Production

Conservation and Preservation

FSG has studied the subject of IMO-PSPC extensively. The product-independent certification of a PSPC compliant coating procedure on the shipyard is now in progress. The first step of the PSPC requirement (Primary Surface Preparation) is already being carried out at a sub-contractor’s steel facility in compliance with the standard. At our own operations here at FSG we have employed a certified paint inspector who is a member of our permanent staff. To the customer this means guaranteed PSPC compliant processing of his product without ever having to worry about the execution of each and every step in the individual phases of the manufacturing processes.

Furthermore, FSG has developed its own system toward a structured and complete line of documentation of all executed conservation processes. Through the compilation of all necessary and relevant documents in electronic form, all documents are automatically available and may therefore be easily viewed and examined. In this way the current status can be identified at any given time.

Independent of the implementation of the standards into the operating process FSG has, within the framework of a national research project, invested time and efforts in varying manufacturing methods for the production of corrosion-resistant edges. It was our aim to develop not only an economical version of manufacturing techniques, but to optimize the quality and life expectancy of edge preservation as well. For this reason, tests were conducted as to the service life of coating systems with regard to varying edge forms, as well as to the analysis of determining factors which may affect corrosion resistance, which is pertinent to edge preservation.

Pipes/Pipe installation

Pipes and pipe installation represent a large portion of the equipment installed on board. Since there is considerable distribution of the most varied of pipe systems throughout the entire ship this requires a wide range of pipe- types, diameters and materials. The expenditures involved in sorting and laying out the pipes during the installation process in such a construction is very high due to the large number of pieces and the difficult handling conditions involved. It is the aim of an optimized work process to be time-efficient through the use of deadline-oriented planning and the availability of the materials for proper assembly, which ultimately affects the time required for the construction of the entire ship.

On the level of manufacturing technology, the use of modern joining systems (welding with MIG or induction welding) is an attempt to reduce the heat input created in the process of joining pipes, to a minimum. As a result, and besides the benefit of obtaining well defined and reproducible levels of quality, it permits the use of smaller material thicknesses, which in turn creates considerable weight reduction benefits.

Shipbuilding

One of the most important developments in production philosophy is the development from customized to precision manufacturing.

While in the process of customization the semi-finished products must first be made to fit prior to their assembly, precision manufacturing offers manufacturing of components at tight geometric tolerances during all of the manufacturing phases, in order to permit assembly of these components, without further fitting procedures, directly with the next larger assembly group, all the way to the completion of the hull.

The greatest challenge in this work process is the secure mastery involving thermal deformation which is primarily created through the welding process. A high level of precision with regard to individual components, highly precise positioning, reproducible, consistent joining and welding processes, and careful consideration given to welding shrinkage during the construction process are important prerequisites to meeting this challenge!

As customisation on the building slip becomes unnecessary, the processing time is considerably reduced. Consequently, the resulting improvement in productivity represents a major factor in FSG’s ability to remain competitive. As incidental labor steps resulting from the assembly process are no longer required, an improved planning ability due to higher process reliability is one more benefit to our customers and is reflected in the permanent adherence to delivery times.

As a result of precision manufacturing, the high level of quality afforded by the cuts and joining preparation as provided by modern plasma cutters remains assured over the course of all of the manufacturing phases involved. The availability of such precise joint geometry makes it possible to attain high-quality and reproducible welding processes. The thermal input, and consequently the level of deformation may thus be small and corrective steps may therefore be minimized.

Finally, less stress on the steel is created, so that the original material properties remain completely intact, an advantage which is hence passed on to the customer.

Welding Technology

It becomes clear that with a number between 120 and 140 kilometers (74.5 to 87miles) of welded joints per ship, the level of importance of welding technology is considerable, as far as the quality of the product is concerned.

Therefore FSG relies almost exclusively on modern wire welding techniques; 85% of this is gas-shielded arc welding, the most prominent form of application, with the remaining percentage going to submerged arc welding. In addition, highly advanced automation- and mechanization levels also contribute to good reproducibility and sustainable test results. Therefore, not only in flat or sectional manufacturing, but also during modular construction and in the process of building the ship’s body on the building slip, the use of tractor welders is preferable in all positions.

This will provide assurance of a uniformly high joint quality, even in areas where the quality can no longer be verified through an inspection process at a later time.

Moreover, impulse welding is being used in more and more applications over the course of more recent years. In combination with high-quality welding additives even smaller fillet welds can be carried out, while guarding against porosity. In other words: no repairs on the welding seams or joints, less welding shrinkage, and consequently a reduced tendency to result in deformation. A reduced risk of deformation or buckling also means less corrective steps and fewer adverse effects on the quality of the material.

In panel construction FSG uses both side welding applications. In this manner, welding deformation is kept to a minimum and corrective action to the panels with the unavoidable steel stress is eliminated. Moreover, the single run-two run welding method is suitable for welding high-strength and ultra-strength steel grades.

However, it is not only the application of the most up-to-date welding technology which determines the superior level of quality, but also the qualifications of new generations of skilled workers that contribute greatly to the high welding quality output at FSG. In order to lay claim to the high level of their own training, FSG trainees regularly participate in relevant competitions. This is how FSG provides, for example, half of the competitors who have come out of district competitions and are going into national competitions in the year of 2011.