INDUSTRIAL TRAINING AT

COLOMBO DOCKYARD PLC

Ranwala P.C.J RU/E/2010/142

Department of Mechanical and Manufacturing Engineering

PRESENTATION OUTLINE Introduction about Colombo dockyard PLC. History , Present status, Main services

Training Experiences workshops details, involved works

Management techniques Waste management, Human resource management

Conclusions

Introduction to Colombo Dockyard 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

Training Experiences,

Training CenterSafety • 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 ShopFabrication and Installation of Pipe Lines.• Pipe Lines Joint, Pipe Bending, Flanges.

Pipe Line Color CodePipe Line Welding• Shielded Metal Arc Welding (SMAW)• Tungsten Inert Gas Welding (TIG)• Metal Inert Gas Welding (MIG)

Tungsten Inert Gas Welding• 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

Engine Fitting Workshop

Repairing of 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

• Turbochargers

Critical clearance (K) Impeller clearance (L)Disc clearance(M)

Figure No: 04

Figure No: 05

Hull Construction ShopResponsible for 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

Roller bending machineUse for 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 FCAW2) Gas shielded FCAW Shielded gas is CO2

Figure No: 08

Figure No: 07

Various types of machines Lathe machine/Milling machine/Boring machine/Grinding machine/Drilling machine….etc

Manufacturing of Brass Hose Valve Manufacturing a suspended plumbBore a anchor pin

Machine Shop

Figure No: 09 Simple drawing of hose valve

Figure No: 10 suspended plumb

Plant Shop Repairs and 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

Electrical Workshop Electrical repairs, 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

Calibration Section All the 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

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

Management Techniques

Human Resource 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

Conclusions

Worked in different 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.

THANK YOU