bluuebunny/crossref_metadata_2025 huggingface dataset:
Wired for Disaster: Cableway Improvement Program
Authors: Hendricks Verle , Pokrywka Jim , Creek Cliff
Published: January 2021

Throughout a ship's life cycle, as systems are installed, modified, or removed, breaches of the technical requirements for proper installation of electrical and electronic cables occur. The majority of these deviations are a result of insufficient attention to cable installation requirements during ship design or production caused by shortcuts to reduce costs or meet schedules, and overall poor workmanship. In January 1984 on the USS Tattnall (DDG-19) a fire originating in a locked compartment spread through electrical cableways. Before being contained, this fire caused loss of life, extensive damage to critical systems and prevented the ship from completing her assigned mission. An investigation revealed that the fire started as a result of cableway discrepancies. Further surveys performed on various ships revealed findings which included: the cableway discrepancies found on the Tattnall were not isolated, but common to the fleet in great numbers, and 15% to 20% of all dead-ended cables were found to be still electrically energized. To develop a systematic and trackable method of removing cableway discrepancies and reduce the risk of fire, Commander Naval Air Force, Atlantic Fleet (COMNAVAIRLANT) tasked American Systems Engineering Corporation (AmSEC) and Naval Sea Systems Command Detachment (NAVSEADET) (PERA CV) to develop a program to assist in correcting cableway discrepancies in aircraft carriers. The program has since displayed great success evidenced by Navy-wide attention and expansion of the program to include aircraft carriers under Commander Naval Air Force, Pacific Fleet (COMNAVAIRPAC).
Thermal Reclamation of Used Blast Grit
Authors: Sandstrom William A. , Patel Jitendra G.
Published: January 2021

Naval and private shipyards generate thousands of tons of used blast grit annually and dispose of it in landfills. Also, thousands of steel bridges in the United States are on a repaint maintenance schedule that requires grit blasting for surface preparation; this used grit also goes to landfills. However, for environmental reasons it is becoming prohibitively expensive to landfill used blast grit containing paint residues. The Institute of Gas Technology (IGT) has conducted test work to develop a process to clean used blast grit for reuse. Four reclaimer feasibility tests were conducted with used blast grit from the Long Beach Naval Shipyard. The results of these tests revealed that the organic material component of the used grit was fully oxidized to carbon dioxide and water. Some of the metallic oxides of copper, zinc, titanium, and lead from the used grit were largely elutriated into a cyclonic collector. The calcined (reclaimable) fraction from this test work amounted to approximately 95 percent of the used grit charged. Major oxide and organic component analyses revealed no significant general chemical difference between the virgin and reclaimed grit.
Applying Group Technology (GT) to Increase Productivity in a Job-Shop Environment
Authors: Davison Dennis
Published: January 2021

Decreasing the high cost of small lot production in a job-shop environment is a continual problem for shipyard shops supporting extensive repair and overhaul work. In the past, reducing cost in this area has been a desirable but mostly unattainable goal. However, continued development of computer solutions to manufacturing problems utilizing Group Technology methods has made possible significant savings in this area.
Designing Partial-Penetration Tee Joints for Naval Ships
Authors: Gaines Edward T.
Published: January 2021

This paper reviews development of weld design equations which can be used to analyze bevel partial-penetration tee joints. The method developed herein follows closely the development of equations for the design of square-edge partial-penetration tee joints which was presented at the 1986 Ship Production Symposium. For U.S. Navy ship design, technical authority is vested in the Naval Sea Systems Command (NAVSEA). The published NAVSEA design criteria for partial-penetration tee joints are so conservative that it is mathematically impossible to design a conventional, 100 percent efficient partial-penetration bevel tee joint. With a more rigorous engineering analysis, the alternative method for bevel joints outlined in this paper might be an acceptable replacement for the simple, though unduly conservative existing design criteria.
The National Shipbuilding Research Program: An Overview and Status Report
Authors: Schaffran Robert
Published: January 2021

The National Shipbuilding Research Program (NSRP) was formed in 1971 under the U.S. Maritime Administration (MarAd) as a collaboration with the shipbuilding industry to improve the productivity and international competitiveness of U.S. shipyards. Since 1982, the U.S. Navy has been increasing its participation in and support of the NSRP. This year marks the transition of NSRP management responsibility from MarAd to the Navy. Under Navy management, the NSRP is now organized into a voluntary Industry/Government Planning section, a Navy NSRP Program Management and Administration sections, and a contractually based Industry Execution and Implementation section.
Hazardous-Waste Minimization in the Naval Shipyards
Authors: Duvall David A.
Published: January 2021

