Military Institute of Science and Technology

Department of Naval Architecture and Marine Engineering

Industrial Training ,NAME 450

REPORT ON
KHULNA SHIPYARD LTD (KSY)

SUBMITTED BY:
Lt Israt Jahan
Roll : 201724049
NAME 5

1
 INDEX

S/N Contents
01 Acknowledgement
02 History of KSY
03 Designing and planning
04 Platter shop
05 Machine shop Outdoor
06 Machine shop Indoor
07 Electric Shop
08 Maintenance Shop
09 Carpentry Shop
10 Anchor Section
11 Rubber Factory
12 Foundry Shop
13 Summary

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ACKNOWLEDGEMENT

First of all, we are deeply grateful to Almighty Allah, who gave us patience and strength to
complete the Industrial Training overcoming all obstacles.
We are grateful and we wish to express our deepest gratitude to instructors,for invaluable
guidance, for the long time and tremendous effort to offer every possible help to finish this
industrial Training within their very busy time schedule.
We would like to thank our instructors who guided us at various Shop.

3
At a Glance KSY

Khulna Shipyard Limited (KSY) is an independent Government commercial enterprise under

Ministry of Defense, Government of Bangladesh, operated by Bangladesh Navy. The Shipyard
works directly under the Naval Head Quarter.

KSY with over six decades of reputation has been leading the Bangladesh Shipbuilding
industry and had built a wide spectrum of ships conforming to rules and regulations of
leading international classification societies. By making investments in fostering talent and
upgrading its technologies and facilities, the company is making vigorous efforts for
becoming a leader.

KSY over the years has been developed into a leading ship building and repair organization. It
also undertakes marine services as well as manufacturing of engineering items in order to
support country's industry including power sector.

Skills, expertise and experiences gained over more than 60 years of ship design and
construction will certainly ensure the continuity of our traditional quality and craftsmanship.
Its purpose is to help the customers in their maritime operations through the effective
repair/maintenance boats and vessels.

This is achieved by the development and construction of functional vessels, which we carry
out in continuous consultation with maritime operators. These ships are specially designed
and built to meet the operational and commercial needs of our present and future
customers.

In our striving for effective business development, we consider continuity in the relationship
with both our customers and our suppliers is of the basic importance. Satisfied customers are
fundamental to our success. Consequently, the multi-skilled work force and professional
management are always dedicated to the supply of the best possible quality vessels and
services.

Historical Background of KSY

KSY is about 56 years old. The construction works of KSY started in 1954 under supervision of
the East Pakistan Industrial Development Corporation (EPIDC) with the technical support of
M/s. Stulcken Sohn, West Germany provided the design for the construction of the yard
facilities.

After completion of works, It was commissioned on 27th November 1957, with the objective
to build and repair ships of various clients, for defense, coast guard, oil company, ports,
BIWTC, BIWTA etc and manufacture engineering parts to support other industries.

4
M/s. Burness Corleft and Partner, UK and M/s. Maienform SA, Swiss administratively and
technically managed the company up to 1967. Afterwards the control was vested with its
own expert engineers both technically and administratively.

At last Bangladesh Navy took over the responsibilities of KSY since 09 May, 1999, although,
the enterprise was ceremonially handed over by the honourable Prime Minister of the People
Republic of Bangladesh on 03 October 1999.

The shipyard commenced ship repair operations in the year 1957 and has undertaken repairs
of all types of vessels including up gradation of ships of private company as well as periodical
lay up repairs and life extension of ships of Navy, Coast Guard, Fisheries etc. The yard has,
over the years, developed adequate capabilities to handle complex and sophisticated repair
jobs.

Besides these, many heavy duty spares for different industries have also been made by this
organization. It's versatile dock facilities can accommodate a good no. of ships at a time for
repair or new building.

