modularization in ship equipment

Transkrypt

modularization in ship equipment
MODULARIZATION IN SHIP EQUIPMENT
Intermodul s/03/G
Task No. 1
Opinion of modularization degree in existing naval constructions.
( Based on Polish and Northern Europe shipyard experiences.)
Author:
Approved by:
Accepted by:
Krzysztof Gockowski
Krzysztof Nawacki
Alicja Kościńska
Gdańsk
October 2005
⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯
SHIP DESIGN AND RESEARCH CENTRE S.A.
DESIGN DIVISION
80-369 Gdańsk Al. Rzeczypospolitej 8
tel.(48 58) 511-62-25, 511-62-42
fax(48 58) 511-62-43
e-mail: [email protected]
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CONTENS
Preface................................................................................................................................3
Module and Modularization – main brief foredesign.........................................................4
Applied blocks....................................................................................................................6
3.1
Hull and hull-equipment blocks ................................................................................ 8
3.2
Superstructure block................................................................................................. 10
3.3
Funnel block............................................................................................................. 12
3.4
Sanitary block (sanitary cabin)................................................................................. 14
3.5
Accommodation block (habitable cabin) ................................................................. 16
3.6
Ventilation and air conditioning control block. ....................................................... 18
3.7
Fuel booster block for main engine.......................................................................... 20
3.8
Fuel or lubricating oil separator block. .................................................................... 22
3.9
Lubricating oil block for main engine...................................................................... 24
3.10 Turbocharger lubricating oil block for main engine. ............................................... 25
3.11 Block of fuel burner for boiler. ................................................................................ 27
3.12 Sanitary water hydrophore block . ........................................................................... 28
3.13 Sewage treatment plant block. ................................................................................. 30
3.14 Fire fighting blocks. ................................................................................................. 32
3.14.1 Fire fighting unit CO2................................................................................... 32
3.14.2 Fire fighting water fog unit ........................................................................... 33
3.15 Refrigerating compressor block with condenser...................................................... 34
3.16 Air compressor block. .............................................................................................. 35
3.17 Module equipment of RoRo and RoPax type ships. ................................................ 36
3.18 Various blocks.......................................................................................................... 38
4.
The opinion of modularization /equipping block degree applied in the Polish
shipyards...........................................................................................................................39
5. Modularization in world solutions ...................................................................................40
5.1
Module building of the ship ..................................................................................... 41
5.2
Module building and equipping of war-ships .......................................................... 42
5.2.1 Flex standard ................................................................................................... 42
5.2.2 MEKO ............................................................................................................. 43
5.3
Container ships - module construction of the engine room. .................................... 44
6.
The opinion of modularization/equipment block degree applied in the North Europe
shipyards...........................................................................................................................47
7.
Summary ..........................................................................................................................48
Literature ...................................................................................................................................49
1.
2.
3
MODULARIZATION IN SHIP EQUIPMENT
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1. Preface
Conception of module building of ships in naval industry in Poland and on the
world-wide is well-known and applied from many years. Range use of modules
depend on knowledge, technology and organization of work in the shipyard .
Type of ship, his destination and quantity vessel in series is also significant.
The main task of this study is to determine modularization degree building vessel in
Polish shipyards and in the Northern Europe based on accessible information from
shipyard, press or literature.
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2. Module and Modularization – main brief foredesign
Following study shows range of use module/block of building of ships and theirs
equipment in the Polish and the Northern Europe shipyards.
In this study, nomenclature is got from particular countries and/or from particular
manufacturers.
In ship industry instead of ”module and modularization”, terminology
“ship block equipment”, “functional block” or simple “blocks” is used.
Generally it is possible to accept, that “equipment ship blocked” mean
modularization and blocks mean modules.
What are blocks and building block and ships equipment?
In Polish ship industry there are a few different blocks type. Name of block
generally determine block functions and place where it is installed on the ship.
The most often applied blocks:
-hull block
(assemble space-section joint in one large construction, for example after peak
block);
-hull equipment block
(hull block partly or entirely equipped, for example superstructure block or
funnel block);
-functional block- “block”
(assemble of elements fulfilling determine functions on ship, connected with
each other and assembled on common frame, for example fuel feed, habitable
block).
Common features of all blocks in general can be define as determination.
Block – assemble of elements fulfilling definite functions on the ship, about planning
out spatial dependent on distribution and overall dimensions of elements come in
composition of block. Elements of block are assembly to each other and (or) assembly
to stiff foundation frame.
Technology of construction of hull ship block depends on ship assembling on a
slipway or dock from large hull blocks. Those blocks are build in assembly room or in
special place in the shipyard from smaller elements - the three-dimensional section of
the hull.
The system of ships building from large hull blocks affected on shortening time of
building hull. Natural consequence was equipment work adjustment to this status. So,
the technology of blocks ship equipping was worked out.
This technology makes possible to lead ships blocks equipment work in reinforcement,
pipelines and devices.
Next point was blocks hull equipping in more and more complicated and filled of
equipment, pipelines and fittings in smaller blocks, functional and assemble blocks. [2]
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What for the technology of block ships building and equipping is used?
Generally applying blocks and block building technology and ships equipping affected
on increasing productivity of production process, shortening the time of ship building,
degrease the costs of ship building and increase the level of safety during executed work.
The fact of problems is use during the ship building with larger number blocks, which
put together and mutually connection they will make up the equipment of ship. If the module
are bigger than equipping is simpler. The more elements go into composition of one module
then more assembly work is done beyond the ship in convenient conditions in workshop. If
the blocks are bigger than number of individual transport operations is less. Compact building
block, assembled in frame, makes up natural protection of building inside equipment,
mutually connected in rigidly, compact construction.
Advantages and limitation of using the blocks and ship blocks equipping
The most important advantage of modularization is possibility to separate building
processes of the ship from its equipping process.
