Report Kelvin

Abstract
Piasau Slipways Sdn. Bhd. (PSSB) focuses on building tugboats, barges and small
vessels and also provides ship repair services. Throughout these 13 training weeks, the
industrial training activities mainly focused on the piping system of two 55ton bollard
pull tug ships. The purpose of these 55ton bollard pull tug ships is to import iron ores in
bulk from Brazil, then further export the processed iron ores through blending and
pelletizing in smaller vessels to other clients within the Asian regions. Once the harbor
tug ship is approved for sailing, the ship will be tendered over to the owner, Nautilus Tug
& Towage Sdn. Bhd. PSSB offers two units of the 55ton Bollard Pull Tug ships, with the
code/name of YD408/BPT Larut and YD409/BPT Lumut respectively. This projects
tender started in early 2012 and the ships construction started on 1st September 2013 and
currently one of the ships (YD408/BPT Larut) had been successfully delivered to the
owner on 22/2/2015. Meanwhile, YD409/BPT Lumut was still under construction and
was expected to be completed by early March 2015.
There were 11 types of piping systems been exposed throughout these 13 training
weeks, under a 2 years experienced piping engineer, Miss Elizacorina ak. Siguru
supervision. Many types of piping systems activities had been conducted and the
activities conducted were literatures studies on piping systems, site visit on piping
systems, assisted supervisor, contractors and yards foremen in hands on the pipes and
fittings, conducted material listing for each of the piping systems, assisted engineers and
Germanisher Lloyd (GL) representative in doing inspection and last but not least interact
with other engineers on solving tasks given by supervisor or any problems encountered
throughout these 13 training weeks.
Table of Contents
Chapter 1: Backgrounds of Company............................................................................1
Chapter 2: Summary of Duties.......................................................................................3
2.1 Week 1 (1/12/2014 6/12/2014)............................................................3
2.2 Week 2 (8/12/2014 13/12/2014)..........................................................7
2.3 Week 3 (15/12/2014 20/12/2014)......................................................13
2.4 Week 4 (22/12/2014 27/12/2014)......................................................15
2.5 Week 5 (29/12/2014 3/1/2015)..........................................................17
2.6 Week 6 (5/1/2015 10/1/2015)............................................................19
2.7 Week 7 (12/1/2015 17/1/2015)..........................................................21
2.8 Week 8 (19/1/2015 24/1/2015)..........................................................23
2.9 Week 9 (26/1/2015 31/1/2015)..........................................................25
2.10 Week 10 (2/2/2015 7/2/2015)..........................................................27
2.11 Week 11 (9/2/2015 14/2/2015)........................................................29
2.12 Week 12 (16/2/2015 21/2/2015)......................................................31
2.13 Week 13 (23/2/2015 25/2/2015)......................................................35
Chapter 3: Working Experience...................................................................................36