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Yard Facilities

‣ A slipway with a capacity to dock and undock vessels up to 700 tons light weight and
overall length of 90 m.
 Ships repair on dock in eight berths, each of 100 m in length for berthing.
 A set of slipway and carriage to dock and undock vessels up to 700 tons light weight and
overall length of 90 m.
 Ten Berths (Tracks) each of 100 m length to build/repair vessels; two of which are under
fabrication shed.
 Berth Crane: One x 8 tons capacity and 2 x 5 tons capacity.
 Jetty Crane: One x 30 tons capacity.
 Mobile Crane: One x 30 tons capacity, One x 10 tons capacity
 Workshop Crane: Shops are equipped with overhead crane of various capacities ranging
from 5 to 30 tons. Procurement of new cranes is in progress.
 Production Capacity: 2000 tons of steel work per year.
 Excellent assembly and outfitting area ensure a good working environment for high quality
construction under tight schedules. These shipbuilding areas have ample space and
equipment for the simultaneous outfitting of 10 medium/ 20 small sized vessels.

Aim:
Our aim of this industrial training is to gather practical knowledge from KSY

6
 DESIGN & PLANNING

Jorip boat design by KSY

The design & planning section is the one of the key section that perfoms the new building
and innovations in the vessel designing .
Some of the basic function of the D & P are the new design , design modification, tender
processing , project management etc. The major drawings of the ship are :
 Basic design
 Hull construction design
 Outfitting design
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  Machinery and piping design
 Electrical design

Basic design:
The basic design includes the GA plan, lines plan, load line calculation, power and resistance
calculation, intact stability, damaged stability, propeller calculation, capacity plan

Hull construction design:

It includes midship section drawing, shell expansion drawing, frame drawing, longitudinal
drawing, engine foundation drawing, superstructure construction drawing, skeg construction,
rudder construction, bilge keel construction.

Outfitting design :
The outfitting design includes hatch design, derrick design, ladder design, manhole design,
mast design, railing,door, windows design

Machinery & piping design :

The design of bilge pipes ,sounding pipe,lube oil system,fuel oil system,
Black water system, shaft line design are included in this section.

Electrical design :
The electrical load balance , cable tray ,load distribution,air cooling system,navigation lights,
switch board system these designs are included here.

DESIGN & PLANNING STEPS :

 For design of ship the shipyard collects a proven design.the design collection is done
usually either by procurement from abroad or the design house of Bangladesh.Then
on receiving the design the d&p section makes necessary arrangement and
modifications as per the owner requirements.The hull form is kept according to the
proven design.
 Then taking the GA plan and lines plan they give input in RHINO software to generate
the 3D model.necessary adjustment is done for hull smoothness.Though the shipyard
procured ‘FORAN-B’ software the use of this has not yet been started to a great
extent.
 The 3D modelling once completed the model is given input in hydromax software to
carry out stability check.
 Then by taking the desired speed in consideration with help of maxsurf software we
determine how much power is required to establish in the ship.usually its done using
MAXSURF resistance module by “HOLTROP MENNEN” procedure.

8
Now in case if a ships fails to meet stability criteria the methods that are followed to rectify
problems is:
 Increasing metacentric height
 Lowering the center of gravity which is done by increasing the weight of underwater
portion such as underwater plate thickness & making superstructure light .
 Keeping machineries in underwater portion
 Sustainable increase of breadth
 Very conventional technique is ballasting of underwater portion

PRODUCTION DESIGN:
Once the planning is done the production design is initiated.the production design includes :
Scantling calculation which includes the determination of the size of stiffening members that
would prevent buckling.The frames ,sections, bulkheads and longitudinal sections are
designed.usually for seagoing vessel more than 120m length we go for longitudinal
construction & smaller crafts undergo transverse construction .
After the skeleton of the ship is made it goes of hull plating.Then with help of various RULE
BOOK rudder and propeller are designed.
Then the sea water system , fresh water system,fuel oil system,lube oil system,piping system
,tank plans are designed and the final spool drawing is provided for production.
Then the electrical drawing is made to show how the wires will pass though one part of ship
to another.The breakers,switch boards,equipments which will be placed where is mentioned
where it will be placed.
Finally Outfitting design is done.it covers wide range of equipments including
winch,mast,capstan,guard rails,bollard etc. each of the equipment bears a definite
“EQUIPMENT NUMBER” which gives us size of outfitting equipments according to RULE book.
Finally we had site visit in the fabrication shed and we were briefed how from design they
make ships step by step.This attachment was really helpful for us to understand production
from drawings and so on.