Separating building hull processes of the ship from its equipping process in the independence
modules, have in general the following advantages [3]:
- it is possible to simultaneously design hull and ship equipment,
- it is possible to simultaneously building of hull ship construction and
equipping the ship,
- there are smaller difficulties in ship building and same building is faster,
- the time of utilization the slipway/dock is shorter,
- building and equipping of hull blocks and functional blocks is more
comfortable, quicker, safer and cheaper,
- there is smaller quantity of transport operations executed by shipyard,
- ordering special subcontractors, to deliver items and resources is easier,
- the time of building shortens on result of use standard blocks and systems,
- there is easier work in non blocked / modularization zones of remaining space
of marine power plant,
The applying of block building and ship equipping require some charges connected with:
- larger range of the project work connected with correct planning and arranging
of blocks, guaranteeing the free access to block and transport -disassembly
routs,
- the partial adaptation the construction of hull ship or the superstructure to
blocks,
- the small growth of occupied space by blocks,
- the small growth of block weight in relation to traditional solution,
- the shipyard dependence from blocks vendors (in case of ordering block
building to subcontractors).
The experiences of individual shipyards may be different and entirely another
what it results of technology, shipyard has, workers' experience, the types of built ships
or the shipowner's requirements ordering the ship.
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Present above foundation, advantages and disadvantages of block ship equipping
technology are introduced generally, because they do not make up main subject of this
study.
3.
Applied blocks
In the Polish shipbuilding industry first conceptions of ships blocks equipment its
go back to half years of 60 of last century. In the beginning period river shipyard has the
biggest achievement. They couldn’t take full advantage of their achievement. This method
was adopted by naval shipyard and put into practice. They gradually develop it what lead
in creation the system of ships design and block equipment.
Many different types of hull and engine room blocks was made connecting both
construction and equipment. To most often applied blocks belong:
- hull blocks;
- hull-equipment blocks;
- functional and assemble-“blocks”;
The applied technology of ship hull building blocks generally concerns on hull
section doing in shipyard, which are connected in big hull blocks, and these in final shape
of ship hull. The technology and transport ships possibilities influence on size and level of
equipment blocks.
Hull and hull-equipment blocks what are applied:
- ships hull blocks, for example double bottom, forepeak;
- superstructure block;
- funnel block;
During hull blocks building they are equipped in equipment and pipelines in the
possibly largest degree. In the event of superstructure module the following blocks are
used:
- sanitary block;
- accommodation block;
- control ventilation and air conditioning block;
These blocks are the most often made and delivered through specialized producing
institutions this type of modules for shipping and land industry. What is characteristic,
these block are offered in series of type.
Equipping of the hull ship interior and in particular engine room equipping
because of large quantity of equipment, pipelines and fittings is the most job -consuming
and the most dangerous works. The large quantity of equipment and them different
destination influences on degree of modularization / equipment block of the engine room.
Also the type of ship and tasks, what has to be fulfilled, influence on shape of engine
room and its equipment.
Generally there are two groups of blocks:
Blocks, group of devices fulfilling particular and often very complexity function the
systems of engine room. They have worked out series of types and can be applied on
different types of ships.
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Blocks, group of devices realizing defined tasks for concrete ship and which are designed for
given ship or to service concrete device. Often they are designed under shipowner's individual
requirements. Many firms which deliver devices included in composition of ship engine
room, deliver his constructions in modules / blocks. There are firms which are designing and
building modules on order from the shipyard. These factors influence on large variety of
modules / blocks in regard of devices saturation degree, size and shape.
Introduced below applied blocks to equipping of engine room are used in general on all built
in Polish shipyards types of ships and can be bought by shipyards or made in the shipyard.
There are also introduced blocks, which are made only with special order on concrete type of
ship or only to service of concrete type of device.
The most often applied Polish assembly block -"blocks ”/ modules in the Polish shipyards
modules belong:
- fuel preparation block;
- fuel separator block;
- oil separator block;
- preparation of fuel for main engine block;
- preparation of fuel for turbocharger block;
- fuel preparation block for auxiliary boiler;
- hydrophore sanitary water block;
- sanitary block-sewage-treatment plant;
- system of fire-fighting block;
- compressing refrigerating block with condenser;
- air compressor block.
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3.1
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Hull and hull-equipment blocks
The hull block this is the steel spatial construction of part hull ship, which is
assembled with many spatial sections consist together in one larger part (Pic.1). Every spatial
section is made from steel sheet joint together. The frames, brackets and pillars stiffened the.
to build the block steel shipping usual and special are used. Block is protected against
influence of corrosion and (or) paint.
The size of block is limited by shipyard transport possibilities and endurance of block
construction (during transport).
Pic. 1 Process building of block hull from section [4]
Pic.2 Hull block during transportation and in the dock. [5]
On the slipway or in the dry dock blocks are connected together to create the final shape of
hull ship. It consists of several hull blocks ( 3) and blocks of superstructure and funnel.
16
17
01
02
03
04
05
06
07
08
Pic.3 Division construction of the ship on hull blocks [4]
09
15
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Pic. 4 Hull block assembly on the slipway [6]
Hull-equipment blocks these are blocks, which were during the building equipped partly or
entirely with devices, pipelines or/and armatures, etc.
.
Pic.5 Hull-equipment block [4]
MODULARIZATION IN SHIP EQUIPMENT
Opinion of modularization degree in existing naval constructions
3.2
Str.
10/50
Superstructure block
The superstructure block is steel (or different materials) spatial construction, which
include social and life rooms for crew and passengers. The devices and systems of
communication and control of ship movement in superstructure are installed.
Simple shipping steel, special or other materials are used to build this block. Block is
suitably secured against corrosion and painted. .The superstructure block during building is
equipped with sanitary and habitable blocks, navigational equipment and communications
systems. The block has the air conditioning, sanitary, electric power supply installation and
fire – fighting systems.
Pic. 6 Block of superstructure after painting, prepared to transportation. [7]
The joining of funnel block with superstructure block is the frequent solution. In case of
smaller superstructures the blocks such as one element are assembled on the ship. The larger
blocks of superstructure and funnel because of shipyard transport possibilities and
deformation of construction block possibility are divided in two or more parts.
Pic. 7 represents the block of superstructure and funnel divided in two parts during
transportation.
Pic. 7 The upper half of superstructure and funnel block [8]
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The degree of total equipment superstructure depends on type of ship, size of superstructure,
shipowner requirements and technological ability of shipyards. Some superstructures can be
equipped in sanitary cabins not only, habitable, larger devices and main installations. Into the
ship superstructure block is delivered with entirely equipped interior. With forms of walls and
ceilings and with lining on the floor. All room, devices and systems are able to use after
connecting to power supply.
Pic. 8 The superstructure block during assembling on the ship [5]
Pic. 9 Interior of rooms in the superstructure. [5]
MODULARIZATION IN SHIP EQUIPMENT
Opinion of modularization degree in existing naval constructions
3.3
Str.
