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Colombo Dockyard PLC provides industrial training where trainees gain experience in various workshops like machinery outfitting, engine fitting, hull construction, and more. Trainees learn skills like pipe fitting, welding techniques, machining operations, and motor rewiring. The training also provides exposure to quality control processes, waste management techniques, and human resource practices at Colombo Dockyard. The training overall provided hands-on experience in ship repair activities and familiarized the trainee with engineering operations, maintenance, safety practices, and teamwork.
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- 1. INDUSTRIAL TRAINING AT COLOMBODOCKYARD PLC Ranwala P.C.J RU/E/2010/142 Department of Mechanical and Manufacturing Engineering
- 2. PRESENTATION OUTLINE Introductionabout Colombo dockyard PLC. History , Present status, Main services Training Experiences workshops details, involved works Management techniques Waste management, Human resource management Conclusions
- 3. Introduction to ColomboDockyard PLC It was Established in 1974. located within the port of Colombo, the hub of all major shipping lanes connecting the west, the Middle East, the Far east, as well as Africa and Australia. Main services are, Ship Repairing Ship Building Heavy engineering Offshore engineering contributing 1.2% of Sri Lanka’s total export earnings Figure No: 01
- 4. Training Experiences, Training Center Safety •High probability to happen an accident. • Safety overall, safety helmet, safety belt, and a pair of safety shoes are Provided to every employers and trainees. Machinery Out Fitting Shop Fabrication and Installation of Pipe Lines. • Pipe Lines Joint, Pipe Bending, Flanges. Pipe Line Color Code Pipe Line Welding • Shielded Metal Arc Welding (SMAW) • Tungsten Inert Gas Welding (TIG) • Metal Inert Gas Welding (MIG)
- 5. Tungsten Inert GasWelding • The arc is formed using non-consumable tungsten electrode. • Filler rod add as reinforcement layer. • Shielded by inert gas (Argon, Helium) • Clean weld is obtain but generally slower and more expensive. Metal Inert Gas Welding • Metal wire electrode is automatically fed through the torch. • Shielded by Argon gas. • Eliminate slag removal. • Advantage of Higher deposition rates. Figure No: 02 MIG Welding
- 6. Engine Fitting Workshop Repairingof Storm valve, turbochargers, Heat Exchangers, pump and piston rods. • Storm valve Swing-check valve with closing device. There are vertical type, horizontal type and angle type valves. Used in sanitary piping system of ships. Figure No: 03 Storm Valve
- 7. • Turbochargers Critical clearance(K) Impeller clearance (L) Disc clearance(M) Figure No: 04 Figure No: 05
- 8. Hull Construction Shop Responsiblefor all the hull works regarding construction of new ships Plate cutting, bending, rolling, welding. CNC Plasma cutting machine. O2 is pressurized and blown at high speed, at the same time electrical arc is formed turning some of that gas to plasma. The plasma is sufficiently hot to melt the metal and cut. Figure No: 06 Plasma cutting
- 9. Roller bending machine Usefor rolling plate into semi circular, cylindrical shape or cone. Flux-Cored Arc Welding (FCAW) Electrode is a continuous consumable tubing that contains flux core. 1) Self-shielded FCAW 2) Gas shielded FCAW Shielded gas is CO2 Figure No: 08 Figure No: 07
- 10. Various types ofmachines Lathe machine/Milling machine/Boring machine/Grinding machine/Drilling machine….etc Manufacturing of Brass Hose Valve Manufacturing a suspended plumb Bore a anchor pin Machine Shop Figure No: 09 Simple drawing of hose valve Figure No: 10 suspended plumb
- 11. Plant Shop Repairsand maintenance of plant equipment. Airless Spray Painting Machine Used to spray hull protective coatings and painting It Consist with, 1) Air motor 2) Sprayer pump • Reciprocating pump with two ball checks. Faults • Blocked filters • Damaged displacement rod • worn-out seals Figure No: 11 Sprayer pump
- 12. Electrical Workshop Electricalrepairs, modifications and troubleshooting Three Phase Induction Motor • consists of a rotor and a stator • common in ships as its low maintenance rate. Rewinding of motor Figure No: 12 Motor rewinding
- 13. Calibration Section Allthe calibration work of ship repair and ship building • Record of bearing load test Dial gauge, filler gauges and hydraulic jack • Record of main engine crank shaft deflection Deflection gauge • Record of calibration of chrome liner Out side micrometer screw gauge . Figure No: 13 Bearing load test
- 14. Quality Control Department •Maintain the quality of the out puts of the company up to the standard levels. Non destructive testing Visual inspection-VT Dye Penetrant –PT Ultrasonic Testing –UT Magnetic Particle -MT Radiography Testing –RT Figure No: 14 Material for dye penetrant test
- 15. Management Techniques HumanResource Management • Development oriented performance evaluating system. • Improve team spirit, more effective, productive and efficient in work. • Best employees are honored with annual awards. Waste Management -Approximately 14,000 tons of different types of waste generated. -Waste oil and oily sludge are re-used as alternate energy in cement industry. - Monthly Yard Cleaning Day
- 16. Conclusions Worked indifferent workshops as well as in ships. • Experience about repairing of valve, turbochargers, coolers. • practiced machining operations of lathe machine, milling machine • familiarize with the welding process, modern plate cutting & rolling technologies. • Some knowledge about motors and rewinding , NDT methods, measuring instrument, calibration techniques etc. I was able deal with Engineers ,foremen, supervisors, and laborers understand their problems, attitudes , strength performance and team work.