9
 PLATTER SHOP
Platter shop in the main part of production of shipyard. There are two parts of

platter shop in KSY. One is main shop another is fabrication shed. There is two

types of working procedure exist in platter shop. Those are-

1)Sub-assembly / Traditional method

2)Block assembly

In KSY traditional process in being practiced. Mainly sub-assembly is the skeleton

of ship building and block-assembly is dividing the ship structure into various

parts. There is some limitation in KSY behind not following method such as-

1)Limited carriage system

2)Length limitation up to 75m

3)Loading crane limited up to 70 tons

Platter shop perform mainly two segment job. Those are-

-New Ship Building

-Repair works

The process of this two segment is described below-

NEW SHIP BULIDING PROCESS:

1) Bending: There are two types of bending is conducted in KSY platter shop. One is
permanent bending another one is temporary bending. For bending of platters of
them are
-Roller
-Hydraulic press machine
-Grinding machine

In this platter shop, plate of thickness (8-12) mm can be bend

2) Penetration: For fine penetration this shop is equipped with various machineries,
such as –
i. CNC cutting machine
ii. Welding machine
iii. Grinding machine

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 3) Fine works: For fine works some useable machineries are-
i. Gas cutting
ii. Manual
4) Finishing job: After cutting and fine works the job is done with-
i. Manpower distribution
ii. Raw material supply

Manpower Distribution
↘ OIC

↘ Officer

↘ lead man

↘ Worker ↓

1)GAS cutter

2)Mechanic

REPAIR WORKS
Repair works deal with the repairing of existing ship. This is also divided into various
segment. Those are-

Manpower Distribution
↘ OIC

↘ Officer

↘ Lead man

Worker

Materials:
1) They are estimated by design and planning section
2) There are two types of materials

Purchases:
Demand→Main store
↘ ↓
Commercial

Plates: Some of the plates are

1) Mild steel (MS)

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 2) Stainless steel (SS)
3) Aluminum (Al)

There are various types of welding conducted in platter shop. The welding method

and pattern is depending on the material. Most using metals in ship building

industry is mild steel (MS), stainless steel (SS), aluminum.

Mild steel has Two types of welding

-Electrode (Stick welding)

-CO2 (Wine rolling)

Carbon dioxide welding is fast, average quality and stick has porosity. Carbon dioxide welding
normally used in compact or enclosed compartment and stick welding is used in outside wall
of the compartments.

Aluminum metal needs MIG welding. MIG welding means metal inert gas welding.
The gas is helium but the helium is a costly gas. There are few more types of welding –

1) Bimetallic joint (MS-AL)

2)Special welding (SS-MS)

3)TIG welding

4)MAG welding

These welding are described below-

Bimetallic welding: This type of welding is using mild steel and aluminum joint.
TIG welding: tungsten inert gas (TIG) welding consist of pipe and high pressure.
There is an electrode which creates arc with low production and better quality.

MIG welding: Metal inert gas (MIG) welding is equipped with argon gas and for filler
metal aluminum is used.

MAG welding: Metal active gas welding is also a most using welding, that is consist
of an active gas.

Submerge arc welding: This type of welding conducted for underwater operation.
They have some special type of filler metal with special coated on it.

12
This shop is also equipped with various machinery. There is plate edge beveling machine, it
makes the surface of plate ready for welding up to thickness of 14 mm

There is a shearing and punching machine, which cuts up to 12 mm angle acts like a cutting
scissor. Job cutting of five types of shapers can be performed at a time.

There is a leg operated shear machine that cut up to 5 mm plate and guillotine shear
machine cut up to 8 mm plate.

There is also a CNC cutting machine. It is an amazing equipment. it cuts any metal by plasma
up to 25 mm. The allowance required is 25 mm.

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 Machine shop (outdoor):

We get knowledge on the works of the outdoor unit

 Manpower:

There are 12 officer, 150 worker in the outdoor unit

Works:

 All machinery equipment like propulsion system (propeller ,bush , bearing)

 Steering system (rudder alignment)
 All machinery in ship (pump ,fuel oil transfer pump)
 Different valve survesing and construction
 Pipeline construction & repair
 Cooling pipeline ,fuel oil piping system ,lub oil piping system.
 Material:
MS, Stainless steel, Cu-Ni , Cu ,Al

