General Procedure of Shipbuilding

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General Procedure

of Shipbuilding

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1 FROM CONTRACT TO DELIVERY

2 CLASSIFICATION SOCIETY 3 LARGE CONTAINER VESSEL

SUMMARY

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> From Contract to Delivery

1

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CONCEPT CONCEPT

From Contract to Delivery

1 Contract/ Business Dept.

Ship Sales Engineering Dept.

Basic/ Production

Purchasing of Material Purchasing Dept.

Owner/ Class Approval

Hull

Hull Outfitting

Machinery Outfitting Electric Outfitting Painting

Quality Assurance Production Control A/S

Owner Project Owner Project Shipyard

CONTRACT

DESIGN

PRODUCTION

DELIVERY

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CONCEPT CONCEPT

From Contract to Delivery

1 SHIPBUILDING

PROCESS

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BRIEF SPEC’

1 From Contract to Delivery INITIAL STAGE INITIAL STAGE

Owner

Project Planning Contract/ Business Dept.

Ship Sales Engineering Dept.

Negotiation Technical Meeting

Full Spec’/ Class Cost Balance

Letter of Intent

Total Quantity Option Delivery Date

Contract Specification

Contract G/A, Midship, Piping Diagram Accommodation Plan

CONTRACT Purpose

Route Economic

Broker

* Owner

* Shipyard Shipyard

OFFER

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1 From Contract to Delivery INITIAL STAGE INITIAL STAGE

ROLES

in SHIPBUILDING

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1 From Contract to Delivery INITIAL STAGE INITIAL STAGE

 GENERAL ARRANGEMENT

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1 From Contract to Delivery INITIAL STAGE INITIAL STAGE

 75K MIDSHIP

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1 From Contract to Delivery

 75K MIDSHIP

INITIAL STAGE

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1 From Contract to Delivery

 DIAGRAM OUTFIT

INITIAL STAGE

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1 From Contract to Delivery INITIAL STAGE INITIAL STAGE

 DIAGRAM OUTFIT

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1 From Contract to Delivery INITIAL STAGE INITIAL STAGE

 DIAGRAM OUTFIT

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1 From Contract to Delivery

 DIAGRAM-MACHINERY

INITIAL STAGE

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1 From Contract to Delivery

 DIAGRAM-MACHINERY

INITIAL STAGE

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1 From Contract to Delivery

 DIAGRAM-MACHINERY

INITIAL STAGE

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1 From Contract to Delivery

 ACCOMMODATION PLAN

INITIAL STAGE

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1 From Contract to Delivery

 ACCOMMODATION PLAN

INITIAL STAGE

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1 From Contract to Delivery

 ACCOMMODATION PLAN

INITIAL STAGE

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DESIGN STAGE DESIGN STAGE

1 From Contract to Delivery

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DESIGN STAGE DESIGN STAGE

1 From Contract to Delivery

SPIRAL

DESIGN

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DESIGN STAGE DESIGN STAGE

1 From Contract to Delivery

Definition of Requirements

Definition of Requirements Length

Breadth Depth Draught

Form

Power

Area

Weight Displacement

General Arrangement

Range Seakeeping Manouvrability Strength

Economic Analysis

Constraints (Design)

Constraints (Design Process)

COnstraints

(Design Environment)

Next Design Step

Choice

Empirical Calculations

Form Selection

Machinery Selection

Ship Type

Type

Ship Area/

Weight

Weather Deck Arrangement

Calculationsr Preliminary Control Longitudinal Strength Ship

Life

SPIRAL

DESIGN

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DESIGN STAGE DESIGN STAGE

1 From Contract to Delivery

SPIRAL

DESIGN

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DESIGN STAGE DESIGN STAGE

1 From Contract to Delivery

Key Design or Key Plan Production Design

Lines, Propeller

General Arrangement Trim & Stability

Loading, etc.