Editor's Notes
- #3 collaboration was made with Onomichi Dockyard Co. Ltd of Japan in 1993. Consist of 4 dry drock ,capacity of two 8000 DWT and 30000 DWT recently build 125000 DWT dry dock . Company has been concentrating more on building new ships to the international market since 2003. Now it reputed in building high quality ships that meet stipulated international standards within a shorter time period Sri Lanka as one of the largest export earners for the country, contributing an impressive 1.2% of Sri Lanka’s total export earnings
- #4 Consist of 4 dry drock ,one for ship building and others for ship repair. Company has been concentrating more on building new ships to the international market since 2003. Sri Lanka as one of the largest export earners for the country, contributing 1.2% of Sri Lanka’s total export earnings
- #6 (Tig) Heat of the arc create a pool of molten metal and a filler rod is applied to the pool as reinforcement layer that is used to fuse the two pieces of metal together. stainless steel and non-ferrous metals such as aluminum, magnesium, and copper alloys (MIG) No filler rod is used as in the case of TIG .No flux in the coil Normally metal wire electrode is contacted to the positive pole of the power source, and the work piece to the negative pole
- #7 High risky valves because they are open to the ship side exits. applied Belzona to construct the edges
- #8 It consists of a compressor wheel and exhaust gas turbine wheel coupled together by a solid shaft. Used to boost the intake air pressure of the engine by extracting energy from the exhaust gas and using it to drive the compressor wheel. Dismantling of turbocharger should always be started from the compressor side. Critical clearance (K) distance between the compressor end cover mounting face and shaft end Impeller clearance (L) Pull the rotor shaft towards the compressor until the impeller comes in contact with the insert and determine K2 , Impeller clearance L = K - K2 Disc clearance(M) Thrust the rotor shaft towards the turbine side until the turbine disc and nozzle ring comes in contact with each other and measure K1, Disc clearance M = K1 – K
- #9 Optical plate cutting Pug machine CNC plasma most accurate and effective cutting machine
- #10 New three roller bending machine was installed. Its Upper roller is fixed and bottom two rollers are independently adjustable. Pre pinch both ends of plate 3. Rollers B and C move to a pyramid position in relation to roller A and the cylinder is rolled. FCAW to be developed, arc shielding was provided by a flux core, thus leading to the name self-shielded flux-cored arc welding .The core in this form of FCAW includes not only fluxes but also ingredients that generate shielding gases for protecting the arc. The second version of FCAW, developed primarily for welding steels, obtains arc shielding from externally supplied gases, similar to gas metal arc welding. This version is called gas-shielded flux-cored arc welding. Because it utilizes an electrode containing its own flux together with separate shielding gases, it might be considered a hybrid of SMAW and GMAW. Shielding gases typically employed are carbon dioxide for mild steels or mixtures of argon and carbon dioxide for stainless steels.
- #11 Wore the safety equipment such as goggle and dust mask. • Work piece (brass bar of 30mm in diameter) was clamped in the three jaw chuck. • Done the facing operation for the free end. • Measured 62 mm along the rod using venire caliper and scribed it to make it visible. • Done the straight turning operation to reduce the diameter up to 26mm till the scribed mark in two stages. • Hereafter done the drilling operation using 12mm drill bit. Note:- When rotate a one fully round Hand wheel in tailstock, dead center goes 5mm.That hand wheel mark 200 parts.so, when pass 40 parts of the scale dead center goes 1mm. • Then scribed 32mm from the free end of the rod and marked four equal divisions. • Then done four taper turning operation of angle 5 0 in each division. • Using a form tool separated the hose valve from the rod. • Manufactured 10 hose valves according to the above procedure
- #12 The rod moves up and down with the action of the air motor. Fluid is loaded on the upstroke and displaced on both the upstroke and down stroke. Displacing fluid on both the up and down strokes ensures an even flow of fluid to the hose and gun. Filter may be blocked due to the paint solidifies inside. • Sleeve and the sleeve housing may be damaged. • The system is not sealed well due to worn-out O-rings, leather rings and the Teflon seals. • If there is damage in the displacement rod the system is not sealed well. • The ball at the valve may not seat properly due do some damages, then the leakages can be happened. • Balls at the ball valves may have been damaged and that may cause for the leakages.
- #13 The stator consists of a number of overlapping windings offset by an electrical angle of 120° stator is connected to a three phase alternating current supply, it establishes a rotating magnetic field which rotates at a synchronous speed it induces a voltage in rotor and in return the current as rotor is short circuited at the end . So there is a current flow in a magnetic field . Fleming’s left hand rule force is generated and the rotor is rotated. Separated the stator and part. • Winding diagram was drawn. Sample winding diagram shown in Fig No: 2.42. Fig No: 2.40-Winding diagram 45 • Counted the number of slots, coil set, slot pitch and turns of each coil. 1. slots =18 2. Coil set = single set -3 / double set -3 3. Slot pitch = 1-9(double set) , 1-8 (single set ) 4. Turns of a coil set =108 • Took copper wires and measured the diameter by using micrometer screw gauge. Diameter was 0.52mm.Therefore by using standard wire gauge chart corresponding gauge no of wires was 24.5. • Removed all existing windings of the stator and send to cleaning room for cleaning process. • Cleaned stator was kept in the oven; it should have to bake first 2 hours in 95 0 Celsius temperature and another 6 or eight hours in 125 0 Celsius temperature. • After the baking oven procedure, sprayed anti-corrosive paint for stator. • Brought it into winding room and insulation papers were put in side the slots. • Wound up the coils by using winding machine and placed it considering the slot pitch. • Labeled winding coils (A1 ,A2 / B1,B2 /C1 ,C2) and connect A1 Finishing(f) to A2 coil finishing(f) and so on. (According to the drown wiring diagram Fig No:2.42) • Finally star connection was established
- #16 recognizes employees who perform well and who are committed to the organization. such Best Employee of each Division, Best Safety Inspector, Best Division/Department, Best Employee Suggestions