Non-destructive test,Mechanical test,Tensile testBending testHardness testImpact test,Chemical analysis,Corrosion testMacroscopic testMicroscopic test,Chemical test,Metallurgical test,Visual inspectionLiquid penetrant testUltrasonic testMagnetic testRadiographic test,Welding Procedur
37、e Mather metal(grade,Thickness)Welding consumable.（Bland name,grade,Shield gas and Backing）Kind of joint（Butt or Fillet）Welding PositionDetails of edge preparations according to the thickness of base metal(including standard tolerances for edge preparation condition,i.e.groove angle,root gap,and mis
38、alignment),number of electrodes and arrangement,leg length or throat thickness,layer or pass sequence and welding parameter(amperage,voltage,welding speed,heat input,current).Preheating and interpass temperaturePost weld heat treatmentOther conditions necessary for the welding procedure,Maker needs
39、take approval of Welding Procedure and related specification(chapter 2.2.2-1,Part M).And Following particulars must have been described in the Welding Procedure Specification(Chapter 4,Part M).,Welding Procedure Specification,Qualification Test of Welding ProcedureButt Welding,Finished inspectionWel
40、ded surface is to be regular and uniform and is to be free from injurious defects,such as cracks,undercuts,overlaps,etc.Tensile testThe ultimate tensile strength is not to be less than the minimum ultimate tensile strength specified for the base metalBend TestThere is to be no crack nor any other de
41、fect greater than 3mm in length in any direction on the surface of bent specimenImpact testThe minimum absorbed energy of three specimens are to be in accordance with the Rules(The percent brittle fracture of the specimens is to be measured)Macro-structure inspectionThe etched section is to show no
42、crack,poor penetration,lack of fusion and other injurious defectsNon-destructive testInternal inspection(X-ray,US)and surface inspection(MP,liquid penetrant)are to show no crack and other injurious defects,Qualification Test of Welding ProcedureFillet Welding,Finished inspectionFillet welding is to
43、have a regular and uniform surface,and is to be free from cracks,undercuts,overlaps,and other injurious defectsMacro-structure inspectionWelded joint is to be free from excessive difference between upper and lower fillet length,cracks and other injurious defectsFracture testThe remaining test assemb
44、lies after the macro-structure specimen has been removed are to be broken by pressing as shown in the sketch.There is to be no cracks,blow holes,poor penetrations and other injurious defects in the fractured surfaceNon-destructive inspectionSurface inspection(MP,liquid penetrant)is to show no crack
45、and other injurious defects.,Welder Qualification Certificate(valid for 3 years),Each welder intended to engage in the automatic welding operation is to be of a well experienced welder for the specific welding work concerned,Horizontal,N,Kinds of Welder（Arc welding）,Grade（Thickness）,Classes of Quali
46、fication（Welding Position）,ABoth side weldingincluding backchipping andback welding,NOne side weldingwithout backing,(Basic Position：START),Grade 1 and Grade 2 are necessary in shipbuilding usually.,Flat,F,Vertical,V,H,Over head,O,All Position,Z,Pipe,P,Grade 3(t:No restriction),Welder Qualification,
47、Grade 2(t19mm),Grade 1(t5mm),Kinds,Grades and Classes of Qualification,Welding Position at Qualification Test,The specimens are to show neither crack nor serious defect greater than 3mm in length in any direction on the outside surface due to the bending,Plate,Pipe,Welding Application Plan,Welding W
48、orks,Table 1.Selection of Welding Consumables,Table 2.Control Standards for Processing and Welding for Rolled Steels for Hull,3.Shop Work and Sub-Assembly,Patrol Survey(Investigation of quality control)Quality Standard,Patrol Surveyduring Shop Work and Sub-Assembly,Identification of steelsConfirmati
49、on of proper use of steels according to the approved drawingsAccuracy of edge preparationProper fitting of strong back,temporary tack-welding,run-off tab,etc.Accurate fitting of members and corrective measures for defectsProper welding sequenceAdequate welding method(including back gouging condition
50、s)conforming to approved“welding procedure specification”Strict enforcement of rules for arc striking and short bead especially for high tensile steel and Grade E mild steelQualification of welders,Agreed Rules and Quality Standard,Ships owner,ClassNK,Ship builder,Specification:Conformance to NK Rul