12/50
Funnel block
The funnel block this is steel spatial construction, which included exhaust gas
installations and points: of input and output of air. The block of funnel is made from metals
steel sheets joint together and stiffened by stiffener and brackets. To the constructions of
block the usual shipping steel is used. The block is conserved by temporary protection and
(or) paint. The size of block is limited by shipyard transport possibilities and endurance of
block construction (during transport).
Pic. 10 Funnel block [4]
Pic. 11 Funnel block
during transport [5]
Many factors influence on the funnel block equipment: the type of the ship, type of
propulsion, applied devices, shipowner's requirement and applied technology by the
shipyards. The most often in composition funnel block is used:
- the exhaust pipe of main engine, generating sets and boilers;
- waste-heat boiler;
- spark arrester;
- ventilation pipes,
- gravity tanks,
- air intake ;
- air outlet;
- elements of block construction: steel sheet, stiffening, grating; etc.
MODULARIZATION IN SHIP EQUIPMENT
Opinion of modularization degree in existing naval constructions
Pic. 12 Funnel block in different realizations [4]
Str.
13/50
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Str.
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3.4 Sanitary block (sanitary cabin).
The sanitary block this is the spatial construction fulfilling the functions of sanitary
room. Sanitary block is designed to assembly on ship equipped as completely the
bathroom to service of crew or passengers cabins. The construction of block makes
possible his transportation and easy assembly on the ship. Sanitary block is adapted to
connecting water installation, electric, ventilation and air conditioning on the ship. Pic. 13
represents the different realizations of the block.
Pic.13 The view on different realizations of sanitary cabins of the firm LUBMOR. [10]
The kind of cabin equipment, colour and additional equipment is delivered by shipowner's
requirements.
Pic. 14 View on equipped sanitary cabin of the firm
WetCab. [11]
Pic. 15 View on equipped sanitary cabin of the firm
MODUL. [12]
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Sanitary block is made as a frame construction. The walls and ceiling of block are made
with panels from metal galvanic sheet filled of the mineral wool. The panels from internal
side cabin are covered with the decorative PCV foil, glued with ceramic plates or covered
with varnish coats. The construction of floor is made from steel sheet anticorrosive secured.
The floor is glued antislip ceramic panels or smooth with grating. Bringing warm and cold
water pipelines are insulated antisweat. Pipelines inside block are covered decorative
coating, for example nickel-chrome. There are doors, installed with wings that are made
with covered PCV foil sheet and filled with mineral wool.
Pic. 16 WetCab sanitary cabins constructions. [11]
The equipment of sanitary block depends on type of the block or shipowner's requirement.
The most often used equipment in the block:
- tank or shower cabin with battery;
- water-closet bowl (gravitation or vacuum );
- wash-basin with battery;
- exhaust vent;
- heater or preheating electric floor;
- handle for toilet paper;
- toilet cabinets or mirror;
- wall lamp from socket;
- holders, hangers;
- basket on soap and sponge;
- and other according to wishes.
MODULARIZATION IN SHIP EQUIPMENT
Opinion of modularization degree in existing naval constructions
Str.
16/50
3.5 Accommodation block (habitable cabin)
The accommodation block is spatial construction that fulfilling functions of living room.
The accommodation block is designed to assembly on ship as completely equipped vital room
for crew and passengers. The construction block makes possible his transportation or easy
assembly on the ship. The accommodation is adapted to connect the water installation,
electric or ventilator and air conditioning on ship. Pic.17 represents the different realizations
of accommodation block.
Pic. 17 Different realizations of the habitable cabins. [9]
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Str.
17/50
The accommodation block is made as a frame construction. The walls and ceiling of block are
made with panels from metal galvanic sheet filled by mineral wool. The panels from internal
side of cabin are covered of the decorative PCV foil, glued with ceramic plates or covered
with varnish coats. The construction of floor is made from steel sheet anticorrosive secured.
The floor is glued lining. The accommodation block is equipped in bathroom with toilet. The
accommodation block is equipped with furniture, the audio-video equipment and decorative
elements of interior cabin decorations.
Pic. 18 Construction of living cabin [13].
The equipment of living block depends on block type or shipowner's requirements. There are
the most often used equipment block:
- couch, sofa, bed;
- armchair, chair;
- table, desk;
- wardrobe, chest of drawers;
- lamps, lighting;
- decorative elements of interior decorations of cabin;
- sanitary room, so as a sanitary cabin;
- audio- video equipment;
- and other according to wishes.
MODULARIZATION IN SHIP EQUIPMENT
Opinion of modularization degree in existing naval constructions
3.6
Str.
18/50
Ventilation and air conditioning control block.
Ventilation and air conditioning control block is spatial planned elements set joint with
functional elements. The main task of control room is to suitable prepare of air in relation to
temperature, the moisture and cleanness. The large quantity of size and variety of units
included in composition of control block makes possible to assembly the most suitable
composition in relation to efficiency of device, energy consumption, outside dimensions, air
treatment or air intake and air outlet system.
Pic. 19 Air conditioning central view [14]
Each set included in composition of control, fulfils defined functions. Sets are composed of:
- filters;
- air heaters;
- air coolers;
- air moisteners;
- air fans;
- control and power supply devices;
- throttling valve, sensor, automatic and control;
- damper, heater recovery system.
MODULARIZATION IN SHIP EQUIPMENT
Opinion of modularization degree in existing naval constructions
Str.
19/50
Casing of air conditioning block is made from: aluminum and plastics frames with
constant/demount covers. Standard centrals are equipped with assembled frame. Sets are
connected by special profiles, outside mounting for easy and fast assembly or disassembly
particular units of controls.
Pic. 20 Equipment of air conditioning central diagram [14]
1.
2.
2a
3.
4.
5.
6.
Filter-pressure control;
Thermostat anti/freeze;
Electric heater + safety thermostat;
Engine of the pump with heater;
Servo-motor of throttling valve;
Fan engine with heater;
Filter-pressure control;
MODULARIZATION IN SHIP EQUIPMENT
Opinion of modularization degree in existing naval constructions
Str.
20/50
3.7 Fuel booster block for main engine.
Fuel booster block it is planned space unit with each other joint elements, which are
installed on the common frame and fulfill important functions in fuel system on the ship.