Hull Key Plan : Midship Section

Construction Profile & Deck Plan Shell Expansion

Structure Drawing : Cargo Hold

Engine Room/ Fore Body/ Aft Body Stern Frame/ Accommodation

Production Drawing : Shop Drawing/ Cutting Plan

Structural Analysis : Static Analysis –Coarse Mesh/ Fine Mesh Fatigue Analysis

Sloshing Analysis

Bow Impact & Slamming Analysis Vibration Analysis

Painting

Purchasing Order : Steel Plate, Angle etc, Paint

 DESIGN STAGE

Hull Design

Basic Design

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1 From Contract to Delivery DESIGN STAGE DESIGN STAGE

Key Design : Piping Diagram, Ventilation Mooring, Anchoring, Steering Life Saving, Fire Fighting Traffic Arrangement

Production Design : Pipe Piece, Traffic Piece, etc Small Equipment

Accommodation Design : Interior, Piping, Outfitting Purchasing Order : Pipe, Valve, Equipment

Key Design : E/R Piping Diagram,

Machinery Arrangement, M/E, Generator, Boiler, Compressor Production Design : Pipe Piece, Vent Piece, etc.

Small Equipment

Purchasing Order : Equipment, Valve, etc.

Hull Outfitting Design

Machinery Outfitting

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1 From Contract to Delivery DESIGN STAGE DESIGN STAGE

Key Design : Automation

Electrical System Navigation Equipment Production Design : Cable Piece

Light Equipment Purchasing Order : Switch Board

Equipment, Cable, Sensor

Electric Outfitting

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1 From Contract to Delivery PRODUCTION STAGE PRODUCTION STAGE

Yard Facility Production Control

Material Control

Production Control

Production – Hull, Hull Outfitting,

Machinery Outfitting, Paint Quality Assurance

Grand P.E

P.E Block

Painting

Inspection

Owner/ Class Pre-Outfitting Each Block Assembly

Sub-Assembly

Dock Erection CONDITION

HULL PRODUCTION

Cutting

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1 From Contract to Delivery PRODUCTION STAGE PRODUCTION STAGE

Pre-Outfitting In Block

Outfitting In Dock

Outfitting In Quay

Block Painting Dock Painting Cosmetic

Painting OUTFITTING PRODUCTION

PAINTING

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1 From Contract to Delivery PRODUCTION STAGE PRODUCTION STAGE

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1 From Contract to Delivery PRODUCTION STAGE PRODUCTION STAGE

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1 From Contract to Delivery PRODUCTION STAGE PRODUCTION STAGE

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1 From Contract to Delivery PRODUCTION STAGE PRODUCTION STAGE

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1 From Contract to Delivery PRODUCTION STAGE PRODUCTION STAGE

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1 From Contract to Delivery PRODUCTION STAGE PRODUCTION STAGE

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1 From Contract to Delivery PRODUCTION STAGE PRODUCTION STAGE

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1 From Contract to Delivery PRODUCTION STAGE PRODUCTION STAGE

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1 From Contract to Delivery PRODUCTION STAGE PRODUCTION STAGE

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1 From Contract to Delivery PRODUCTION STAGE PRODUCTION STAGE

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1 From Contract to Delivery PRODUCTION STAGE PRODUCTION STAGE

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1 From Contract to Delivery PRODUCTION STAGE PRODUCTION STAGE

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1 From Contract to Delivery PRODUCTION STAGE PRODUCTION STAGE

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Shipyard Ship owner

1 From Contract to Delivery DELIVERY & A/S DELIVERY & A/S

Official Sea Trial Shipyard, Owner, Class

Speed Endurance Tank Test

Anchoring/ Mooring Rudder, Steering Vibration, Noise

Equipment Operation Navigation

Correction If Any

Delivery

Sign Departure A/S

(1 YEAR)

READY TO SEA TRIAL

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1 From Contract to Delivery DELIVERY & A/S DELIVERY & A/S

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1 From Contract to Delivery DELIVERY & A/S DELIVERY & A/S

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> Classification

2

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2 Classification ^{MAJOR WORK} ^{MAJOR WORK}

 DRAWING APPROVAL

 INSPECTION DURING BUILDING

 CERTIFICATION

 INSPECTION AFTER DELIVERY

Yard Design Maker Design

Intermediate Periodical

SHIP’S SAFETY DURING LIFE TIME

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CLASS PROCESS

T0 Contract

RFC Signed

T0 + C Delivery to Owner

Ad 523 signed by

LPO

Commercial Design review Follow-up in service

SHIP NEW CONSTRUCTION :

LPO : Local Plan Approval

RFC : Request For Certificate

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CLASS PROCESS

Design review : basically 4 BV actors

Field surveyor

LPO

Marine Center

BV Non surveyors

DTM support

DTM : Dept. of Technical Marine

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CLASS PROCESS

T0 Contract

RFC Signed

T0 + C Delivery to Owner

Ad 523 signed by

LPO

Design review

LPO core activity : Design review

• Design review can start before RFC signed ( TAKE CARE - CONTRACT DEFINITION )

•Completed when Ad 523 + annexes are examined and signed

( technical green light given to Condition Monitoring –

CM for Class certificate )

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CLASS PROCESS

T0 Contract

RFC Signed

T0 + C Delivery to Owner

Ad 523 signed by

LPO

Design review

LPO core business : Design review against Referential

• Referential : BV Rules / IMO Reg.