 Terminology:
 STP – STP stands for sewage treatment plant .It is used in sanitary line where
black water is mixed with Cl
 Oil separator- It is used to separate oil
 Oil water separator – It is used to separate oil & water .Then oil is stored.
 Variable frequency unit- To put up water from below .Moral of mechanical is
measurement
 To measure the shaft alignment straight gauge ,filler gauge ,dial gauge is needed.
There are two types of pumps

 Gear type – This type of pump is used where there are high pressure & viscous
 Centrifugal pump – This is used where viscosity is low

 Material – For sea water pump Cu ,Cu-Ni is used for flammable liquid pump Ms ,Ms-
black ,galvanize Ms is used
 There are two types of pipe
 Sime pipe
 Simless pipe

 Pump selection:
 Tank height

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  Pipe length
 Pump power
Manometric head is the pump head consists of delivery & Suction head

 There are two types of valve

 Ball valve
 There are two types of shaft alignment
 Piano wire method
 Laser light method
 Piano wire method is subjected to sagging due to own weight of wire & used for initial
alignment
 Laser light method is used for final alignment
 Alignment refers the alignment of bearing A & P bracket ,bush housing etc.
 In the stern gland there is bush

 There are 3 types of bush

 Rubber cutlass bush

 Lignum bita or wooden bush
 Gun metal or white metal bush
 Rubber bush cooled by sea water
 Gunmetal bush cooled by lub oil
 Bushes are changes usually within 12-18 months
 To align the shaft the piano wire passes through geometrical center of couplings and
thus misalignment is measured which cause hull vibration
 Most shafts are keyless ,some are keyed
 Deep sea seal is used for water tight integrity .Inside it there is rope packing and this
seal remains at fwd & aft of stern tube.

 Azimuth propulsion system needs rotating capability . No rudder is needed.

 Propeller itself rotates in require angle & requires a lot of engine power.

15
 Stationary and rotary part of journal of shaft was shown . Rotary part consists of
rubber & iron and there remain a hole which helps the air cooling.
 The size of the journals are designed according to shafts dimension & calculation.
 Hydrophore system was shown which has two pumps .Pumps are used to get
required sea water onboard for domestic purposes as well as some water cooling
purposes.
 A tank is fitted with hydrophore system which hold the water pumped . 3 N/cm2
pressure is the starting pressure and when the desired starting pressure arises the
hydrophore system runs automatically .

16
MACHINE SHOP ( indoor ):

The indoor section of machine shop plays a vital role in shipbuilding industry. The KSY
machine shop indoor section is equipped with various machineries.
The list of machineries include:

 Different sized leathe X 13

 Radial drill machine X 2
 Pedestral drill machine X 1
 Shaper machine X 4
 Milling machine X 4
 Surface grinding machine X 1
 Cutter grinder machine X 2
 Engraving machine X 1
 Horizontal boring machine X 1
 Slaughter machine X1
 Power saw machine

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Functions:
Some major repair works are conducted in machine shop indoor section. These are mainly
the repairing of different parts of ships.

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These are:

Propeller repairing:
If the tip of the blade is damaged because of corrosion or other incident that can be repair
according to the constructed metal of that blade. If the blade is damaged by more than 45%,
it can’t be repaired. Up to 5% of tip loss can be repaired here, more than that we need to
replace the propeller. If there is a crack it be repaired also.

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CPP repairing:
CPP stands for controllable pitch propeller. It is constructed with O-ring, bracket, main shaft,
holo shaft etc. A hydraulic function is attached to the hub. Normally the seal of the hydraulic
system breaks and oil leakage. These problem can be solved or repaired by this shop.
We came to know about CPP shafting and propeller mechanism and various problems
replaced with controllable pitch propeller.

Apart from these we came to know about fixation of plummer blocks and also knew that if
any problem occur outside the hull then the ship need to be docked.

20
 Electrical Shop
Today we had an attachment with electrical section. They mainly work with the power side
and the radio electrical section work with communication. Electrical shop performs various
type of work. More over some significant jobs are
1. Cable laying according to the GA drawing while hull is completed
2. Supply of electricity to the shipyard
3. Electrical works on board ships
4. Maintenance of electrical equipment
As a part of visit we were taken to the power house of the shipyard . Its high tension line. Its
having 11000 KVA per phase.
Objective :
1. To learn about the power distribution of the shipyard
2. To learn about the works and coordination of the electrical section.