The main task of fuel booster block is “exactly” cleaning heavy fuel by filters:
automatic and indicator. Heating up by electric or steam heater suitably viscosity of heavy
fuel is achieved. Heaters are controlled by viscometer. The fuel pumps press heavy fuel
through block installations and press suitably prepared heavy fuel to injection’s pump. Pump
work, automatic filter, viscometer and heaters are controlled by control set, which “collect
data” about work block from control-measurement armature. On the blocks there are installed
fuel consumption meters by engine. Pumps with filters are also installed for diesel oil fuel for
emergency generator set. Many factors influence on detailed solutions of preparation fuel
blocks: requirement of engine producer and devices included in composition of the block, the
shipyard and shipowner requirements and technological possibility realizations block or his
installation on ship. [15]
Pic. 21 illustrated preparation fuel block solution for main engine and generator sets.
Pic. 21 Simplified diagram of fuel booster block [15]
Heavy fuel for main engine and generator set is taken from daily service tank and is supplied
to the block by feed pump 1 with filter 6. Heavy fuel flow through flow-meter 9 and
automatic self-cleaning filter 7. Then it is passed to degasifying tank 3, in which is mixed
with heavy fuel return from main engine and from generating sets. Booster pumps 2 overpress heavy fuel to steam- 4 or electric-heater 5. In regarding to heavy fuel quality it can be
passed to homogenization module. The viscosity of heavy fuel after heaters is checked by
viscometer 11, which controls work of heaters 4, 5. Heavy fuel for generating set flows
through indicator filter 8 before feeding the injection's pump. Heavy fuel for main engine
directly feeds injection's pump. Devices and pipelines are heated up by steam, drips are
draining by dehydrator 10. There are on block installed control - measuring devices and
system steering block, which co-operates with engine control room . [15]
MODULARIZATION IN SHIP EQUIPMENT
Opinion of modularization degree in existing naval constructions
Pic. 22 The fuel booster block , during
tests at manufacturer [15]
Pic. 23 The fuel booster block installed
on the ship [15]
The most important elements of block equipment are:
- screw pumps initial and circulating;
- filters protection for pumps;
- automatic filter;
- indicator filter;
- viscometer;
- flow-meter;
- steam-heater, shell-tube heat exchanger or plate;
- electric heater;
- degassing tank;
- dehydrator;
- electric set steering of pumps work ;
- electric set of service automatics;
- electric set of service p electric power supply ;
- completely cabling;
- pressure control;
- manometers, thermometers;
- complete pipelines with fittings.
Str.
21/50
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Opinion of modularization degree in existing naval constructions
Str.
22/50
3.8 Fuel or lubricating oil separator block.
Fuel or lubricating oil separator block is spatial planned space unit joint each other
elements, which are installed on the common frame.
The task of the fuel or lubricating oil separator block is to achieve acceptable quality by
fuel or oil as a result of elimination unwanted constant impurities and suspended impurities in
separator process.
Pic. 24 ALFA LAVAL module from two separator blocks
[16]
Pic. 25 Separator set
WSK „KRAKÓW’’ S.A. [17]
The effective fuels and oils whirl requires assurances whirled factor of suitable temperature
and viscosity. It is done by the heater. Cleaned in separator medium leaves separator and it is
ready to use in shipping systems, during when separated water and slime are removed to slime
tank. Moreover using steering module in separator block guarantee controlling of the whirl
process.
Pic. 26 “Westfalia” Separator[18]
MODULARIZATION IN SHIP EQUIPMENT
Opinion of modularization degree in existing naval constructions
Str.
23/50
The separator block permit to compose all indispensable whirl components of system in one
place reducing demand on place or facilitating service. There is possibility to join in one
module several blocks of separators.
Pic. 27 ALFA LAVAL Separator block [16]
Equipment of separator block:
-
fuels/oils supply screw pump feeding cleaned medium through heater to separator;
oil/fuel heater - plate type;
three-way directing pneumatic valve moving not cleaned medium in dependence on
orders from steering module, to centrifuge or to tank / engine;
electromagnetic valve steering inflow of technical water;
the steering module together with control-measuring devices in order to control
separator process;
set of armature which is assembled with: control valve on outlet from the separator,
pneumatic stop valve closing outlet of clean oil;
common foundation frame with drip tray;
optional the sludge tank with transport sludge pump.
MODULARIZATION IN SHIP EQUIPMENT
Opinion of modularization degree in existing naval constructions
3.9
Str.
24/50
Lubricating oil block for main engine
Lubricating oil block for main engine it is spatial planned assembly mutually with all
together connected elements which are installed on common frame and fulfill defined
functions on the ship. The task of lubricating oil main engine block is suitable preparation
of main engine lubricating oil. Heat is taken from oil by the cooler, next oil is cleaned by
added filter and again pressed to the installation of main engine lubricating.
The lubricating oil block is made directly under requirement of main engine producer.
Its equipment (heat exchanger) co-operate with cooling water installation that’s reason of
different solutions of blocks (pic.28, 29).
Pic. 28 Lubricating oil block with pumps for main engine[19]
Pic. 29 Lubricating oil block for main engine[19]
This type of blocks are very often made acc. to shipyard, shipowner or engine producer
requirements.
Installed on common foundamental frame the example - equipment of block it is
following: plate cooler or jacket-pipe cooler, oil filter – accurate, multi-chamber, screw pump
and protect filter pump, control-steering assembly, thermostatical three-way valves, set
pipelines with fittings, cabling.
MODULARIZATION IN SHIP EQUIPMENT
Opinion of modularization degree in existing naval constructions
3.10
Str.
25/50
Turbocharger lubricating oil block for main engine.
Turbocharger lubricating oil block for main engine it is spatial planned assembly
mutually with all together connected elements, which are installed on common frame and
fulfill defined functions on the ship.
The task of turbocharger lubricating oil block for main engine is cleaning, cooling and
feeding lubricating oil into turbocharger.
The turbocharger lubricating oil blocks for main engine are made directly under
requirement of main engine or/and turbocharger system.
The principle of block work is following; oil is sucked in by screw pump from oil tank
and flows to radiator where the heat is absorbed and further through filter where the
impurities are removed flows to turbocharger.
Pic. 30 Turbocharger lubricating oil block for main engine
with jacket-tube heat exchanger [20]
Pic. 31 Turbocharger lubricating oil block for main engine
with plate heat exchanger [19]
MODULARIZATION IN SHIP EQUIPMENT
Opinion of modularization degree in existing naval constructions
Str.