• LPO Interpretations :

- allowed with BV Rules ( within general conditions) - not allowed for IMO Reg.

• Rules : technical interpretations / protect interest of Owner ( final CLIENT )

• High technical knowledge frequently requested as Clients may be less educated / powerfull than BV

• Great risk of uncontrolled move from design review

activity to Consultancy activity

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CLASS PROCESS

T0 + C Delivery to Owner

Ad 523 signed by

LPO

Follow-up in service

LPO activity :

• Design review at any time in case of conversion

• Rules : technical interpretations / protect interest of Owner

• Technical support of CMs / Station surveys

• Several LPOs may be concerned

• Technical documentation processing ( drawings + calculation sheets )

Scrap

or

Change

of

Class

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TECHNICAL ASSISTANCE TECHNICAL ASSISTANCE

 Different from Class design review : BV acts as designer in scope of Consultancy

 Technical expertise and knowledge is ( must be ) sold to Client

 Highly profitable

 HIGH RISK OF :

- transfer of Yard know-how

- confusion on status of conclusions - pressure from management

 ALWAYS BE CLEAR ABOUT THE CAP YOU WEAR / THE FORMAT OF

COMMENTS YOU ARE ALLOWED TO GIVE

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2 Classification IACS MEMBERS IACS MEMBERS

 MEMBER

ABS : American Bureau of Shipping BV : Bureau Veritas

CCS : China Classification Society DNV : Det Norske Veritas

GL : Germanischer Lloyd

KR : Korean Register of Shipping LR : Lloyd Register

NK : Nippon Kaiji Kyokai

RINA : Registro Italiano Navale

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2 Classification IACS MEMBERS IACS MEMBERS

 ASSOCIATES

IRS : Indian Register of Shipping

 REQUIREMENTS

- Procedural Requirement - Unified Requirements - Unified Interpretations

- Guide Line & Recommendations, etc.

 Web Site

www.iacs.org.uk

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> Large Container Vessel

3

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1 General : Large Container Vessels

2 Bureau Veritas References in Large Container Vessels

3 BV Hull Expertise

- Steps of review process - Torsion analysis

- Fatigue analysis - Bow flare analysis 4 BV Lashing Expertise

5 BV Shaft Alignment Expertise

6 Parametric Roll Calculation

SUMMARY

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 The size range for the largest containerships is expected to increase significantly in the near future as economies of scale remains the dominant operational factor driving efficient transport.

 The Largest containerships currently in service are in the 7000-8000 TEU range. Many leading shipyard have developed designs for vessels with additional containers rows, tiers and holds. Increase main dimension and capacity up to 9000/10000 TEU.

 In the future the carrying capacity of containerships is expected to increase to 12000 TEU and above

1 ^GENERAL LARGE CONTAINER VESSELS LARGE CONTAINER VESSELS

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 Fleet development for container ships

1 Fleet development in '000 teu

0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000

1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004

GENERAL LARGE CONTAINER VESSELS LARGE CONTAINER VESSELS

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 Order Books for container ships

1 Order book Feb 2005, number of ships

0 50 100 150 200 250

<1000 1000- 2000

2000- 3000

3000- 4000

4000- 5000

5000- 6000

6000- 7000

7000- 8000

8000+

GENERAL LARGE CONTAINER VESSELS LARGE CONTAINER VESSELS

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 Challenges with the increase of size of containerships

• Torsion/Warping stress

• Fatigue

• Acceleration forces on lashing

• Engine power

• Shaft alignment

• Parametric roll

• Slamming/Bow impact

1 ^GENERAL LARGE CONTAINER VESSELS LARGE CONTAINER VESSELS

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 LAST MAIN REFERENCES

• HHI

» 1x5,500 TEU containerships for YANG MING LINE

» 1x7,800 TEU containership for CMA CGM

» 10x5,100 TEU containerships for CMA CGM (under building)