Power House :
Power house is station of electrical supply through shipyard. The diagram is

21
 PDB
VCB

Fus
es

Transfor 11kv outp

mer
Step
down ut (440-
380)

low tension
pannel (LT)

Other
Main shop other Shop
building

Fig : Power house Diagram

Initially the power form PDB come to the VCB( vacuum circuit breaker ) by drop fuse . From
VCB it gets transferred to 3 fuses . From fuse it goes to the transformer . Then it will be
stepped down from 11000KV to output of (440 – 380) volt .
From transformer it goes to low tension panel from there it will be distributed to various
shops . A power factor value of (0.8 -0.9) is maintained . To keep power factor correct
capacitor bank is used . The Capacitor bank is connected in parallel with low tension panel .
There are 60 in no of capacitor having capacitance to provide support up to 1200 KvAR .
There is a bus bar in vacuum circuit breaker when there is any overload it will give alarm.

Air compressor :
One if the important features of power house is air compressor . Automatic air compressor is
operated. An air tank is attached to the compressor when compressed air is used the
pump automatically fills the bank . There are 2XAtlas COPCO air compressor these are used
to produce compressed air for sand blasting and they are kept in reserve tank and when the
pressure reduces the compressor automatically.

22
Factors of Generator:
The generator is both having 1500 rpm .
1. When the generator is overloaded or overspeed , it shuts down
2. If the engine is run on low fuel or low lube oil then generator shuts down
3. If the generator is over load, engine chees down

in their cases the generator gives signal . There are 2 generator one of 700 KVA another of
560 KVA . There is moulded case circuit breaker on generator by switching that on and using
the change over switch the power is taken. To start the generator 4 batteries each of 12 volt
is used which is connected in parallel and 24 volt whichhhhh act as starter for DC motor.
Regarding the problems of generator the alternator coil is checked , AVR checked ,if there is
air lock in fuel line the machine shop people works on it
Voltage control devices are
VCB = vacuum circuit breaker
ACB = Air circuit breaker

Change over Switch:

The change over switch is used to transfer from PDB power to generator power . The north
berth, south berth, plater shop full power is switched on or off by knife switch .
We had visited the battery charging and repair room. The Sulphuric acid is given feed is 1200
– 1500 gravity

Conclusion
The power house visit ended with observing the transformers and knowing their step down
function. The two transformer are in action and two kept reserve in case of any failure of
other two.
From above we came to know about the electrical section and power house in brief . The
knowledge which we gained practically will surely help us in our future days to work as an
engineer.

23
 MAINTENANCE SECTION
Maintenance section is one of the important sectors in Khulna shipyard. The basic job of this
section is to support the whole shipyard organization by repair and maintain the works done
here. The manpower of this section includes Officer (3 in no.), staff (1 in no.) and workers (25
in no.).
There are three types of maintenance is done in regular basis. They are-
1)Routine maintenance
2)Schedule maintenance
3)Breakdown maintenance
There remain various scopes for this maintenance section which are divided into 3 parts.
They are- i) Mill & Maintenance
ii) Vehicle & Transport
iii) Air & Water supply
In broad sense the scopes are described as:

 Installation, repair and maintenance of all type of machinery at KSY.

 Installation, repair and maintenance of pipelines at KSY. i.e. fresh water pipeline, sea
water pipeline, compressed and liquid pipelines.
 Installation, renovation, repair and maintenance of all type cranes; such as Portable
crane, Overhead crane, Jetty crane, Derrick crane etc.
 Installation, repair and maintenance of all vehicles at KSY.
 Repair and maintenance of all pumps at KSY.
 Above all, all types of mechanical repair and maintenance are done in this section.
There are different types of machineries like engine, pump and other machines kept to brief
the procedure to installation, repair and maintenance. There details are written below-
o 4 cylinders automobile engine (3 in no)
o 2 cylinders diesel engine (2 in no.)
o Fuel pump & injector remains in diesel engine and spark plug & carburetor remains in
petrol engine.
o Butterfly is the updated device of carburetor for air-fuel mixture.
o Various types of compressors are; Air compressor, Rotary compressor, Centrifugal
compressor etc.
o Air compressor is two types.
such as: a. Dynamic
i)Axial
ii) Rotary
b. Reciprocating

