Abstract
Shipyards and dockyards are places which repair and build ships. These can be yachts, military vessels, cruise liners or other cargo or passenger ships. Dockyards are sometimes more associated with maintenance and basing activities than shipyards, which are sometimes associated more with initial construction. The terms are routinely used interchangeably, in part because the evolution of dockyards and shipyards has often caused them to change or merge roles.
Shipyards are constructed by the sea or by tidal rivers to allow easy access for their ships. In the United Kingdom, for example, shipyards were established on the River Thames (King Henry VIII founded yards at Woolwich and Deptford in 1512 and 1513
The site of a large shipyard will contain many specialized cranes, dry docks, slipways, dust-free warehouses, painting facilities and extremely large areas for fabrication of the ships.
After a ship's useful life is over, it makes its final voyage to a ship breaking yard, often on a beach.. Historically ship breaking was carried on in dry dock in developed countries, but high wages and environmental regulations have resulted in movement of the industry to developing regions.
Introduction
Suez shipyard history:
Suez shipyard has been established since about 142 years ago when an agreement has been signed between the governor of Egypt " Prince Saeed " and French company on April 1862 to construct a graven dock for ship repair and shipbuilding with principal dimension 140 m length and 25 m width.
The execution of project started on Aug.1882 by manual means. All works finished October 1866. on 1963 becomes on of an affiliated company of Suez Canal Authority .
The location of Suez Shipyard in the south entrance of Suez Canal, this unique location gives the Suez Shipyard grate importance in ship repair market.
Suez shipyard owned:
1- Floatingdock: Is the largest one in the middle east .
A floating dry dock is a sort of pontoon for dry docking ships that has floodable buoyancy chambers and a "U" shaped cross-section. The walls are used to give the dry dock stability when the floor is below the water level. When valves are opened the chambers are filled with water, the dry dock floats lower in the water, allowing a ship to be moved into position inside. When the water is pumped out of the chambers, the dry dock rises and the deck is cleared of water, allowing work to proceed on the ship's hull.
Shipyards operate floating dry docks, among other means of hauling or docking vessels. The advantage of floating dry docks is that they can be moved all over the world and also can be sold second-hand. During World War II, the U.S. Navy used such (floating) drydocks extensively to provide maintenance in remote locations. One of these, the 850-foot AFDB-3, saw action in Guam, was mothballed near Norfolk, Virginia, and was eventually towed to Portland, Maine, to become part of Bath Iron Works' repair facilities.
2- Dry dock :
A drydock is a narrow basin or vessel that can be flooded to allow a load to be floated in, then drained to allow that load to come to rest on a dry platform. Drydocks are used for the construction, maintenance, and repair of ships, boats, and other watercraft.
3- Syncrolift :
Is another way for the construction, maintenance, and repair of ships, boats, and other watercraft By using docks lifting by 6 cranes
4- Diesel work shop :
Where all maintenance and repair of diesel engines are done
5- Machining work shop :
The place consist of lathes and saws
6- Painting work shop :
Where all painting operations are done
7- Body work shop :
Where all steel sheet are repaired
8- Electric work shop.
Shop safety
General Shop Safety rules:
Most of the hand tools and many of the power tools are in common use in most households and are familiar to us. We should recognize that through proper practice of methods and safety rules and common sense accidents can be avoided. The following are some additional shop safety rules:
1. Do NOT use any of the machines until you have received proper instruction for that machine by your instructor.
2. All safety guards must be in their proper position at all times.
3.Machines must not be operated while the instructor is out of the room.
4.All tools must be removed from the machine before it is turned on.
5. Machines must come to a complete stop before adjustments are made.
6.Loose clothing must be fastened or removed.
7.Dangling jewelry must be removed.
8.Short sleeves or pulled-up long sleeve clothing is acceptable.
9.Do not distract or allow your attention to be distracted while using any of the machines.
10. The floor around machines must be kept clear of scraps, shavings, or any other items that may be in the way of the operator’s feet.
11.Boots or shoes that fully enclosed foot must be worn (i.e., no sandals).
12. Power must be turned off immediately after using a machine.
13. Horse-play and running is absolutely forbidden at all times.
14.No student should start or stop a machine for another student.
15.The operator must ensure that everyone is clear of the machine before turning it on.
16. Only one person may operate a machine at one time. Do not crowd the person operating a machine. Stand at least 3’ away from the operator.
17. Do not attempt any adjustments on the machines. If the machine is not set-up correctly or to your requirements, check with the instructor.
18.Inform the instructor of any unsafe conditions existing in the shop.
19.Safety glasses must be worn while operating machinery and power tools.
20.Properly shielded hoods must be worn for welding operations.
21.Always use common sense.
22. Everyone entering shop area must wear safety glasses.
23. Permission should be obtained to operate machinery.
24. Never use your hands or any part of your body to break a machine to stop a stop.
25. Only one operator at a time should control a machine.
26. Loose clothing should be fastened or removed.
27. NOT work alone.
28. You must don safety glasses, cover goggles, or face shield before entering the shop.
29. Shoes must be worn in the shop. No one wearing sandals will be allowed to enter any shop area. The minimum Footwear must cover the entire foot.30. Do not operate any equipment unless you are familiar with its Operation and have been authorized to operate it. Questions Regarding the use of equipment should be directed to the shop supervisor.