Regulations and other costly constraints affecting the handling and disposal of hazardous waste materials are becoming increasingly restrictive and costly. Hazardous waste has become one of the most critical problems facing our nation today. Fines and criminal charges against companies and individuals for noncompliance are increasing. Disposal sites are decreasing. Real costs can amount to 10 to 15 times the original purchase price for hazardous materials. Future prospects are that the problem will certainly grow worse. The naval shipyards have taken an aggressive approach to waste minimization. Using industrial-engineering techniques, the shipyards are implementing source reductions to reduce the quantities of hazardous generation as a by-product of their industrial processes. This paper discusses the problems associated with hazardous waste and describes a program to minimize the generation of this waste.
Productivity: How to Organize the Management and How to Manage the Organization
Authors: Chirillo L. D.
Published: January 2021

Thanks to an accident in timing, the National Shipbuilding Research Program (NSRP) facilitated access to an extraordinary organization before, during, and after the 1973 Oil Shock served notice that individual shipyards as well as entire shipbuilding industries had to be reformed. In Japan, the decade before was referred to as "The Golden Age of Shipbuilding." The reference was made not just because of the great and unprecedented peacetime shipbuilding market that had existed. It was also made to acknowledge the extremely effective management practices that evolved while building ship after ship without interruption from the late fifties through the early seventies. A more appropriate name is "The Golden Age of Shipyard Management Development." This paper reviews both the basic and condensed production organization of a Japanese shipyard, examines management accounting practices, and discusses the versatility and significance of a product work breakdown approach.
Producibility in U.S. Navy Ship Design
Authors: Hofmann Hans A. , Grant Raymond S. , Fung Siu
Published: January 2021

Recent NAVSEA studies of a twin-skeg hull form design applied to a T-AO type ship indicated many areas of possible improvement in producibility. This paper reviews the findings of producibility studies and attempts to indicate specific areas where an improvement in producibility and attendant cost savings for Navy ships are possible without any degradation in ship performance and survivability. Most available studies on producibility have an inherent trait of elaborating on details of shipyard producibility. This paper attempts to confine itself to the producibility aspect of the design phase, ending with the completion of contract design. It was determined that the concept of the producible, designed-to-build ship was worth further investigation for incorporation into future designs because of potential cost savings. The paper concludes with recommendations for a method of application of producibility to the Navy ship design process for MSC-operated T-ships.
Strategizing and Executing the Implementation and Utilization of Zone Technology at Philadelphia Naval Shipyard
Authors: Burrill Larry D. , Munro Barry S. , O'Hare Mark S. , Baba Koichi
Published: January 2021

The strategy in the development and implementation of zone technology at Philadelphia Naval Shipyard (PNS) is discussed. Frank disclosure of the valuable lessons learned and current status is also presented. Equally important is what the future has in store for zone technology at PNSY, which is also described. This paper provides a candid presentation of the experiences in the implementation of zone technology in a demanding repair environment.
A Systems Approach to Small Parts Painting
Authors: Hansen Les , Appleton William
Published: January 2021

Shipyard painting is most often viewed as pure ship construction operations, where the painting of the hull, deck, superstructure, and cargo spaces makes up the total effort and cost. This view may be justified when analyzing various trade production costs as parts of the total ship cost. However, parts preparation and painting costs are significant when looked at in summary as a new construction or repair contract sub-cost item. Once addressed, the historical means and methods for small parts painting in shipyards appears to leave much room for improvement. What happens, then when a systems approach is applied to shipyard small parts painting? Can study techniques, analysis, and design be adapted to facilitate painting systems which are cost effective for this industry? This paper attempts to answer these questions by presenting discussion of Manufacturing concepts of parts painting, Use of industrial engineering analysis, Systems configurations, and Systems cost and justification.
A Systematic Approach to Producibility and Lessons Learned for Naval Shipbuilding
Authors: Byrnes Richard , Marcus Henry S.
Published: January 2021

Producibility refers to lowering of acquisition costs of a system without degradation to system performance. The Navy has conducted many efforts in pursuit of improved ship producibility, but no systematic methodology or study format is currently implemented in Naval Sea Systems Command (NAVSEA). Two factors which suggest that a standard, systematic approach to ship producibility should be implemented are the large size of the NAVSEA design organization with its myriad of ship programs, and the requirement of access and manipulation of large volumes of digital data and process documentation. A "Producibility Framework" is offered which models producibility in the ship design and construction process as an iterative algorithm in which producibility concepts are identified, evaluated, incorporated into or rejected from the design, and examined to provide lessons learned and feedback. The framework is described using the DDG-51 Guided Missile Destroyer as the major illustrative case.
Design Through Manufacture: A Computer-Aided Design Advisor for the Manufacture of Submarine Hulls
Authors: West Harry , Gallo Michael
Published: January 2021