26/50
Turbocharger lubricating oil block for main engine can be made on separate frame founded
separately in engine room (Pic.30, 31) or directly joint with lubricating oil tank (Pic. 32)
Pic. 32 Turbocharger lubricating oil block for main engine mounted on the oil tank top [20]
Turbocharger lubricating oil block for main engine can be additionally equipped with
separate preliminary cleaning of lubricating oil system, which is assembled with: centrifugal
fine filter together with booster pump, set of pipelines with armature.
Example of lubricating oil block equipments is:
- screw pumps;
- jacket-tube cooler exchanger or plate cooler exchanger;
- multi-chambers filter;
- thermostatical three-way valves;
- set pipelines with fittings;
- overflow valve;
- cabling;
- control box;
MODULARIZATION IN SHIP EQUIPMENT
Opinion of modularization degree in existing naval constructions
3.11
Str.
27/50
Block of fuel burner for boiler.
Block of fuel burner for boiler it is spatial planned assembled mutually with all
together connected elements, which are installed on common frame and fulfill defined
functions on the ship.
The task of block of fuel burner for boiler is preliminary preparation of fuel. Fuel is
cleaned (by filters) and is heated up in heaters to obtain required fuel viscosity size before
apply to burner of the boiler. These blocks can be built in different level of equipment:
- block with heaters, the booster pumps and filters on the suck-side;
- block with booster pumps and filters on the suck-side.
Pic. 33 Block of fuel burner for boiler [20]
Fig. 34 Diagram of pumps block for auxiliary boiler supply [20]
-
The example - equipment of block built on common fundamental frame is following:
screw pumps;
net filter on the pump suction ;
jacket-tube heater exchanger or plate heater exchanger;
set pipelines with fittings;
completely cabling;
control box;
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Sanitary water hydrophore block .
Sanitary water hydrophore block it is spatial planned assembly mutually with all
together connected elements, which are installed on common frame and fulfill defined
functions on the ship.
The task of sanitary water hydrophore block is to deliver to the crew and passengers
sanitary water (warm, cold) and drinkable. Water is destined to secure personal hygiene for
crew and passengers and to fulfill vital and economic needs.
Pic. 35 Simplified diagram of hydrophore block of drinkable and sanitary water [20]
Working of hydrophore block is following:
Pumps press water to the hydrophore tank, which contain air. Air is compressed in reservoir
so long until pressure will grow up to maximum working pressure, then follows the
disconnection of work pump by pressure switch. Being under pressure water can be taken
with any point of the network. During taking the water, pressure in tank falls down and when
minimum value occurs it turns on pump and then tank is refilled.
The hot water for sanitary system is heated up by heaters unit.
Water is taken from hydrophore tank and through circulatory pump feeds water heater and
further to sanitary system of warm water. Destined to drink water is taken from hydrophore
tank and transferred through special filters and disinfection UV lamps system and further to
the system of drinking water. Work of all devices is supervised by control - inspection unit.
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Pic. 36 Hydrophore block of drinking and sanitary water with heater [20]
Hydrophore blocks very often are divided into two separated blocks, first - hydrophore to
service of sanitary cold and drinking water and second - sanitary warm water block.
Pic. 37 The hydrophore block for cold and warm
water [21]
Pic. 38 Circulation block of warm water [22]
The example - equipment of hydrophore block:
- centrifugal pumps;
- pressure tank;
- fittings, safety-valve, pressure valve;
- filter of drinking water, system of water disinfection ,
- hot water tank;
- steam-heater, electric heater of sanitary warm water;
- set pipelines with armature, cabling;
- control set .
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Sewage treatment plant block.
The sewage treatment plant block this is a spatial planned mutually unit with all
together connected elements, which are installed on the common frame.
The task of sewage treatment plant block is processing dirtied water in order to adjust
correct chemical and biological composition acc. to requirements of rules of sea protection
regulations against pollutions from the ships.
Pic. 39. represents the biological - chemical sewage treatment block of sanitary type LK
production “WARMIA” Grudziądz, (present WARMANOVUM).
Pic. 39 Sewage treatment block [22]
The sewage treatment block is made as a tank divided on four chambers:
pre-chamber, aeration chamber, sedimentation chamber and chlorination chamber (Pic 40).
Fecal sewages is directs to preliminary chamber 1 this chamber has capacity for 5-6 hours of
fresh sewages input. Sewages are directed to disintegrate grid 8, where every type solid
impurities are stopped. In chamber l in order to averaging, sewages are continuous mixing by
circulation pump 6. Flowing through grid 8 many times - solid impurities are fragmented .
Two level float sensors control sewages circulation in the chamber. Steered valve 17 on
branch pipeline is installed to remote control dosing, through this sewages are directed to
aeration chamber 2. Time relay dosing valve controls, which control uniformly batching,
during whole day, fresh sewages to biological processing chamber 2.
The whole content of airing chamber is submitted continuous oxygenate. Oxygen is
taken from air delivered by blower 5. The air is pressed through system 18 the fine-blister
airing. Machined by aeration chamber sewages flow to sedimentary chamber 3, where is
sedimentation settlings and clarifying liquid. The settling deposit is turned back from chamber
3 to chamber 2 through recirculation system 15. Collecting on surface chamber 3 surface
scum is also turned back to chamber 2. Driving medium of deposit recirculation is
compressed air. Cleaned and cleared liquid flows to chlorination chamber 4. To chlorination
chamber is delivered also: grey sewage, called also discard waters. Grey sewages come from
kitchen, laundry and bathrooms. Kitchen sewages before inlet to chlorinating chamber pass
through degreaser sedimentation..
To chlorination chamber disinfectant is delivered (e.g. hypochlorite sodium solution).
The float sensors controls level of liquid in chlorination chamber.[22,23]
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Pic. 40 The biology- chemical sewage treatment plants type LK – 50 WARMA [23]
Tags and the most important elements of sewage treatment
block:
1. Preliminary chamber
2. Aeration tank
3. Sedimentation chamber
4. Chlorination tank
5. Blowers
6. Circulating pump
7. Transport pump
8. Disintegrating grid
9. Raw sewage and sludge
10. Venting
11. Grey sewage inlet
12. Chlorinator
13. Emergency overflow
14. Pure water outlet
15. Sediment recirculation
16. Control systems
17. Dosing valve
18. Aeration system
Raw fecal
sewages
Sediment
Pure water
Grey sewage
Air
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Fire fighting blocks.