31. No work may be performed using power tools unless at least Two people are in the shop area and can see each other.
32. Use the shop vacuum cleaner to remove chips. Never use compressed air guns to clean clothing and hair.
33. Machines must be shut off and locked-out before servicing.
34. Do not wear ties, loose clothing, jewelry, gloves, etc. when operating shop equipment.
35. Wear appropriate clothing for the job (i.e. do not wear short Sleeve shirts or short pants when welding).
36. Do not work in the shop if you are tired, or in a hurry.
37. Never indulge in horseplay in the shop areas.
38. All machines must be operated with all guards and shields in Place.
39. Do not use your bare hands to remove chips and shavings From the machine, use a brush or hook.
40. Never use a rag near moving machinery.
41. Do not strike a hardened tool or any machine with a hammer.
42. Practice cleanliness and orderliness in the shop areas. Use the shop vacuum cleaner. MEMS Student Shop Safety Rules
43. Keep the floor around machines clean, dry and free from trip hazards. Do not allow chips to accumulate. Use the shop vacuum cleaner.
44. Think through the entire job before starting.
45. Before starting a machine, always check it for correct setup and always check to see if the machine is clear.
46. Do not drink alcoholic beverages before or during a work session in the machine shop area. Do not bring food/snacks into the shop.
47. Don’t rush or take chances. Obey all safety rules.
48. If you have not worked with a particular material before, check the materials safety data sheet (M.S.D.S.) for any specific precautions to be taken while working with the material. Also, ask the shop personnel before cutting any unusual material.
49. Heavy sanding and painting should only be done in well ventilated areas.
50. Follow all appropriate precautions when working with solvents, paints, adhesives or other chemicals. Use appropriate protective equipment. Review the M.S.D.S.
51. Check the condition of power cords and plugs on portable tools before using them. Do not use a tool that has a worn
Diesel workshop
The diesel engine has been the engine of choice for heavy-duty applications in agriculture, construction, industrial, marine unit and on high way.
The diesel engine has no spark plug, that it intakes air and compresses it, and that it then injects the fuel directly into the combustion chamber (direct injection). It is the heat of the compressed air that lights the fuel in a diesel engine.
The injector on a diesel engine is its most complex component and has been the subject of a great deal of experimentation -- in any particular engine it may be located in a variety of places. The injector has to be able to withstand the temperature and pressure inside the cylinder and still deliver the fuel in a fine mist. Getting the mist circulated in the cylinder so that it is evenly distributed is also a problem, so some diesel engines employ special induction valves, pre-combustion chambers or other devices to swirl the air in the combustion chamber or otherwise improve the ignition and combustion process.
The main differences between the gasoline engine and the diesel engine are:
· A gasoline engine intakes a mixture of gas and air, compresses it and ignites the mixture with a spark. A diesel engine takes in just air, compresses it and then injects fuel into the compressed air. The heat of the compressed air lights the fuel spontaneously.
· A gasoline engine compresses at a ratio of 8:1 to 12:1, while a diesel engine compresses at a ratio of 14:1 to as high as 25:1. The higher compression ratio of the diesel engine leads to better efficiency.
· Gasoline engines generally use either carburetion, in which the air and fuel is mixed long before the air enters the cylinder, or port fuel injection, in which the fuel is injected just prior to the intake stroke (outside the cylinder). Diesel engines use direct fuel injection -- the diesel fuel is injected directly into the cylinder.
· One big difference between a diesel engine and a gas engine is in the injection process. Most car engines use port injection or a carburetor rather than direct injection. In a car engine, therefore, all of the fuel is loaded into the cylinder during the intake stroke and then compressed. The compression of the fuel/air mixture limits the compression ratio of the engine -- if it compresses the air too much, the fuel/air mixture spontaneously ignites and causes knocking. A diesel compresses only air, so the compression ratio can be much higher. The higher the compression ratio, the more power is generated.
The four strokes of the internal combustion engine are as follows (and in order): Intake, Compression, Power, and Exhaust. These four strokes require two revolutions of the crankshaft. The process continuously repeats itself during the operation of the engine. So, if a four-cylinder engine requires two complete revolutions of the crankshaft to ignite all of its cylinders.
The Intake Stroke:
On the intake stroke, the intake valve has opened. The piston is moving down, and a mixture of air and vaporized fuel is being pushed by atmospheric pressure into the cylinder through the intake valve port.
The Compression Stroke:
After the piston reaches the lower limit of its travel, it begins to move upward. As this happens, the intake valve closes. The exhaust valve is also closed, so the cylinder is sealed. As the piston moves upward, the air/fuel mixture is compressed. On some small high compression engines, by the time the piston reaches the top of its travel, the mixture is compressed to as little as one-tenth its original volume. Thus, the compression of the air/fuel mixture increases the pressure in the cylinder. The compression process also creates the air/fuel mixture to increase in temperature.
The Power Stroke:
As the piston reaches the top of its travel on the compression stroke, an electric spark is produced at the spark plug. The ignition system delivers a high voltage surge of electricity to the spark plug to create the spark. The spark ignites the air/fuel mixture. The mixture burns rapidly and cylinder pressure increases to as much as (600psi). All of this pressure against the piston forces it down in the cylinder. The power impulse is transmitted down through the piston, through the piston rod (connecting rod), and to the crankshaft. The crankshaft is rotated due to the force.
The Exhaust Stroke:
As the piston reaches the bottom of its travel, the exhaust valve opens. Now, as the piston moves up on the exhaust stroke, it forces the burned gases out of the cylinder through the exhaust port. When the piston reaches the top of its travel, the exhaust valve closes, and the intake valve opens. The cycle repeats again with the intake stroke. The four strokes are continuously repeated during the operation of the engine.