A computer graphics based advisory system has been developed to aid in the design and manufacture of submarine hulls. The design and manufacture advisor incorporates models of the materials (steel) and processes (bump forming, roll bending, welding, and fixturing) used for the manufacture of the hulls, and allows the user to explore the effect of different material qualities (described in terms of variances of thickness and yield strength), and different manufacturing parameters (punch penetration, punch spacing, and number of fixtures, for example) on the resulting quality (circularity) of the hull section. By "designing through manufacture" in this way the resulting design of the submarine hull section is not just a geometric representation of the desired shape of the hull, but incorporates explicit information about the materials and processes used to create the shape, and of the quality that results from the designer's choice of materials and processes.
In Search of a Level Playing Field: The Shipbuilders Council of America and the Issue of Foreign Shipbuilding Subsidies
Authors: Stocker John J.
Published: January 2021

This paper discusses the origins of decision by the Shipbuilders Council of America to file a petition under Section 301 of the Trade Act of 1974 charging Japan, South Korea, West Germany and Norway with unfair trade practices in shipbuilding and ship repair. The progress of negotiations between the U.S. Trade Representative and foreign governments is presented, as are the actions of the Organization for Economic Cooperation and Development (OECD) to address the reduction of unfair subsidies. The paper provides insight into the future course of action of the U.S. Government as well as the Shipbuilders Council of America in their continuing effort to provide for the reentry of U.S. shipbuilders into the worldwide commercial shipbuilding and ship repair markets.
A Note on Total Quality Management: Building Quality or Bureaucracies?
Authors: Chirillo Louis D.
Published: January 2021

I recently read a paper about Total Quality Management (TQM). In seven pages of text the term "Total Quality Management" or the acronym "TQM" was repeated 152 times. In addition, the author employed repeated usage of the word "quality," by itself or in terms that border upon becoming cliches. Further, the paper described a dedicated infrastructure piled on a regular organization in the form of a special office and various committees. Barely afloat amid the promotion of TQM, per se, was the simple truth, "quality improvement comes from process improvement."
Task Definition as a Route to Effective Production of Modern Warships
Authors: Maccoy Dennis , Dobson David C.
Published: January 2021

Construction of a modern warship can occupy a period of more than three years, during which time more than three million man-hours may be expended, and it is necessary to control the acquisition, production and installation of some 250000 items of material and equipment. To execute the process effectively requires an efficient means of planning and control, and this paper describes the approach to that task adopted by a United Kingdom shipyard. The concepts of Build Strategy, Work Packaging, Materials Definition, Process Engineering and Labor Cost Control, as related to the shipyard's organization structure, are explored. The paper describes the establishment and operation of a system of planning and control based on task definition.
What Can Adhesives Offer to Shipbuilding?
Authors: Winkle I.E. , Cowling M. J. , Hashim S. A. , Smith E. M.
Published: January 2021

This paper presents an overview of recent research into the feasibility and advantages of using toughened structural adhesives to replace some conventional welding for primary structures in the shipbuilding and associated marine industries. The concept is explored through its application to the stiffener/ plate connections of thin-plated grillage structures where a number of advantages can be identified. These include the potential for elimination of thermal distortion and residual stress with little penalty in cost or weight. Data are becoming available on such longer-term problems as durability in the marine environment, high-temperature performance (including creep), fatigue and impact resistance. Research is continuing to improve understanding and increase confidence in application to large-scale structures. The paper concludes that the benefits to be gained from using adhesives to achieve novel structural configurations, possibly involving dissimilar materials, will provide continuing impetus to research and development in this area.
SEAWOLF Producibility II: Transition from Design to Production
Authors: Brucker B.R. , Baseler R.W.
Published: January 2021

SEAWOLF Producibility initiatives have been presented to past Ship Production Symposiums. The technical content of these papers was based on work accomplished during the SEAWOLF Detail Design effort and articulated the point of view that the SEAWOLF Producibility Program was an important step in advanced ship production. The lead ship of the SEAWOLF Class started construction in late 1989. The opportunity now exists to validate a number of the elements of the design for production. Electric Boat Division, as lead shipbuilder, has the opportunity to review a number of the specific initiatives, such as Digital Data Transfer, Sectional Construction Drawings, Planning and Sequence Documents, Computer Integration of information processing and the combination of SEAWOLF products that support improved work control. The method of approach is to describe the SEAWOLF producibility element developed during detail design and then assess the benefit to the shipbuilding process.
A Return to Merchant Ship Construction: The International Impact of the NSRP and American Technology
Authors: Sarabia Antonio , Gutierrez Rafael
Published: January 2021

In the mid-eighties, the state-owned shipbuilders of Spain were suffering from many typical shipyard problems, making them uncompetitive. After making a strong reentry in the commercial shipbuilding market, they engaged in a process of reorganization of the entire production system according to modern Japanese practice. The goal was to become competitive with the world's best. The know-how was acquired via cooperative agreements with leading Japanese shipbuilders as well as through the use of American consultants and National Shipbuilding Research Program (NSRP) related literature. A comprehensive technological improvement plan has been launched and the initial results are very promising.
Zone Technology Implementation at Philadelphia Naval Shipyard—Phase III
Authors: Petersen-Overton M. D.
Published: January 2021