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 i) Single stage
ii) Double stage
iii) Multi stage
iv) Diaphragm
Rotary compressor types are- a. Screw type
b. Vane type
c. Lobe type
d. Water ring
o Low compressor exerts 10 bar
Medium compressor exerts 200 bar
High compressor exerts above 200 bar
o The compressors are used to drive the pneumatic machines.
o The power house compressors are screw type rotary compressor
o Chain, pulley etc. devices are maintained in this sector.
o For load lifting different types of jacks are used.
o They are- i) Mechanical jack
ii) Hydraulic jack
o Basing on power, pumps are two types- a. Submersible pump
b. Centrifugal pump
The submersible pump has an impeller which remain under water while operation.
For example, sea chest pump.
The centrifugal pump is used for above water operation and its impeller has a suction
pipe to transfer water.

 There is a difference between engine and machine.

Engine converts thermal energy of fuel into mechanical energy which is used by
engine itself.
Machine is an assembly of different parts which itself cannot produce energy.

25
 CARPENTRY SHOP
Carpentry shop is the second from the aspect of work they perform onboard. They have
three departments. They are
1. Sand blasting section
2. Furniture and cabinet section

3. Cell making section

Besides Platter Shop has a number of bending, shearing etc. machinery to repair and renewal
the ships. The facilities provided by the shop are:
 Wooden Works.
 Furniture Making and ship fitting works
 Pattern Making
 Sand Blasting and Painting
 Lagging and Insulation
 Fabrication of Clothing and Rexin Items

In the carpentry shop they have bend saw and circular saw.by these tools they cut the
wooden blocks and trees in different shapes. The side planning machine smoothest one side
of the plane. The thickness in auto planner is set according to preset scale and three sides are
smoothened automatically by this.
The blade angle of circular saw moves at a different angle up to 900.the hand lever is having
the option to cut by a set scale.
Tenon machine uses cutter heads or saw blades to form projections on piece of stock.it cuts
in cone sides and there is a mechanism to produce Al and Bin on the sides.in the mortise
machine the bin is created.it is leg pressed hydraulic machine.by changing it cutter head
grooves are made in different sizes.
The copy rouder machine cuts the side of work pieces in a present design.
There are also double head boring machine and zigzag saw which cuts as per the drawing
done on the board.
There is a wood turning machine in this shop which works like a lathe machine. There is also a
pattern and gift making section.

26
In the sail making section they do the work of lagging which is the heat insulation and the sail
making section performs all ships husbandry works and supply them.
There is also sand blasting section .the berth is both automatic and manual .in sand blasting
section 7mX14m block can be blasted. There are ten blowers to suck dust and blasting is
done by iron grinding.

27
 ANCHOR SECTION
Anchor section is consisted of different types of anchor elements. There is also a slipway
carriage. The slipway is both upward and downward. The ratio of upward and downward slip
is 1:10
The slipway carriage is consisted of an operating carriage and a loading carriage. Where side
docking process is followed to take up the ship for docking and undocking .the carriage
length is of 270 ft, breadth is 25ft and draft id 4m.
The initial requirements for docking and u docking are GA plan. The materials that are
needed for docking are
 towing carriage
 block
 docking girder
 trolley etc.

After the collection of GA plan docking girders are placed. Then the loading carriages
are aligned at the center .cross rope are placed to pull the ship towards the chalk.

28
29
30
 RUBBER FACTORY

Khulna shipyard limited added Rubber Factory in the industry. Rubber Factory is used to
produce quality rubber product for ships, submarines, tugs, pontoon, jetties etc. for
Bangladesh Navy, Bangladesh Coast Guard, Border Guard, Port Authorities and other
maritime organization.

Scope
Rubber Factory ensures their customers that the equipment is both safe and long-lasting one
with their made products in terms of duration, quality, reliability and technology.