3.14.1 Fire fighting unit CO2.
Fire fighting unit CO2 system this is a spatial planned mutually unit with all together
connected elements, which are installed on common frame and fulfills important functions
in fire fighting - system on the ship.
The task of CO2 block is:
storage of extinguishing medium in proper conditions;
feed extinguishing installation during fire with extinguishing medium (CO2).
The most often used volumetric extinguishing installations applied to extinguish fire in engine
room on ship and vessels is CO2 installation. The CO2 installation can be made in two kinds:
bottle-type, called also high-pressure;
tank-type, called also low-pressure;
CO2 installation work throughout filling room with CO2 gas, what causes decreasing content
of oxygen in air below burning margin. Tank-type CO2 installations are used on ships where
there is no possibility to use very large quantity of CO2 bottles.
Fire fighting CO2 block consists:
pressure tank properly equipped and insulated;
two independent cooling devices, entirely automatic;
indispensable control-inspection armature enabling remote supervisor control
and adapted to remote emission of CO2 from tank.
Pic. 41 Fire fighting CO2 block [24]
The tank is made as a steel boiler drum with convex bottoms about welded construction.
From outside is isolated and covered with aluminum sheet or galvanized iron.
Inside the tank there are placed two evaporators of cooling devices. The tank is equipped with
safety-valves. Taking CO2 from tank to extinguishing installation is done through cut-off
valve steered by hand, placed directly on tank and remote controlled valve, placed on the
main CO2 pipeline.
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3.14.2 Fire fighting water fog unit
Fire fighting water fog unit this is a spatial planned mutually unit with all together
connected elements, which are installed on common frame and fulfill important functions in
fire fighting - system on the ship.
The task of fire fighting water fog unit is storing and feeding under high pressure
extinguishing medium to installation water mist system, during fire. Fresh water is used as a
medium.
Principle of operation of high-pressure water fog installation consist in production very
small water drops (0,1 mm) with high momentum, which absorb the energy of fire, cools
exhaust gas and hot air surrounding fire source, and makes impossible to inflow oxygen to
burning material [25], [26].
Typical installation consists with pump unit, water accumulator, feed pipelines,
sprinklers, distributor control and alarm installation. Pumped unit is supplied by two electric
or combustion engines, is placed outside protected room, one engine is treated as reserve. If
the electric engine is applied then it has to have the supply possibility with emergency source
of energy. In general installation works using fresh water with proper purity, stored in the
tank.
Pic. 42 Fire fighting water fog unit [27]
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Refrigerating compressor block with condenser.
Refrigerating compressor block with condenser this is a spatial planned mutually unit with
all together connected elements, which are installed on common frame and fulfill important
functions on the ship.
The task of refrigerating compressor is to service cooling systems on the ship. Block feeds
cooling medium to cooling devices and it receives steams of cooling medium, liquidates its
and feeds to cooling devices again.
Pic. 43 Refrigerating compressor block [36]
Pic. 44 Refrigerating compressor block [21]
Following devices are assembled in composition block in general:
- refrigerating compressor piston type driven by electric engine;
- jacket-and-tube condenser;
- liquid refrigerant tank;
- liquid separator with loading valve;
- pipelines with fittings;
- control-measurement devices;
- control panel..
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Air compressor block.
Air compressor block with condenser this is a spatial planned mutually unit with all
together connected elements, which are installed on common frame and fulfill important
functions on the ship.
The task of compressor block is supply compressed air to:
- starting on main engine and generating set;
- control of automatics;
- drive of devices;
- air scavenge valve, systems, etc.
We distinguish: starting air compressors blocks and service air compressors blocks. There
is often used to connect blocks both the delivering starting air to combustion engines and
to service of shipping systems. Compressors sets are applied also, where compressor is
installed above tank on compressed air and blocks where compressors and tanks with
compressed air are installed on common frame.
Pic. 45 Air starting compressors block.[37]
Generally composition compressor air block is assembled with:
- compressor air tank equipped with armature;
- piston type compressed-air compressor, electrically driven;
- pipeline unit with fittings;
- automatic dehydration compressor;
- liquid separator/filter compressed-air for automatic;
- control panel with starter;
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Module equipment of RoRo and RoPax type ships.
Analyzing up to now achievements in range of the modularization engines room in
Poland and over the world. CTO S. A. made an attempt to elaborate module equipment in
engine room on ships RoRo and RoPax type. It is further evolutionary development at present
applied idea of block equipment engine room.
As distinction from solutions of Thyssen Nordseewerke shipyard, where is applied module
solution of engine room spatial system based on many-tiered module frames to build engine
room in vertical, for ships with traditional high decks.
Described in American specification patent - No. 5.299.520[28] and No. 5.899.161 [29] and
also in chapter 5.3.
In this solution is accepted, that equipment engine room is basing on module frames
which width is not above the allowed width of land road vehicle semi-trailer, while the length
of individual module frame is length multiple by length of the smallest one, where every
module frames are beard with not less that by four support columns. The module frame is
rectangular, and its support columns have equal height [30].
Pic. 46 Module frame [30], [4]
Introduced on Pic. 46 module frame M1 is built from rectangular section and has B
width approximately equal to standard width of semi-trailer land saddle vehicle and length L,
which is multiplication length of the smallest frame module M0 accepted to built engine room
shipping of concrete ship. Frame module M1 is strengthen inside by ribbing C adjusted to
building, destined for it shape functional equipment. Frame module M1 has four support
columns with H height made with rectangular section and supplied in foods-collars with
adapted to installing holes in foundation of naval engine [30].
The module frames are provided to install on its devices included in installation
located in ship engine room. Devices are installed on module frames with pipelines, cable
lines, controls and fittings. Finished functional blocks, e.g. fuel preparation blocks, separator
blocks are able to install them in module frames. In this way in assemblies-frames it is
possible to install considerably more equipments in comparison to engine room where
functional blocks are installed only. Both on frames and among them it is possible to install
the gratings of engine room floor. Height of support column it is possible to choose so, that
free space under frame could be used to install pipelines.