Phase I implementation of zone technology at the Philadelphia Naval Shipyard (PNSY) began with the planning of the Service Life Extension Program (SLEP) of the USS Kitty Hawk (CV-63) in 1986 with the assistance of Japanese engineers from Ishikawajima-Harima Heavy Industries Co., Ltd. (IHI). Phase II of zone technology implementation included the continuing work on the USS Kitty Hawk, extensive planning efforts for the USS Constellation (CV-64) SLEP, and the execution of a number of smaller availabilities. Phase III of zone technology consists of the completion of the Kitty Hawk SLEP, the final planning and commencement of the Constellation SLEP utilizing 100 percent zone technology, and the planning and execution of all future availabilities utilizing the concepts of zone technology. Significant lessons learned from prior availabilities, particularly the Kitty Hawk, have been identified and implemented on the Constellation SLEP. Encouraging results from smaller availabilities are presented. Initial comparisons between the Kitty Hawk and the Constellation SLEP work performance in cost and schedule are reviewed.
Photogrammetry: Shipcheck of USS Constellation (CV 64) Arresting Gear Engines
Authors: Sparacino Peter L. , Krulikowski Joseph W. , Kenefick John F.
Published: January 2021

Arresting gear engines are large, heavy pieces of machinery which are costly to replace because of expensive repairs and modifications to existing decks. These costs can be avoided and the units installed in a more timely efficient manner if the photogrammetric process is used. This paper outlines the methods and techniques for using photogrammetry as a planning tool. It also demonstrates the practicality of collecting dimensional data from existing ship structures and foundations and using these data directly in the manufacturing phase of the equipment.
Permanent Composite Cladding of Deteriorating Steel Hulls
Authors: Horsmon Albert W.
Published: January 2021

The 42.7 m (140 ft) steel steam yacht (S/Y) Medea was nearly condemned in 1988 because of deteriorating steel hull plate. However, it was recently restored with a structural foam and composite skin bonded to the outside of the remaining steel structure. The composite repair was completed at a cost of $220000 compared to the $1.7 million estimated to crop and replace the wasted steel plate. The repair, the events leading up to the repair, including U.S. Coast Guard approval, the structural and production decision making processes involved, and the projected use of an integrated production system for similar future applications are described in this paper. The use of similar processing technology to apply the glass epoxy composite coating on the wooden coastal minehunters (MHCs) is also discussed.
Management of Technological Change and Quality in Ship Production
Authors: Frankel Ernst G.
Published: January 2021

Ship production, like other manufacturing and assembly activities, must keep up with technology to assure achievement of required productivity, quality, and technological advance expected by an increasingly demanding marketplace. The ship market has not only become technologically sophisticated, but customers now no longer buy on price alone. They want quality in design, detailing, operability, maintainability, reliability, usability, all in addition to a fair price, reliable delivery schedule, and effective follow-on service. In other words, the shipbuilding industry is finally emerging as a market-conscious, responsive industry aware of user needs. To perform this newly rediscovered function, shipbuilding has to assure better management of technological change in both product and process technology and assure continuous total quality management from design and production to delivery and follow. Many shipbuilders are new at this because many assumed a seller's marketplace. In this paper, the management of technological change and quality in ship production is presented as a formal step-by-step procedure which should be undertaken at regular (quarterly or at least yearly) intervals to assure that the yard maintains its quality and performance in process and product terms.
A Future Role of Quality in Shipbuilding—Reducing the Odds
Authors: AI-Kattan M. Raouf
Published: January 2021

Shipbuilding suffers from many of the problems unique to the so-called made-to-order industries. These problems are usually caused by the need to use existing resources to produce products to different design requirements and specifications. The major problems usually result in the inability to predict both the capability of design and production methods to meet the new product requirements. The lack of sufficiently long production runs to justify the development of a prototype to analyze these potential problems has long been used as a defense for poor performance and high levels of rework. Other industries are now using quality techniques, familiar to shipbuilders, to reduce the cost and numbers of prototypes. Toyota in particular is set to reduce new model development by half over the next decade. This paper sets out a methodology for the assessment of design and production capability as an approach to quality improvement in the shipbuilding industry and addresses the all-important cultural factor that is key to the success of any performance improvement program.
Using Fiber Optics for Laser Cladding
Authors: ley John Bart , Denney Paul , Grubowski Al
Published: January 2021