3.1 Project Carried Out............................................................................... 36
3.2 Supervisory work................................................................................. 59
3.3 Problem encountered and solving experiences....................................77
Chapter 4: Conclusion...................................................................................................80
Reference Lists................................................................................................................81
Appendix.........................................................................................................................82
Appendix A: Schematic diagrams of piping systems in a BPT ship............82
List of Tables
Table 1: 55ton Bollard Pull Tug ship details.................................................................2
Table 2: Week 1 summary of duties........................................................................... 3
Table 3: Pipes and bends in ships.............................................................................. 5
Table 4: Valves used in ships................................................................................... 6
Table 5: Week 2 summary of duties........................................................................... 7
Table 6: Common fittings used in BPT ships................................................................8
Table 7: Common valves used in BPT ships.................................................................9
Table 8: Week 3 summary of duties.........................................................................13
Table 9: Week 4 summary of duties.........................................................................15
Table 10: Week 5 summary of duties........................................................................17
Table 15: Week 10 summary of duties......................................................................27
Table 18: Several types of common piping corrosion....................................................33
Table 19: Corrosion and its preventions....................................................................34
Table 21: Material listing for bilge, ballast, firemain & wash deck system..........................39
Table 22: Material listing for fuel oil transfer system....................................................42
Table 23: Material listing for engine cooling system.....................................................45
Table 24: Material listing for domestic fresh water & sea water supply..............................48
Table 25: Material listing for grey water & black water system.......................................50
Table 26: Material listing for oily bilge & dirty oil system.............................................53
Table 27: Material listing for oil dispersant system......................................................54
Table 28: Material listing for lube oil system..............................................................55
Table 29: Material listing for external fire fighting system.............................................57
Table 30: Material listing for CO2 fire fighting system..................................................58
Table 31: Supervisory work for the BPT ships' piping construction progress.......................59
Table 32: Summary of the construction progress for both ships.......................................69
List of Figures
Figure 1: Flow chart of shipyard piping engineers roles..................................................4
Figure 2: Bilge, ballast, firemain & wash deck system block diagram...............................38
Figure 3: Fuel oil transfer system block diagram.........................................................41
Figure 4: Engine cooling system block diagram..........................................................44
Figure 5: Domestic fresh water & sea water supply system block diagram.........................47
Figure 6: Oily bilge & dirty oil system block diagram..................................................52
Figure 7: Lube oil piping system block diagram..........................................................56
Figure 8: Exhaust pipeline for port side....................................................................67
Figure 9: Exhaust pipeline for starboard side..............................................................68
Figure 10: Exhaust problem encountered..................................................................77
Figure 11: Initial design for the new exhaust arrangement..............................................78
Figure 12: Final design for the new exhaust arrangement...............................................79
Chapter 1: Backgrounds of Company
Piasau Slipways Sdn. Bhd. (PSSB) was formed on 17 October 1977, located at Lot
516, Piasau Industrial Estate. During that time, PSSB focused on building tugboats,
barges and small vessels. PSSB also provided ship repair services. As time passed by and
high fluctuation of economy, more vessels were required for timber products
transportation, PSSB decided to improvise their services by constructed a new shipyard
located at Lot 523, Kuala Baram Industrial Estate, 98000, Miri, Sarawak (Shin Yang
2013). Ever since 1996, PSSB had constructed and fabricated more than 199 vessels
which include motor launch, dump barges, hopper barges, coastal and deep sea tugboats,
landing crafts, container vessels and oil tankers for domestic and overseas market (Shin
Yang 2013).
According to Shin Yang (2013), the vision of PSSB is to be the Premier Shipbuilder
& Integrated Marine Structural Fabricator and One-stop Quality Marine Engineering &
logistics service provider in South East Asia and beyond. Meanwhile the missions are:
To operate a Modern Integrated shipbuilding base benchmarked for

Excellence in providing comprehensive, innovative and efficient Quality
services.
1
Adaptability to changes to retain sustained success and steadfast in

commitments to Heath, Safety, Environment and Quality values.
Committed to achieve Quality Assurance Management through quality

Planning, quality Improvement and quality control.
An integrated and proactive Heath, Safety & Environment Management

System, with full concern for preserving the Environment, health and safety
of its Employees, Neighboring Community and Customers
Currently, PSSB focuses on the construction of harbor tug ships, which offers
technical specification details within the scope of supply and services for the ships
design, engineering, construction and performance of sea trials for the ships.
The current project ongoing in PSSB is the ship construction of 55ton Bollard Pull
Tug (BPT) ship for VALE Malaysia Manufacturing (VMM) Project, located at Teluk
Rubiah, Perak state, Malaysia. As a brief introduction of this project, the purpose of this
project is to import iron ores in bulk from Brazil, then further export the processed iron
ores through blending and pelletizing in smaller vessels to other clients within the Asian
regions. Once the harbor tug ship is approved for sailing, the ship will be tendered over
to Nautilus Tug & Towage Sdn. Bhd. PSSB offers two units of the 55ton Bollard Pull
Tug ships, with the code/name of YD408/BPT Larut and YD409/BPT Lumut
respectively. This projects tender started in early 2012 and the ships construction
2
started on 1st September 2013 and currently is still under construction and is expected to
be completed by early February next year, 2015. Based on the final conceptual design,
both of these BPT ships have identical details as shown in Table 1 below:
Table 1: 55ton Bollard Pull Tug ship details

Ships details
Length
Breadth
Depth
Submerged depth
Diesel oil tank capacity
Fresh water tank capacity
Number of engines
Engines type
Dimension
28.00m
11.80m
5.00m
4.00m
150.50m3
51.20m3
2
Four
stroke
diesel
engines
turbochargers
Engine rating capacity
1920kW @ 750RPM
Bollard pull forward performance
About 60.00 ton
Bollard pull aft performance
About 56.10 ton
Free
running
speed
forward 12 knots (maximum)
performance
with
The supervisor in charge throughout these 13 training weeks is a 2 years

experienced piping engineer, named Miss Elizacorina Ak. Siguru.
Chapter 2: Summary of Duties

2.1 Week 1 (1/12/2014 6/12/2014)
For the first week, few things regarding piping system for ships were learnt which
were summarized as shown in Table 2 below.
Table 2: Week 1 summary of duties

Date
Time
11.00 am
Duration
15 minutes
Types of duties
Briefing on piping engineers roles in shipping.
Exposure on ship building, piping construction
2.00 pm
3 hours
standard and ship design titled: 55T Bollard Pull
3 hours
1 hour &
Tug ship, 2012 via AutoCAD software.