Capability
The factory is capable of manufacturing vessel's shaft seals, under water 'A/P Bracket' rubber
bearings, propeller seals, CPP system seals, different 'O' rings, engine mountings, rubber
impellers, hydraulic and pneumatic seals, rubber gaskets, bellows, door and hatch seals, jetty
fenders etc. Maximum rubber product size up to LXBXH= 2m X 2m X 1.2m Vulcanizing
capacity up to 1200 tons. The factory possess around 300 molds of submarine rubber item
fabricated in China. KSY mold fabricating machines are capable of fabricating any shape of
rubber mold. With these mold various sophisticated rubber item can be produced which is of
international standard

Departments The departments of rubber factory are

1. Product & Mold Design.
2. Rubber Item Production.
3. Quality Control & Test Laboratory.
4. Research & Development.
Machineries

31
 1. There are CNC machines for mold fabrications,
2. Kneader and rolling mills for rubber compounding,
3. Calendar machines for manufacturing fabric sheathed rubber,
4. Sand blasting machine for metal insert inside rubber,
5. Hydraulic press machines for vulcanizing
6. Various test equipment for strict quality control.

It is indeed a complete solution arena for customized rubber item production.

Product Range

 Arch Jetty
 Fender Rubber
 Cutlass Bush
 Submarine rubber items
 Tug Fender
 Lip Seal
 Shaft Gland Sea
 Rubber Bellows
 Rubber Impeller
 Rubber Gasket
 Rings
 Door Seals
 Engine Mounting
 Rubber Mat
 Call Jetty Fender

Quality
1. Provides reliable and dependable rubber product.
2. Modern laboratory equipment to ensure quality

The quality procedure of this rubber factory is certified by international classification society
‘Bureau Veritas’.

About the Factory

32
KSY Rubber Factory possess total 50,000 sq. ft. Area, where main production workshop is
17,000 sq. ft. Equipped with different production equipment, mold warehouse, raw material
store and finished product store. There is a separate test laboratory of 3,200 sq. ft. and office
space of 3,200 sq. ft. Besides, there is an open space (26,600 sq. ft.) for future expansion. The
factory possess around 300 molds of submarine rubber item fabricated in China.

33
FOUNDRY SHOP
MACHINERIES/EQUIPMENT PACK

34
Content

SL Name of Machineries Page No

No

01 Cupola Furnace, Capacity – 3.5 Ton 03-04

02 Cupola Furnace, Capacity – 1.5 Ton 05-06

03 Tilting Crucible Furnace, Capacity – 300 Kg 07-08

04 Fixed Crucible Furnace, Capacity – 100 Kg 09-10

05 Overhead Crane, Capacity- 10 Ton 11-12

06 Moulding Sand Preparation Machine 13-14

07 Rockwell Hardness Testing Machine 15-16

01. Cupola Furnace, Capacity – 3.5 Ton

PRINCIPAL PARTICULARS OF THE EQUIPMENT:

a) Name of the Equipment: Cupola Furnace

b) Capacity: 3.5 Ton

c) Quantity: 02 Nos
d) Types of Configuration: Manual Operating and Control System.
e) Types of Fuel: Hard Coke
f) Spare Parts:
i) Motor of the blower ii) Outer-shell MS plate iii) Firebrick.

g) Manufacturer name and address: Data Missing.

h) Purpose: Melting and casting of Cast Iron Family metal only. Steel can’t be
melted and casted due to maximum reachable temperature 14500C.

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Cupola Furnace, Capacity – 3.5 Ton

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02. Cupola Furnace, Capacity – 1.5 Ton

PRINCIPAL PARTICULARS OF THE EQUIPMENT:

a) Name of the Equipment: Cupola Furnace

b) Capacity: 1.5 Ton
c) Quantity: 01 No
d) Types of Configuration: Manual Operating and Control System.
e) Types of Fuel: Hard Coke

f) Spare Parts:
i) Motor of the blower ii) Outer-shell MS plate iii) Firebrick.
g) Manufacturer name and address: Data Missing.
h) Purpose: Melting and casting of Cast Iron Family metal only. Steel can’t be melted and
casted due to maximum reachable temperature 14500C.

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Cupola Furnace, Capacity – 1.5 Ton

03. Tilting Crucible Furnace, Capacity – 300Kg

PRINCIPAL PARTICULARS OF THE EQUIPMENT:

a) Name of the Equipment: Tilting Crucible Furnace
b) Capacity: 300Kg
c) Quantity: 03 Nos

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 d) Types of Configuration: Manual Operating and Control System.
e) Types of Fuel: Diesel.
f) Spare Parts:

i) Motor of the blower ii) Outer-shell MS plate iii) Firebrick.

g) Manufacturer name and address: Data Missing.

h) Purpose: Melting and casting of non-ferrous including Copper alloys, Aluminium, Zinc
Anode, White metal and Cast Iron Family metal. Steel can’t be melted and casted due
to maximum reachable temperature 14500C.

