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Scientific approach pays off for SHI

Thu 14 Apr 2016

Scientific approach pays off for SHI
Geoje Shipyard can claim the world’s greatest dock turnover rate

Samsung Heavy Industries’ (SHI’s) Geoje Shipyard can claim the world’s greatest dock turnover rate – the number of ships that a dock can launch. Dock turnover rate is a reliable yardstick for measuring a shipyard’s technical capacity and production efficiency.

The largest dock at the yard, Dock No 3, is 640m long, 97.5m wide and 13m deep. Ships built at this dock are mostly ultra-large vessels, including liquefied natural gas (LNG) carriers, ultra-large container ships and LNG floating production, storage and offloading vessels. The dock has the world’s greatest production efficiency, with a yearly dock turnover rate of 10.

This turnover rate of 10 has been achieved through SHI’s scientific approach to building. This includes making large-sized ship blocks, shortening the main engine loading period and utilising facility space efficiently by using ultra large-sized cranes.

SHI is a leader in the high technology, high added value ship market. It has built the world’s largest LNG carrier, at 266,000m3 and has secured orders for the world’s first ever very large ethane carrier and the world’s largest, 21,100 teu container ship.

Through the development in 2011 of a membrane-type LNG carrier cargo hold design, the first of its kind in the domestic industry, the company has further enhanced its competence in LNG carrier building.

SHI has developed a number of ground-breaking technologies in this area, including its pipe inspection and automatic cleaning robot for LNG carriers. An LNG carrier has a long pipeline which extends to almost 2km. After the welding process to connect the pipes has been completed, cleaning is carried out if necessary to remove undesired substances. As the interior of the pipe is dark and narrow, working inside it is regarded as very difficult. Moreover, the possibility of the presence of poisonous gases used during welding makes the job very dangerous.

To make the working environment more secure and to increase working speed, SHI developed a robot system that conducts inspection and cleaning at the same time. It inspects the inside of the pipe using a camera system, and cleans the inspected space using a brush and suction system. Two cameras are located on the robot’s front and rear sides, and one camera is attached on the robotic arm which has a 360 degree rotating range. When the robot detects undesired substances, it uses the robotic arm to remove the substance. Thanks to this robot, the quality of pipe inspection has improved. The system contributes to cost reduction and reduces the risks of working in hazardous conditions.

Recently, together with France’s Total and class society Bureau Veritas (BV), SHI has developed a concept for a highly efficient LNG carrier. The design is optimised to deliver high energy efficiency to suit future LNG trading patterns and routes and to comply with tougher environmental regulations. It optimises the hullform, propulsion and power-generation systems for conditions including a full voyage with loading and unloading, manoeuvring, a canal passage, and laden and ballast passages.

BV subsidiary HydrOcean optimised the hull lines, using state-of-the-art Navier-Stokes computational fluid dynamics tools for calm water performance and behaviour with waves. BV used its ship energy efficiency calculation and analysis tool SEECAT software to quantify the performance of several dual-fuel propulsion and power-generation systems, using a holistic energy model of the ship.

The team also developed a boil-off gas model, predicting the boil-off gas rate and lower heating value for the simulations. It also used key performance indicators, including capital expenditure and operating expenditure costs, to compare and select the optimal design, taking account of predicted gas and fuel consumption, forced boil-off gas quantity and the mass of cargo gas burned per voyage.

SHI is building two of these 180,000mᶾ vessels under BV class for delivery in 2017 to SK Shipping Co, for charter to Total.

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