Introduction to pipes and bends on ships.
Site visit on YD408 ship for an overview look of
1/12/201
4
2/12/201
4
3/12/201
4
4/12/201
4
5/12/201
4
9.00 am
3.30 pm
15 minutes
8.00 am
4 hours
2.00 pm
2 hours
8.00 am
4 hours
2.00 pm
2 hours
1 hour and
8.00 am
30 minutes
10.00 am
2 hours
2.30 pm
2 hours
the ship.
Case studies on YD408 ships piping system
based on the AutoCAD drawings.
Site visit on YD409 ship for an overview look of
the ship.
Case studies on YD408 ships piping system,
involving piping equipments.
Hands on piping equipments (fittings & valves).
Site visit on YD418 ship for exposure on the
valves and fittings installed in the ship.
Conduct research on the fittings functions
installed in a ship.
Conduct research on the valves functions
4
6/12/201
4
8.00 am
3 hours
installed in a ship.
Site visit on YD408 and YD409 ships on the
piping alignments based on schematic diagrams.
Shipyard piping engineers play major role in reviewing and amending the piping
systems schematic diagram provided by the designers implemented throughout the entire
ships and purchase logical amount of valves, fittings and pipes for the ships. Once the
piping system design is completed and approved for construction, piping engineers will
assist the constructors during the construction process to ensure safe and smooth
construction process. A summarized shipyard piping engineers roles are shown in a flow
chart as shown in Figure 1.
Review and amend schematic diagrams

drawn by designers
Prepare material list for each piping

systems involved
If no leakage is presence, the piping

systems instllation are complete
Once the installation is compelete, assist

commisioning engineers to conduct air test
to identify and solve any leakage
Send the material list to both project

engineer and yard manager for approval
Assist contractors and check the

construction progess to ensure smooth
construction process
Contact suppliers for material purchasing
Contact piping contracors for

fabrication and installtion for the
piping and fittings
Figure 1: Flow chart of shipyard piping engineers roles
For every ship, the mandatory components required are hull, steamers, hold and
hatch, mast, deck fittings, anchor, cable, shackles, rooms and lastly cabins. The pipelines
implemented for these mandatory components come together with piping systems
equipments such as joint, vent, valves, sounding, pipes, penetration and many more,
which must follow the piping construction standard for safe operations.
There are many types of bend and pipes used in ships, which can be summarized as
shown in Table 3 below. However, there are two differences between pipes and tubes.
Pipes are highly resistance towards bending, meanwhile tubes are flexible. Besides,
pipes are classified based on the schedule and nominal diameter, A (Sch. 80, 250A),
whilst pipes are classified based on the outer diameter and thickness. Apart from bend
and pipes, several types of valves are used in the piping systems in ships which are
summarized in Table 4.
Table 3: Pipes and bends in ships

Component
Function
Pipe &
Basic piping equipment for transportation of fluid
Example
Pipe & tubes.
tubes
(Sanguri 2012, 4).

Allow integration of flexibility of design by change in
Bend
flow direction of the medium carried inside it (90 0 Miter bends.

pipe bends) (Sanguri 2012, 10).
Allow integration of flexibility of design by change in
Elbows
Nipple
Adapters
flow direction of the medium carried inside it (450 and Street bend.
900 pipe bends) (Sanguri 2012, 10).
A pipe with male threads on each side to facilitate Hexagonal
joining (Sanguri 2012, 19).
reducer nipple.
Extend and terminate similar pipes and connect Hose adapter.
Tee
dissimilar pipes (Sanguri 2012, 23).