» 2x5,100 TEU containerships for CMA CGM (under building at HSHI)

» 2x9,200 TEU containerships for CMA CGM (under building)

» 2x9,200 TEU containerships for CMA CGM (under building at HSHI)

» 2x8,200 TEU containerships for CMA CGM (under building)

» 2x8,200 TEU containerships for CMA CGM (under building at HSHI)

» 1x8,200 TEU containership for YANG MING LINE (under building)

• DSME

» 1x6,500 TEU containership for CGM CMA

2 BV REFERENCES CONTAINER SHIPS BUILDING CONTAINER SHIPS BUILDING

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 LAST MAIN REFERENCES

• HHIC

» 2x1,600 TEU containerships for DELMAS

» 4x1,600 TEU containerships for VROON

» 2x4,300 TEU containerships for CMA CGM

» 3x6,500 TEU containerships for CMA CGM

• SHI

» 8 x 5,770 TEU containerships for CMA CGM

• CSBC

» 18x2,200 TEU containerships for WAN HAI LINES, DELMAS, CMA CGM, YANG MING LINE

• IMABARI

» 3x5,500 TEU containerships for COSCO

2 BV REFERENCES CONTAINER SHIPS BUILDING CONTAINER SHIPS BUILDING

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< 9,200 TEU CONTAINERSHIP >

 Main Dimensions:

• Length btw. PP 333,44 m

• Breadth 42,8 m

• Depth, to upper deck 27,3 m

• Draught, summer 14,5 m

• Speed 24,25 kn

• Power 68656 kW

 Key elements: Between half December and the end of March the complete structure has been reviewed. This was only possible in close cooperation with the Shipyard. Several meetings at the shipyard site, exchanging information and calculation results and discussing the findings, have taken place. Two offices of Bureau Veritas, Korea and Paris, have been working around the clock in order to make the deadlines of the shipyard.

2 BV REFERENCES PROJECT MANAGEMENT PROJECT MANAGEMENT

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Hatch coamings /

Superstructures connection

Bottom Slamming Transverse Bulkhead

connections

Bow Flare impact

Hatch corners

Longitudinal Hatch Coamings

Cross-deck structures

3 BV HULL EXPERTISE CRITIAL AREA OF LARGE

CONTAINER SHIPS CRITIAL AREA OF LARGE

CONTAINER SHIPS

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 DESIGN REVIEW PROCESS

» General and subdivision arrangement

» Mid-ship section : Longitudinal strength and local rule scantlings

» All sections : Longitudinal strength and local rules scantlings

» Torsion model : Warping stress estimation all along the vessel (to be included in the global stress)

» Key drawings: primary members calculation (local + global stress)

» Detail drawings / reinforcement : bracket reinforcement under stack...

» Bow impact and flat forward bottom area

» Other calculations: Loading manual strength analysis, Lashing...

 IN PARALLEL TO DESIGN REVIEW PROCESS

» FEM (VeriSTAR) calculations: double check for design review

» Fatigue Analysis with Mars/VeriSTAR

3 BV HULL EXPERTISE STEP OF REVIEW PROCESS STEP OF REVIEW PROCESS

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» TORCIS calculation

3 MARS - TORCIS ANALYSIS

Estimation of warping stress in side shell , upper-deck all along the vessel N/mm2

Modelisation of all cargo holds

Estimation of shear force in cross deck beams 2 calculations:

wave 60 degree wave 120 degree

BV HULL EXPERTISE TORSION ANALYSIS TORSION ANALYSIS

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3 Fatigue due to warping (L27) 16 years

(L28) 17 years (L29) 13 years (L30) 15 years (L31) 17 years Buckling due to warping

MARS - TORCIS ANALYSIS

BV HULL EXPERTISE TORSION ANALYSIS TORSION ANALYSIS

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 Analyses based on complete ship model

3 Full model of 9200 TEU containership

VeriSTAR is use for

- Buckling analysis (coarse mesh)

- Yielding analysis (fine mesh)

- Fatigue analysis (very fine mesh)

BV HULL EXPERTISE TORSION ANALYSIS TORSION ANALYSIS

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 Methodology and steps of a VeriSTAR CSM calculations

» σ ^X1 ⁼ ^γs1 σ ^s1 ⁺ ^γw1 ^(C ^fv σ ^wv1 ^+C ^fh σ ^wh1 ^{+ C} ^fΏ σ ^{Ω )} 3

Maximum Torsion at fore part 50% Vertical Bending moment

Quartering sea: Maximize static , vertical bending (50%), horizontal bending (100%) and torsion (100%)

