Mechanical Engineering Assignment

INTRODUCTION

CE 1.1

CE 1.2

Keppel Shipyardhas an unrivaled track record for repairing, converting, and upgrading a diverse range of vessels.Our marine expertise includes

• Conversion of Floating Production, Storage, and Offloading (FPSO) / Floating Storage and Offloading (FSO) vessels, Floating Storage and Re-Gasification Units (FSRU), and drillships
• Repair all types of marine vessels, including tankers, containerships, bulkers, and LNG / LPG carriers.
• Upgrading and life extension of vessels
• Jumboisation of vessels
• Fabrication of turrets and topside modules

CE 1.3

BACKGROUND

Since the propeller replacement involves three steps, 1) removal of the propeller cap/cone, 2) Disconnecting the propeller securing nut 3) removal of the propeller from its original position. Now I have to design the procedure for the disconnection of the above items in a sequential manner. The steps involved are

1. Inspection of the aft stern construction drawing determines the strong point for lifting a propeller blade, after which design the pad eyes.
2. Arrangement of the lifting gears, lashing equipment, air pumps, hydraulic fittings, hoses
3. Prepare a lifting plan for the entire process.
4. Prepare and conduct a JHA (Job hazard analysis ) as the tonnage of the equipments more than 20T and its complexity.
5. Prepare the lifting gear certificates, and organize the QA team for inspections.
6. The above items are installed sequentially and inspected at various stages.

CE 1.4

The organizational flow chart is attached and my position is highlighted in blue

PERSONAL ENGINEERING ACTIVITY

CE 1.5

From the beginning of the process, I had first to fetch all the tonnage and dimensions of the items involved. For that, during the kick-off meeting, I highlighted the relevant drawings that have to be provided, which the owner circulated through the ship repair manager.

Once I receive the data, I circulated the above drawings to the engineering department to calculate and verify the pad eyes. Once the pad eyes are confirmed, I sat with the rigging team to generate a detailed lifting plan for the propeller based on the tonnages. Further, the above plan was sent to the engineering department for further stress calculations. The above department advised further for the change in the lifting gears as required.

CE 1.6

This work method statement is to define the lifting and shifting of the propeller. Propeller 84 ton / diameter 8800mm/ 6 blades

Preparation prior to operation

Document/Site Preparation:

1. Preparation of relevant documents for lifting arrangement. (Responsible Party: Machinery Lead)
2. Lifting gear certificates - (Responsible Party: Lifting Lead)
3. Prepare lifting plan:
4. Choosing the appropriate lifting gears (chain blocks, shackles, and wire slings).
5. Conduct JHA before the lifting/shifting operation with all personnel reflected in Organization Chart Submit relevant documents (lifting arrangement, calculation, MPI reports, and risk assessment) for review. (Responsible Person: KSL machinery Lead)
6. Site preparation
7. Any obstruction items are to be cleared before the lifting/shifting operation.
8. Communication check between KSL Lifting Lead and KSL Production Team using a walkie-talkie.
9. Ensure all material in the tail shaft and intermediate shaft are removed.
10. All removed handrails and walkway platforms are suitably secure, and alternative walkways should be provided
11. The lifting area should be barricaded, and only authorized personnel should enter.
12. All additional lifting gears must be checked and verified by the safety Lead before the lifting/shifting operation.
13. Coordinate and highlight in the VSCC meeting the withdrawal of the propeller to be carried out. PTW to apply for Dismantling and Boxing up activities.
14. A Lock out, Tag out should be installed on the Turning gear to avoid any accidental turning of the engine while working on the propeller at the dock bottom.

CE 1.7

Lifting and shifting of propeller

1. Once the lifting arrangement is done, set up the hydraulic tools and loosen the propeller nut. Unscrew the nut and lower down the nut to the floor with the help of the cradle.
2. Put the necessary marking on the propeller and prepare hydraulic tools for propeller jumping.
3. Hook up the fwd chain blocks to the propeller and slowly jump the propeller from the tail shaft taper.
4. Once the propeller is free from the tail shaft, set up chain blocks on the rudder side, pull the propeller from the taper, and make it straightforward for about 1 foot.

CE 1.8

CE 1.9

To weld the engineering-designed eye lugs and set up a side block rigging arrangement for shifting out the propeller blade. Based on the below lifting arrangements, side blocks (with 120-ton) capacity winches are operated and shift the propeller from one side to the other. Further, after reaching the yard crane, hook up the yard crane onto the four blades and lift it to the ground.

CE 1.10

After the withdrawal of the propeller, I requested the vessel superintendent and the class surveyor to witness the MPI test (Magnaflux test). An approved QA personnel performed the test. The person's competency and the equipment test certificate must be produced in front of the surveyor. Outboard seals were overhauled during the process. Once the seals are installed completely, the propeller is reinstated similarly. The communication flow/emergency preparedness during the lifting process is as follows.

1.11

Access Control

Access control was managed by KSL HSE and KSL Machinery Lead led by KSL Project Manager in their respective areas on the ground. Only authorized personnel identified by green vests were allowed to enter the lifting operation vicinity and carry out related works concerning the lifting operation. Watchmen were deployed to prevent unauthorized personnel from trespassing.

SUMMARY

1.12

I successfully adapted my engineering skills to projects in times of problems and failures, which was highly appreciated. The project helped me a lot as professionally as well as in enhancing my skills in management through manpower deployment and scheduling of the tasks as per priority.

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