Gauge adapter.
Extend and terminate similar pipes and connect Street tee.
dissimilar pipes (Sanguri 2012, 26).
Cross tee.
Table 4: Valves used in ships

Valves
Gate
Globe
Butterfly
Check
Stop cock
Diaphrag
m
Angle
Relief
Ball
Function
To stop the fluid flow across the valve completely and minimize pressure
drop across the valve in fully opened position (Vuthaluru 2014).
Regulate the fluid flow for on-off and throttling services (Vuthaluru 2014).
Similar as globe, but used for low pressure drop cases (Vuthaluru 2014).
To allow the fluid to flow in one direction only (Vuthaluru 2014).
To regulate small fluid flow rate within the pipeline (Vuthaluru 2014).
To regulate corrosive and viscous fluid across the valve (Vuthaluru 2014).
Similar as globe, but used with the presence of fittings (Vuthaluru 2014).
Regulate fluid flow rate when pressure consideration is required
(Vuthaluru 2014).
For flow control and on-off service for isolated fluid (Vuthaluru 2014).
These scheduled site visits mainly focused on the piping systems in both of the BPT
ships, in order to have better and indepth understanding on real life pipeline
applications. These scheduled site visits contributed knowledge on the type of valves and
fittings in 10 core piping systems presence which are bilge, ballast, firemain & wash
deck system, fuel oil transfer system, engine cooling system, domestic fresh water & sea
water supply system, grey water & black water system, oily bilge & dirty oil system, oil
dispersant system, lube oil piping system, external fire fighting system and CO 2 fire
fighting piping system.
Exposure on the floating dock and rexpeller were conducted too. The purpose of
this floating dock it to conduct ship repair and docking for ships in the middle of the sea.
Rexpeller is a newly developed technology for ships movement as it combines both
propeller and rudder which promotes azimuth movement for the ships.
2.2 Week 2 (8/12/2014 13/12/2014)
For the second week, few things regarding piping system for ships were learnt
which were summarized as shown in Table 5 below.

Date
Time
Duration
9.00 am
3 hours
2.00 pm
3 hours
9.00 am
2.00 pm
3 hours
2 hours
8/12/2014
9/12/2014
3 hours
10/12/201
8.00 am
minutes
11/12/201
4
12/12/201
4
13/12/201
4
and 30
2.00 pm
2 hours
8.00 am
3 hours
2.00 pm
2 hours
8.00 am
3 hours
2.00 pm
2 hours
8.00 am
4 hours
Types of duties
Application of common fittings and valves in
both YD408 & YD409 BPT ships.
Bilge, ballast, firemain & wash deck piping
system analysis.
Fuel oil transfer piping system analysis
Engine cooling piping system analysis
Site visit on both YD408 & YD409 BPT ships
on bilge, ballast, firemain & wash deck, fuel oil
transfer, engine cooling and domestic fresh
water & sea water supply piping systems.
Domestic fresh water & sea water supply piping
system analysis.
Grey water & black water piping system
analysis.
Site visit on YD408 BPT ships external fire
Oily bilge & dirty oil piping system analysis.
Site visit on YD408 BPT ships oily bilge &
dirty oil piping system.
Oil dispersant piping system and lube oil piping
system analysis.
10
11
Apart from doing research on the theoretical piping equipments used in ships,
analysis was done on the common piping equipments (valves and fittings) used in the
BPT ship, which are summarized in Table 6 and Table 7 respectively. These analyses
were required before making any valves and fittings installation along the pipelines.
Table 6: Common fittings used in BPT ships

Fittings
system, whilst cast iron short radius 450 is widely used for lube oil and
Elbow
Reducer
Applications
Installed between pipes/tubings, which requires bending of 450 or 900.
Galvanized steel short radius 450 elbows are used for water circulation
fuel oil system.

Galvanized steel 900 street elbows are used for connection for hoses to
valves, water pressure pumps and deck drums.

To connect two pipes with different outer diameter/size to meet the
hydraulic flow requirements of the system.

Widely used reducers are bronze threaded reducer and copper sweat
reducer.
To connect two pipes with same outer diameter/size to meet the
hydraulic flow requirements of the system through welding process,
Union
without welding.
Provide quick and convenient connection of pipe and disconnection of
pipes for maintenance.

To extend and terminate similar pipes and connect dissimilar pipes.
Female tee is used to join male threads pipe in a perpendicular
direction.
Male tee is used to join female threads pipe in two perpendicular
directions.
Similar as union, however, gasket is needed in between two flanges for
the ease of pipe removal and maintenance.

Welding process is required.
Tee
Flange
12
Table 7: Common valves used in BPT ships

Valves
Gate
SDNR
Butterfl
y
Applications
To minimize pressure drop across the valve in a fully opened position.
To ensure the fluid flows continuously to the desired location,
otherwise is stopped completely in case of emergency situations.