In many Navy structures, there are many large components that are coated for wear protection (valve seats) and/or for corrosion protection (hatch seals) that require periodic refurbishment. This refurbishment is normally accomplished using conventional arc welding processes which in many cases require that the part be removed from the structure to properly control the pre-weld, interpass, and post-weld temperatures as required by the materials used. The removal of such large components, the thermal requirements, and the resulting distortion can greatly increase the cost for refurbishment. The Navy Manufacturing Technology Office (MANTECH) of the Office of the Assistant Secretary of the Navy has been funding two major programs through Mare Island Naval Shipyard, Naval Sea Systems Command (NAVSEA 5142), and the Applied Research Laboratory, The Pennsylvania State University (ARL Penn State) to decrease such high refurbishment costs. The first program is the development of high-powered laser cladding processes for the refurbishment of components that can be removed from the ship and into a laser materials processing facility. The second, and the primary topic of this paper, is the development of a shipboard laser materials processing system that utilizes fiber optics.
Stochastic Expert Choice in Ship Production Project Management
Authors: Frankel Ernst G.
Published: January 2021

Increasingly rapid and often radical changes in both ship design as well as ship production process technology require more frequent selection from among many alternative technologies and operational strategies under conditions of uncertainty. A stochastic time variant hierarchical decision process, or expert choice method, is proposed for use under such conditions. Such an approach is particularly relevant to ship production because here technical decisions usually involve large investments, changes in production or operations, and often imply or affect strategic change. Expert choice, or the analytic hierarchical process (AHP), offers an approach which allows consideration of all the factors, as well as the risk attitudes of the decision-makers and others involved. The basic AHP method was modified to permit consideration of the probabilities associated with hierarchical relationships of factors and decision-makers. AHP is further suggested to include the effect of time on the determination of the risk, and time dependence of the outcome of alternative decisions. Thereby AHP permits determination of not only the most effective choices, but also timing of complex decisions met so frequently in ship production project management.
Application of PC-Based Project Management in an Integrated Planning Process
Authors: Neumann Richard J. , McQuaide avid J.
Published: January 2021

This paper gives an overview of the National Shipbuilding Research Program (NSRP) task N8-91-6 "Application of PC-Based Project Management in an Integrated Planning Process." The task discusses the development and implementation of a PC-based Integrated Production Planning System (IPPS) which serves as a tool to assist planning organizations in developing, updating, and revising Master Production Schedules (MPS) as well as manning and facility utilization reports. The full report includes a system "User's Manual"-, an appendix containing program logic flow charts, program coding and documentation, and disk copies of all programs and data files developed by the project for use by the system; and a "System Demonstration Disk." Anyone interested in obtaining the full report may do so from the NSRP Documentation Center located at the University of Michigan (telephone 313-763-2465).
A Data Model for Integration of the Precommissioning Life-Cycle Stages of the Shipbuilding Product
Authors: Welsh M. , Lynch J. , Brun P.
Published: January 2021

This paper reports some aspects of the work being carried out on the NEUTRABAS project under the ESPRIT II European research program. The aim of this project is to specify and implement a neutral product definition database for large marine-related artifacts, covering a large part of the complete product life-cycle. The results of this research program will facilitate the effective exchange of product related data between disparate computer-based information systems, and hence promote a movement towards product life-cycle integration. The scope of the product model being developed as the basis for this integration is described in terms of its spatial and steel structural components, together with the implications for integration with other models of outfitting and engineering systems. The model is shown to encompass the wide range of product-related data which is associated with the various precommissioning stages of the product life-cycle. A suitable database architecture designed to support product data exchange and full life-cycle integration based on this product model is described and discussed.
Productive Method and System to Control Dimensional Uncertainties at Final Assembly Stages in Ship Production
Authors: Manninen Markku , Jaatinen Jarl
Published: January 2021

Strict dimensional control of interim products through the different assembly stages is vitally important for profitable ship production [1].3 Studies in Finland show that a 30% reduction in labor costs is possible in hull construction [2]. This reduction can be gained by eliminating unnecessary fitting and reworking using tight accuracy control methods. This paper presents a method for dimensional control of block assemblies. The dimensional control is thereby separated from the positional control of the block. The method is a 3D-coordinate-based approach relative to a positional reference system. Also described is a real dimensional control case and an evaluation of different measurement technologies in performing the proposed task. The evaluation is comparable to a 1990 system study performed at NASSCO in San Diego [4],
Development of In-Process Assurance Welding System
Authors: Kaihara Shoichiro , Kouketsu Masaichi , Saitoh Tatsuo , Murayama Takehiro
Published: January 2021

The in-process assurance (IPA) welding system is the real-time weld quality monitoring system which is possible to abridge the nondestructive test (NDT) or decrease the number of NDTs. It consists of a personal computer, analog/digital converter, and several sensors such as voltage, current, velocity, sound, and torch distance. It is necessary to make clear the relationship between welding conditions and defects. The welding data of the IPA system for the automatic TIG tube welding and semiautomatic TIG and MIG welding were thoroughly studied and the following results were obtained:The IPA system is able to monitor welding conditions;quality control of welded joints is possible by statistical analysis of the IPA system; andwelding sound is useful for assurance of welding quality.
An Approach to a New Ship Production System Based on Advanced Accuracy Control
Authors: Yuzaki Masaaki , Okomoto Yasuhisa
Published: January 2021