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Tilting Crucible Furnace, Capacity – 300Kg

04. Fixed Crucible Furnace, Capacity – 100Kg

PRINCIPAL PARTICULARS OF THE EQUIPMENT:

a) Name of the Equipment: Fixed Crucible Furnace

b) Capacity: 100Kg
c) Quantity: 01 No
d) Types of Configuration: Manual Operating and Control System.
e) Types of Fuel: Diesel.

f) Spare Parts:
i) Motor of the blower ii) Outer-shell MS plate iii) Firebrick.
g) Manufacturer name and address: Data missing.
h) Purpose: Melting and casting of non-ferrous metal including Copper alloys,
Aluminium, Zinc Anode, White metal and Cast Iron Family metal. Steel can’t be
melted and casted due to maximum reachable temperature 14500C.

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Fixed Crucible Furnace, Capacity – 100Kg
05. Overhead Crane, Capacity- 10 Ton

PRINCIPAL PARTICULARS OF THE EQUIPMENT:

a) Name of the Equipment: Overhead Crane
b) Capacity: 10 Ton
c) Quantity: 01 No

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 d) Types of Configuration: Manual Operating and Control System.
e) Types of Power Supply: Electric
f) Spare Parts:

i) Motor ii) Wire Rope iii) Busbar

g) Manufacturer name and address: DEMAG, Germany.
h) Purpose: Handling of liquid metal and other materials.

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Overhead Crane, Capacity- 10 Ton

06. Sand Preparation Machine

PRINCIPAL PARTICULARS OF THE EQUIPMENT:

a) Name of the Equipment: Overhead Crane

b) Capacity: 300Kg
c) Quantity: 01 No
d) Types of Configuration: Manual Operating and Control System.
e) Types of Power Supply: Electric
f) Spare Parts:

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i) Motor ii) Different steel Parts
g) Manufacturer name and address: Data missing.
h) Purpose: To prepare molding sand.

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Sand Preparation Machine

07. Rockwell Hardness Testing Machine

PRINCIPAL PARTICULARS OF THE EQUIPMENT:
i) Name of the Equipment: Rockwell Verzus -710RS Hardness Testing Machine.
j) Capability: Capable to determine the Hardness of Ferrous and Non- Ferrous metal.
k) Quantity: 01 No

l) Types of Configuration: Automatic Control System.

m) Types of Power Supply: Electric
n) Spare Parts:
i) Indenter ii) Calibration Block iii) Anvil.
o) Manufacturer name and address: Innovatest, Netherland; www.innovatest-europe.com
p) Purpose: Used for determining the Rockwell Hardness number of carbon steel, alloy steel,
cast iron, ferrous, non-ferrous metal.

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Rockwell Hardness Testing Machine

Casting Facilities in Foundry shop:

Cast Iron Family:
a)Anchor b) CI Pump House c) CI Fairlead d) CI Flange e)Ductile Iron Rubber Cutlas Bush
Mould f) CI Solid Bar g) CI Bush h) CI Coupling i) CI Impeller j) Gear k) Engine Casing l) Sugar
Mill Roller m) Capstane n)CI Wheel.
Copper Alloys:

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Brass: Different types of Brass Material.
Gun Metal (GM):
a) GM Bush b)GM Sleeve c) GM Flange d) Propeller e)Impeller

f) Butterfly Nut g) Gift Items.

Aluminum:
a) Al Bush b) Al Sleeve c) Propeller d) Impeller e) Engine Mounting Block.
Zinc: Zinc sacrificial anode.
White Metal: Applied for decreasing friction.

SUMMARY:

These are the ides about facilities available in Khulna shipyard Ltd. I have also mentioned the
prospect of shipbuilding industry of Bangladesh. BN is trying to run it commercially by
appointing naval officers at higher echelon of management. The naval authority has restored
discipline in all spheres and reduced production cost quite remarkably and managed to make
it profitable organization. At the same time shipyard has plan to modernize the shipyard in
phase to meet the future challenges.

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