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Pic. 47 Examples of built-up module frames. [4]
Introduced on pic. 48 and 49 schematic arrangement of module frames represents optimum
method of utilization the half space of engine room, assigned by symmetry plane. The
optimum utilization space of engine room is obtained by using module frames M0, M1, M2
M3, M4 and M5 with different lengths. Depending on configuration of naval engine room
space, situated in vicinity of the ship side frames M0 and M2 have some carrying columns
with smaller height that remaining, and this is affected by configuration of engine room
foundation [30].
Pic. 48 Ideological diagram of modules
frames arrangement. [30]
Pic. 49 Example of modules frame arrangement [4]
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Various blocks
The above represented blocks these are blocks with various degree of complication,
overall dimensions and functions, what fulfill on the ship. The quantity of the blocks applied
in engine room depend on many factors; ships type, technological and transporting
possibilities of shipyards, possibility of blocks realization or their purchase. In effect of what
many different blocks is applied to equip engine room. Introduced above blocks do not
describe all that are used and are possible to apply to equip ship or engine room.
Large group of block make up the individual devices installed on frame together with
pipelines set, armature and with control unit. In many cases to make such block decides ship
or engine room type, the specific equipments are applied in engine room, the shipowner's
requirements, etc.
Below there are introduced the examples of units which are included in composition of
this blocks type:
- screw booster fuel pumps to separators;
- screw booster lubricating oil pumps to separators;
- centrifugal pump of sea water service the main engine or generating sets;
- water coolers of main engine or generating set cooling water;
- lubricating oil and cooling filters ;
- anti-fire sea water impeller pumps;
- cargo pump;
- air compressor and air compressor tank;
- evaporators;
- hot well with coolers;
- oil separator of bilge water;
- condensers;
- etc.
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4. The opinion of modularization /equipping block degree applied in the Polish
shipyards.
Block designing, building and equipping ships in Polish shipyard’s is used from half of
the 60th last age. The experiences of individual shipyards are different, what is result of
technologies and transporting possibility, which shipyards has. Shipyard specialization with
building concrete types of ships and strong competition in last years on the building ships
market exert an influence on technologies of block building and equipping ships and its
further development in the Polish shipyards. Analyzing experiences and applied solutions
related to hulk, it is possible to affirm that the level of blocks usage during building of hull is
high. The ships hulls are built from large hulled blocks, which sizes are limited by overhead
crane and shipbuilding cranes possibility only.
The equipment degree of some hulled blocks is high both in pipelines, armature and large
devices or smaller blocks.
The most often it concern of funnel blocks and superstructure which is entirely equipped very
often. It has forms and all installations so, after installing on ship they do not require any
more equipment work. The block equipment of engine room after achieve certain level
become slowing down in its development. The solutions which appeared in last period were
adjusted to shipyard requirements, or vendors of blocks, idea which was worked out and
initiated in beginning of seventieth.
The applied to equipment engine room generally blocks do not cover in potential the whole fit
areas to modularization. This is area for new ideas of modularization solutions in building and
equipment of the ships.
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5. Modularization in world solutions
The part relating modularization in world solutions is limited to applied solutions in
Scandinavian and North Europe shipyards. Study was prepared with support on information
from professional literature, seminars, press information, and web pages of shipyards and
naval equipment manufacturers.
The analyzing of collected materials in area of applying the modules and equipping the
ship during building it can be said that applied solutions in Poland, and in countries of North
Europe are similar. That's why the author in relating solutions part applied in Scandinavian
and North Europe shipyards decided to show the most characteristic and innovative solutions.
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5.1 Module building of the ship
Analyzing of collected materials in area of applying the modules and equipping the ship
during building it can be said that applied solutions in Poland, and in countries of North
Europe are similar.
The hull ship block building with large hulled blocks is applied. These blocks are
equipped in devices, pipelines, fittings etc.
Fig. 50 Hull blocks [31]
The transport ships possibilities, technology applied during building and deformation of
construction block during transport possibility influence on size and level of blocks
equipment.
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5.2 Module building and equipping of war-ships
Different variety of modularization in shipbuilding is applying the special equipment
modules on the war-ships.
5.2.1 Flex standard
The conception of multi-purpose vessel the Standard Flex was worked out in Denmark in
80th - and to half of 90th - 14 units of type SF –300 were built.
There were assumption that the vessel with replaceable modules of armament and
special equipment has possibility, in dependence, to hold many function. By standards the
ships of SF -300 type are used to support or patrol, in dependence on situation can be rearmed
to anti-mine vessel, minelayer, combat ship, etc.
Such ship has suitable pockets inside hull to fix containers with different type of
special equipment. These pockets have standardized size: length 3,5m x width 3.0 m x height
2m.. Containers have double point connecting system with ship installations, so why module
after assembly is connected to all indispensable subsystem automatically (powered,
communication, control, water or different indispensable mediums to work of this module).
Pic. 51 Cannon module [33]
Pic. 52 Conception of module equipment [32]
Arrangement diagram of special modules on Standard Flex 300 type ship [32]:
1 – cannon 76mm OTO Breda Super Rapido;
2 – containers with Harpoon missiles;
3 – torpedo launcher FFV Type 613;
4 – containers with anti-craft missiles Sea Sparrow;
5 – towing sonar Thompson-Sintra TSM 2640 Salomon;
6 – semi-rigidly survey boat;
7 – anti-mine underwater vehicle Double Eagle.
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5.2.2 MEKO
Conception of MEKO based on applying modules both during building and later
during exploitation of the ship. Ship has sockets with standard dimensions, which can be used
to install modules with armament or special equipment. Ship is built from large hull blocks
which are assembly in sections. The equipment of ship is in module also. There are generalvessel modules like propulsion ( yellow color on pic. 53), power supply (electricity) or airconditioning modules. The superstructures elements or masts (green color on pic. 53), where
special or electronic equipment are installed ( blue color on pic. 53) are treated as separate
modules also. That solution makes easier future modernization of ship and replacement of
damaged equipments.
Pic. 53 Modules according to technology MEKO [34]
Ship has sockets which can be used to install modules with armament or special equipment.
(red color on pic. 53). The high efficient is guaranteed by good specially designed system of
control over the ship and operational system adapted to work with different configurations of
armament systems.
Pic. 54 The different armament type, which is possible to install in sockets [34]
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Container ships - module construction of the engine room.
In the shipyard Thyssen Nordseewerke it was found that big possibility to lower the cost
amount is hidden in engine room, because items (materials) and resources cost to building is
almost the half of building costs of whole ship.