Mechanizing and automating have been accelerated in shipbuilding in order to respond to the problem of decreasing numbers of skilled workers and increasing difficulty in recruiting new workers. For effective implementation of mechanization or automation, current hull fabrication systems should be reviewed in order to make them suitable for intended mechanization or automation because geometric inaccuracy hampers implementation and necessitates voluminous work adjustments. This paper proposes a new ship production concept based on using advanced methods to keep the accuracy of the hull structure at a high level, such as numerical simulation of heat deformation in burning, welding and bending; mechanizing to reduce deviations dependent on human skill; and a three-dimensional measuring system for advanced accuracy control together with some examples of its actual application to checking block shape at the assembly stage and shipwrighting at the erection site.
Recent M.I.T. Research on Residual Stresses and Distortion in Welded Structures
Authors: Masubuchi Koichi
Published: January 2021

This paper presents a summary of recent efforts by the Welding Research Group at the Department of Ocean Engineering, M.l.T. The major thrust of the efforts has been to develop technologies of reducing residual stresses and distortion through in-process control. Part 1 discusses reduction of longitudinal bending distortion of built-up beams, reduction of radial distortion and residual stresses in girth- welded pipes, reduction of forces acting on tack welds during butt welding, and reduction of residual stresses and distortion in high-strength steel weldments. Part 2 presents a brief summary of other research studies, including the forming of steel plates by line heating with a high-power laser beam, an intelligent system for flame straightening of panel structures, and the development of a knowledge- based system for minimizing out-of-plane distortion of welded structures.
Integration of Measurements and Maneuvering Technologies Used to Modify Caisson
Authors: Krulikowski Joseph , Sparacino Peter , Giordano Anthony
Published: January 2021

The modification of the caisson in a dry dock is in many ways more difficult than conventional ship modifications. This is because of the accuracy required, location of the measurements, and the size of the structure. The development of computer-based multi-headed electronic theodolite systems made it possible to extract accurate data on large structures. These data were formatted so they could be input directly into a computer-aided design system. The multi-headed electronic theodolite system was used to transfer new design information directly to the structure. The caisson structure was modified and moved safely into position with the aid of a water castor system for final assembly. Final dimension checks verified the accuracy of the system.
Cutting of Structural Materials Utilizing High-Powered CO2 Laser
Authors: Eutizzi Nick , Denney P. E.
Published: January 2021

The method most commonly used for cutting thick [1.90 cm (0.75 in.)] steel where edge quality is of no concern is flame cutting by oxyacetylene torch. This method provides the energy to heat the steel beyond its melting point, and gas pressure forces the molten material (dross) through the thickness of the material. Cutting torches typically remove a kerf of approximately 0.63 to 1.27 cm (0.25 to 0.5 in.). Gas cutting is noisy, generates large quantities of smoke into the environment and forms large pieces of dross which can travel up to 3.04 m (10 ft) and cause fires. Typically, when flame cutting shipboard, a fire watch is required. Also, if any type of flammable material exists on the opposite side of the cut, it must be removed for several inches on both sides of the cut line to preclude backside combustion. A search for a better method of cutting thick steel sections, including those with coating materials attached, centered around a high-powered CO2 laser. The CO2 laser had successfully demonstrated its ability to weld heavy sections of steel with 100% penetration from one side and create a very narrow heat-affected zone. It was decided to expand this welding process to cutting by introducing high-pressure assist gases. The gas would force the molten puddle created by the focused laser beam through the steel material, thereby creating a cut through the material as opposed to allowing the molten material to fuse back together without the assist gases (creating a welded joint). It was decided to take advantage of the laser's high-powered density to cut/vaporize non-metallic material attached to the steel plate. Also, there was interest in the effects of a laser beam on asbestos material.
NIDDESC-IGES Developments—Today’s Solution
Authors: Gischner Burton , Morea Gregory
Published: January 2021