BV HULL EXPERTISE TORSION ANALYSIS TORSION ANALYSIS

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 Methodology and steps of a VeriSTAR CSM calculations

» Coarse mesh modelling : full ship

» Definition of ballast areas and container loading points

» Static calculation with lightship weight: loading conditions

– lightship (checking case)

– ballast (maximum Bending moment) – full load (maximum draft)

– compare data with loading manual (draft,displacement,still water bending moment…)

» Wave Load calculations: load cases

– based on selection of design waves (table 5) – Head Sea (longitudinal strength)

– Beam Sea (transverse strength) – Quartering sea (torsion strength)

» Fine mesh analyses

– based on areas to be analysed (Table 1)

– Hatch corners, cross deck, connection superstructure,connection girders...

6 3D FEM CALCULATIONS

VERISTAR COMPLETE SHIP MODEL COMPLETE SHIP MODEL

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 Principle Design wave load (see also Table 5)

» Maximum Vertical Wave Bending Moment in Hogging condition

» Maximum Wave Torque at vicinity of 0.25L (aft part)

» Maximum Wave Torque at mid-ship

» Maximum Wave Torque at vicinity of 0.75L (fore part)

» Maximum vertical acceleration in inclined conditions

» Maximum vertical acceleration in upright conditions

» Maximum transverse acceleration

 Wave design load to be associate with loading conditions

» Ballast, full load

» Load cases

3 Sea keeping calculation Iterative process

BV HULL EXPERTISE COMPLETE SHIP MODEL COMPLETE SHIP MODEL

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 Stresses and Deformation

3 Head Sea Condition Quartering sea condition

Stress in Hatch coaming Connection superstructure

Stress Hatch corners Stress Cross deck

Stress Girders

Buckling in bulkhead and bilge area Buckling in bottom area

BV HULL EXPERTISE TORSION ANALYSIS TORSION ANALYSIS

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 Areas to be analysed through fine Mesh models

3 - Hatch Corners

- Connection of hatch coaming with superstructure

- Transverse Bulkhead - Support Bulkhead - Transverse Frame - Bottom Girders

Examples:

BV HULL EXPERTISE TORSION ANALYSIS TORSION ANALYSIS

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Typical stress range in head sea Typical stress range in oblique sea

HATCH CORNERS

3 BV HULL EXPERTISE TORSION ANALYSIS TORSION ANALYSIS

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 Support Bulkhead

3 Shear stress

at maximum draft Maximum pressure in alternate condition one bay empty

BV HULL EXPERTISE TORSION ANALYSIS TORSION ANALYSIS

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 Connection with superstructure

3 Stress concentrations

BV HULL EXPERTISE TORSION ANALYSIS TORSION ANALYSIS

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 Steps for Fatigue calculation of side shell longitudinals:

» 1st step : 2D Fatigue Analysis

» 2nd Step: 3D Fatigue Analysis

 Fatigue calculations for Hatch corners

» One Step: 3D Fatigue Analysis

3 BV HULL EXPERTISE FATIGUE ANALYSIS FATIGUE ANALYSIS

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3  Side Shell longitudinals

Fatigue Hot spot 1

Fatigue Hot spot 2 Damage Fatigue Life calculation to be over 20 years

To compare with Mars results

BV HULL EXPERTISE FATIGUE ANALYSIS FATIGUE ANALYSIS

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3  Hatch Corners

In order to increase fatigue life, compromise between:

- sufficient reinforcement - smooth grinding

Hatch corner in the midship and fore part

Hot spot edge of the corner Especially fore part area due to high torsional loads

BV HULL EXPERTISE FATIGUE ANALYSIS FATIGUE ANALYSIS

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3  Hatch Corners

In order to increase fatigue life, compromise between:

- sufficient reinforcement - smooth grinding

Hatch corner in the aft part at ER

Hot spot edge of the corner Smooth Grinding improves the fatigue life by 2

BV HULL EXPERTISE FATIGUE ANALYSIS FATIGUE ANALYSIS

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3  Slamming

Maximum impact in forward area:

- Buckling in transverse frames

- Buckling on side shell plate and stiffeners - Detail connections in forward area

VeriSTAR calculations with maximum vertical acceleration and in sagging condition.