The module engine room was used in the shipyard Thyssen Nordseewerke on thirteen
container ships of average size (1500-1700 TEU) built in years1991-1996. [35]
In result of module building applied by shipyard Thyssen Nordseewerke the engine room
of container ship consisted with two large modules only {starboard and port side), main
engine and three smaller modules being between the engine and front bulkhead of engine
room. Assembling these modules is provided in engine room ship standing on the slipway.
Pic. 55 Free spaces between modules and main engine was marked as "B ”.
This space is designed on tanks, cofferdam, magazines, repair station etc. [35]
The most important assembly were grouped in two large modules (starboard and port side)
with dimensions 12m x 6m x 6m. Every one consists of frame construction which has
screwed (or weld on) individual units together with wires and pipelines. Some units, for
example air compressor set or generator set, are still equipped in after installing on ship.
Units installed in both large modules are part of 60% whole equipment engine room. Every
large module consists of eight smaller modules with dimensions 3m x 3m x 6 m assembled
(fig. 56), equipped and checked in hall of assembly engine room. Every these smaller
modules divide into two parts: upper and bottom. Upper which has 2 m height, thanks to this
average growth worker is able to execute 95% all actions without difficulty; bottom part has
80cm height and cables, pipelines and different elements are inside.
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Pic. 56 Module frame [35]
All engine room modules are assembled with hull but they do not make up its integral part.
There is no inter-decks and pillars in engine room module as in traditional engine room
ensure its stiffness, but similar function fulfills side wide fuel tanks. Module engine room
resemble hold of container ship: like "containers” - modules and sets with machines and
devices are here.
Pic. 57 Adapted hull to assembly of modules [28]
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Like on the container ship, also in engine room module there are foundations and horizontal
modules brackets (Pic. 58). Because of shape of the ship stern the modules can not be
installed directly on inner bottom , they are assembled to foundations ( Pic. 59 ). Only vertical
load can be transfer by its in horizontal plane modules are immobilized in transverse direction
by side tanks ship's, and in longitudinal direction by partial deck from stern and through front
bulkhead of engine room - to bow [35].
Pic. 58 Foundations of modules [35]
Pic. 60 Engine room section with modules installed in [35]
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6. The opinion of modularization/equipment block degree applied in the North
Europe shipyards.
Based on owned materials it is possible to generally affirm that modularization is applied
in European shipbuilding universally.
The degree of applying during building from modules is high. It concern both the hull
blocks and engine room area.
The North Europe shipyards use large hull blocks which are used to build a ship on slipway or
in dry dock. Equipment blocks, funnel blocks and superstructure blocks are also universally
applied which are equipped with devices, pipelines and fittings.
On special attention deserves technology connected with modules and equipment of war
ships. This makes possible not only quick building of ship, but later in exploitation - makes
quicker repairs or modernizations and rearming ship.
The applied technology of module engine room equipping bases on modules equipment
set. Standard modules are applied, which shipyard can buy and the modules that shipyard
makes by itself. There is an interesting solution of total engine room equipping with modules,
which was worked out in Thyssen Nordseewerke Shipyard. It makes possible to almost total
equip engine room ship in the assembly–halls and then transport and install it in hull ship.
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Summary
After analyzing the materials of relating solutions applied in Polish and north Europe
shipyards it is possible to affirm, that ideas and applied technologies are very similar. This
result from fact of co-operation in shipping industry area between individual countries and
from using by shipyards the same supplier to deliver devices and modules.
The degree of modules used during building ship and equipping is high. Complicated,
full of devices modules are applied, which fulfill important functions on the ship. Also
considerably less complicated modules are used.
Generally there is tendency to use as frequent as possible in ship building - big, richly
equipped, modules. Common feature for all modules is, that they can be made by specialized
producers outside the shipyard area.
In case of some modules assembled in ship engine room e.g. fuel booster block,
shipyards buy ready modules only. Therefore the more and more important meanings has cooperation between shipyards and between co-operating firms, because these firms make more
and more "ships part”.
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Literature
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2002
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[20] VN Pumpen GmbH %Co.KG Katalog, materiały reklamowe,
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[25] BOHDAN WOJAKIEWICZ Instalacje tryskaczowe zraszaczowe i mgłowe.
Biuletyn Informacyjny PRS S.A. 3/1997.
[26] SŁAWOMIR AFFEK Wysokociśnieniowe instalacje gaśnicze na mgłę wodną.
Biuletyn Informacyjny PRS S.A. 6/1997.
[27] ULTRAFOG AB Katalog, materiały reklamowe http://www.ultrafog.se
MODULARIZATION IN SHIP EQUIPMENT
Opinion of modularization degree in existing naval constructions
Str.
50/50
[28] Thyssen Nordseewerke GmbH Ship, in particular merchant ship.
United States Patent No. 5,299,520 Apr.5, 1994
[29] Thyssen Nordseewerke GmbH. Ship with plane are elements which extend horizontally
and are located in the hull of the ship. United States Patent No. 5,899,161 May 4, 1999
[30] H.BRYL, K.GOCKOWSKI, T. KOCIŃSKI; Centrum Techniki Okrętowej „Modułowe
wyposażenie siłowni okrętowej, szczególnie statków typu Ro-Ro lub Ro-Pax” Wzór
zastrzeżony Urząd Patentowy RP 2003.
[31] Materiały różne, materiały reklamowe stoczni:
http://shipbuilding.ru/eng/companies/bss/
http://www.btinternet.com/~warship/Today/albion.htm
http://www.engin.umich.edu/class/na276/ppt/shipbuilding_practice.pdf
[32] M.DURA, J.WALCZAK; Inne czasy inne okręty. Nowa Technika Wojskowa 9/1993
[33] W.ZAWADZKI; Duńskie wielozadaniowe. Nowa Technika Wojskowa 3/2003
[34] Blohm+Voss GmbH Katalog, materiały reklamowe, www.blohmvoss.de
[35] RALF BAADE, FREDRICH KLINGE, KEVIN LYNAUGH, KLAUS-MICHAEL
SEIDLER; Modular Outfitting. Thyssen Nordseewerke GMBH. Journal of Ship Production
8/1998
[36] SABROE Katalog, materiały reklamowe http://www.sabroeproducts.nl/
[37] ATLAS COPO Katalog, materiały reklamowe http://www.atlascopco.com