The Initial Graphics Exchange Specification (IGES) was first developed in 1980. It has evolved with continual improvements to the current Version 5.1 which was published in October 1991 [1]. Although IGES has proved to be a very valuable tool, difficulties have been encountered in using it for sophisticated transfers, such as for product models or complicated drawings. The long range solution to these difficulties is the emergence of the Standard for the Exchange of Product Model Data (STEP). The Navy/Industry Digital Data Exchange Standards Committee (NIDDESC) has been a leading player in the development of this international standard. However, in the interim, NIDDESC is also spearheading the efforts to enhance the use of IGES by developing application protocols. Two of these application protocols, for 3D Piping and Engineering Drawings, are the first ones to be developed by the IGES/ PDES (Product Data Exchange using STEP) Organization (IPO), and will lead the way to more productive data transfer before the development of STEP. They will be referenced by the U.S. Department of Defense (DOD) standard for digital data transfer, MIL-D-28000 [2], and should greatly facilitate the occurrence of effective data transfer in these two disciplines. Furthermore, the use of these IGES application protocols is expected to provide significant guidance in the development of application protocols for the emerging STEP standard. This paper focuses on the development of these two application protocols, the involvement of NIDDESC and the shipbuilding industry (as well as the participation of other industry users and vendors), and the significant benefits to be derived from the adoption of these standards.
Development of Computer-Aided Process Planning System for Plate Bending by Line Heating (Report 1)—Relation Between Final Form of Plate and Inherent Strain
Authors: Ueda Yukio , Murakawa Hidekazu , Rashwan Ahmed Mohamed , Okumoto Yasuhisa , Kamichika Ryoichi
Published: January 2021

Plate bending by line heating can be considered as a process in which plates are bent to three-dimensional form by the plastic strain caused during the gas heating and water cooling. Therefore, the plan making for this process can be separated into two parts. The first part is to decide what type and how much plastic strain should be applied on which location on the plate. The second part is to find what are the proper heating and cooling conditions to get the desired plastic strain. The authors investigated the relation between the final form of the plate and the plastic strain or the inherent strain to be applied for the plate bending. For this purpose, the finite-element method (FEM) is employed. Based on the knowledge obtained through the analysis, a method to determine the part of the plate to be heated and the magnitude of the required inherent strain is proposed.
Optimizing Maintenance: Models with Applications to the Marine Industry
Authors: Inozu Bahadir , Karabakal Nejat
Published: January 2021

Past and current replacement models with applications to the marine industry for determining the optimum maintenance strategy are discussed. A new approach to multi-item replacement under budget constraints is presented. This approach considers all replacement decisions of an entire ship fleet (or all component replacements of a single ship) simultaneously. A Lagrangian methodology for the replacement problem is also described.
Comparative Design of Orthogonally Stiffened Plates for Production and Structural Integrity—Part 1: Size Optimization
Authors: Hatzidakis Nicholas , Bernitsas Michael M.
Published: January 2021

Five alternative configurations of orthogonally stiffened plates are compared in order to identify the total cost optimum design including material and fabrication cost. Size optimization is performed within the limitations of structural component standardization for each of the five alternatives. The five optimal structures are then compared in terms of weight, fabrication, and total cost. Discrete sizing optimization is performed in this paper with two design variables, i.e., plate thickness and standardized beam cross section. Constraints are imposed on secondary and tertiary stresses computed by finite-element analysis (FEA); and on primary stresses to prevent plate buckling, stiffener tripping, and overall buckling. Confidence is established in the FEA results by making comparisons with FEA results using the effective breadth method and orthotropic plate theory. Producibility constraints dictated by standardization in shipyard practice are imposed as well.
Training Shipbuilders with the Classroom of the Future
Authors: Boutwell Richard C. , Davis Hugh M.
Published: January 2021

To achieve the quality and productivity gains necessary to compete successfully in a global market, shipbuilders must prepare employees to apply diverse principles to complex problems. Rote learning of facts is no longer a useful paradigm for training employees to accomplish a wide range of shipbuilding jobs. Imagine a classroom where the instructor has the ability to monitor the trainee's level of comprehension and motivation, even as the presentation is underway. This same classroom provides the instructor with instantaneous control over a complete suite of advanced instructional equipment and environmental conditions. Newport News Shipbuilding has used the interactive technologies provided by such a classroom, combined with group facilitation methods, to significantly improve pass rates in a trades radiological control training program from 67% to 89%. One result of this improved pass rate is that retraining requirements in this program have been reduced by 67%. This paper describes the use of this Advanced Technology Classroom (ATC) to meet customer requirements to upgrade classroom performance of radiological control employees. The customer's challenge, our review of the available technology, and the characteristics of the ATC are discussed. The effects of organizational variables, normative change in the classroom, and relevant research concerning the use of interactive instructional technology are also covered. Finally, the implications of the ATC for other shipyard training are addressed.
The Lay-Up and Reactivation of LNG Tankers: Lessons Learned
Authors: Boylston John W. , Riley Paul J. , Van Tassel Gary W.
Published: January 2021

The Liquid natural gas (LNG) industry went from a projected boom in the 1970's to a contracted industry in the 1980's, when many ships were either permanently or temporarily laid up. In the 1990s, many laid-up LNG carriers are being reactivated after as many as 12 years in lay-up. While the capital cost of an LNG carrier should dictate maximum preservation of the asset, the LNG industry is not immune to having to make hard economic decisions during slack times. In this paper, the authors present specific alternate lay-up procedures, together with the relative costs of these alternatives. LNG carriers are steam vessels, as are many of the vessels in the Ready Reserve Fleet (RRF). However, many of the conclusions reached can also be applied to motor vessels, and as such could be of interest to operators and shipyards in all phases of the RRF program. The subjects of dehumidification, inert gas plants, ballast tank coatings and drydocking, among others, are discussed.
Feasibility of a Ship Scrapping Yard in Philadelphia
Authors: McKenney Timothy
Published: January 2021

This paper examines the feasibility of establishing a ship scrapping facility on the present site of Philadelphia Naval Shipyard. Potential ship disposal markets and the current state of the ship-breaking industry are examined. Current methods are reviewed and a new method incorporating emerging technologies is proposed. Five critical financial drivers that impact the viability of domestic scrapping firms are examined. On the basis of this background, two options are proposed for establishing a scrapping facility.
Composites for Large Ships
Authors: Horsmon Albert W.
Published: January 2021

Composites, frequently referred to as fiberglass or FRP, are usually thought of as the material of choice for recreational boats. Recently, though, composites have been used for 57.3 m (188 ft) mine hunters and a 49 m (161 ft) yacht. Ten years ago these FRP vessels would have been at the upper limits of perceived size limitations, but practical limitations on the size of vessels using composites as the primary structural material are premature due to continuing advances in the materials and processing technology. Composites are used for small sections of large steel vessels including non-pressure hull decking for submarines, weapons enclosures for destroyers, and funnels on cruise ships. Potential uses on large cargo vessels include bulbous bows, hatch covers, stern fairings, deck machinery enclosures and nonstructural interiors. This paper reviews current usage and explores future potential on the use of composites on larger vessels.
Commonality-Based Naval Ship Design, Production, and Support
Authors: Cecere Michael L. , Abbott Jack , Bosworth Michael L. , Valsi Tracy Joseph
Published: January 2021

The Naval Sea Systems Command (NAVSEA) began an initiative titled "Affordability Through Commonality" (ATC) in 1992. The effort's long-term goal is to improve the process by which the Navy, with industry's help, will design, acquire, and provide lifetime support for the ships required for national defense. The technical approach considers commonality to be a synergistic combination of the elements of modularity, increased equipment standardization, and process simplification. A division within NAVSEA (SEA 03R3) was created to coordinate efforts towards this fleet affordability goal, specifically to (a) identify and develop analysis tools for a commonality-based process; (b) assemble resources for initiating a decade-long task; (c) develop a plan for a commonality-based approach to ship design, acquisition, and lifetime support; and (d) implement the plan into the mainstream of the Navy's way of conducting business. This paper provides an interim report on the ATC project's first funded year and the implementation progress of the first program to fully adopt commonality principles, the Advanced Surface Machinery Programs (ASMP), SEA 03Z.
Fundamentals of Arc Stud Welding: An Interactive Multimedia Lesson for Shipyard Training
Authors: Cooper Richard B. , Reelr Terry J.
Published: January 2021

Education and Training Panel SP-9's 1991 report, "Recommendations on the Use of Interactive Instruction for Training Shipyard Trade Skills," indicates that although very few American shipyards have used it or are familiar with it, interactive multimedia has great potential as a low-cost, effective method for the training of skilled trade tasks. These findings led SP-9 to develop an interactive lesson that demonstrates how interactive multimedia can be integrated into shipyard training programs to reduce training costs, increase productivity, promote quality awareness, and improve worker competence. The demonstration combines computer graphics, animation, still and motion video, sound, and touchscreen interaction to demonstrate the broad spectrum of the interactive multimedia technology. This paper describes the project as an example of how shipyard training departments can develop their own interactive multimedia courseware by determining appropriate applications of the technology; selecting the most suitable hardware and authoring system for delivering the instruction; researching, planning and designing the lessons; and shooting the video, authoring the courseware, and integrating them into an effective interactive multimedia course.
Prediction of the Low-Cycle Fatigue Life of HY-100 Undermatched Welds in Marine Structures
Authors: Shah Rahul S. , Wang Kuo-Chiang , Kleinosky Mary Jane
Published: January 2021

Finite-element and analytical models are used in this study to predict the low-cycle fatigue life of undermatched (lower yield strength) weldments of HY-100 steel. The objective was to determine the feasibility of replacing conventional overmatched welds in marine structures. Fatigue tests were performed on standard, smooth specimens, notched cylindrical specimens and a four-point-bend test on a full-scale butt beam specimen. Numerical analyses were conducted using finite elements, with a two-surface plasticity algorithm to simulate the cyclic behavior of the individual materials. The stress and strain concentrations at the notches were also evaluated using two analytical models: the Neuber and Glinka relations. The finite-element predictions compared well with experimental data and produced detailed predictions of the strain distributions, which were then used to assess the crack initiation life. Glinka's relation demonstrated superior predictive capabilities for local strains over Neuber's relation.