Uses in all of the piping systems.
Also known as Screw Down Non Return valve.
To ensure that the fluid flow in one direction across it, this is to prevent
the fluid from flowing back to the starting point.

To regulate fluid flow rate at low pressure drop applications.
Usually connect with any flanged pipe.
Common used butterfly valves are geared type butterfly valves, for ease
on control.
Applicable for emergency situations only, whereby the valves will be
Quick
used to stop all the fluid flow almost immediately via controlling
closing
configurations in the control room.

Usually installed along the fuel oil systems pipeline.
To regulate fluid flow rate at different altitude.
This valve transports horizontal fluid to upper area/move vertically
upwards and then move horizontally to the desired location.

These valves are used in engine cooling system.
To regulate the isolated fluid flow rate.
Used in fuel oil transfer system, to prevent the oil from been isolated in
the pipeline, which may cause blockage or difficulties in cleaning.

Similar as angle SDNR valve, but the transportation direction is
different.
Angle storm transports horizontal fluid to lower area/move vertically
downwards and then move horizontally to the desired location.

These valves are used in grey water & black water system.
To regulate fluid flow rate at any pressure drop requirements.
Usually connect with any flanged pipe.
To regulate fluid with tendency of being isolated throughout the
pipeline.
Usually applied in the fuel oil system, as the fuel oil tends to isolated as
Angle
SDNR
Check
Angle
storm
Angle
Ball
time passes by.
13
Fire
hydrant
Transport CO2 from CO2 storage area located in main deck to put out
fire in the engine room.

Applied for firemain system only.
In a BPT ship, there are 10 main piping systems presence which are bilge, ballast,
firemain & wash deck system, fuel oil transfer system, engine cooling system, domestic
fresh water & sea water supply system, grey water & black water system, oily bilge &
dirty oil system, oil dispersant system, lube oil piping system, external fire fighting
system and CO2 fire fighting piping system. Detailed drawings, explanations and valves
applications are addressed in Section 3.1. All of the pipes used in these systems must be
flanged with the gap of 1.50m between two pipes for the ease of construction,
maintenance and removal (Lloyd 2012, 11-33).
Bilge, ballast, firemain & wash deck system
In this system, three different types of piping systems are installed, which are bilge
piping system, ballast piping system and firemain piping system. The purpose of bilge
piping system is to remove small quantities of fluid that have leaked out or condensed
into a dry space with the aid of two centrifugal pumps. The purpose of ballast piping
system is to stabilize the ships weight and coordination by adjusting the input, output
and storage of the fresh water in the ballast tank with the aid of a centrifugal pump. The
purpose of firemain piping system is to transport sea water for firefighting system in the
ship for both main deck and below main deck with the aid of a centrifugal pump.
14
Fuel oil transfer system

The purpose of this piping system is to transport diesel oil to both main and
auxiliary engines with the aid of built-in centrifugal pump installed in each of the
engine; operated at 25m3/h @ 2bar powered by a 220V AC motor and a duplex strainer.
This system also transports diesel oil to generator for electricity generation in the ship.
Engine cooling system
The purpose of this piping system is to transport sea water to cool down two main
engines of the ship via heat exchanger equipment installed in the engines circulated by
generator built-in pump. This system also transports sea water for air cooling system.
Domestic fresh water and sea water supply system
15
The purpose of this system is to transport fresh water supply for ballast tank, engine
cooling, main deck area (toilet, galley/kitchen and washing machine) and for window
wiper water supply in wheelhouse deck area. Generator with built-in heat exchanger is
installed with the closed fresh water circuit for heating and cooling function.
Grey water & black water system
The purpose of this system is to transport both grey water and black water away
from the ship either through overboard or into sewage tank. The black water means
human excretory waste from the washroom, whilst the grey water means waste water
produced other than human waste, such as from kitchen/galley. Black water will be
transported into a sewage treatment plant for treatment and disinfection purposes and
then stored in a sewage tank or discharged to the sea through the below main decks
overboard. Grey water will be discharged directly to the sea via main decks overboard.
If the treated/waste water from the sewage treatment plant and sewage tank is needed to
be discharged to the sea, the water can only be discharged at least 3 nautical miles from
the nearest land (Lloyd 2012, 11-49).
Oily bilge & dirty oil system
The purpose of this system is to transport oily waste fluid/bilge from various
sections in the ships and dirty oil from the engines into a sludge tank and oily water
storage for disposal upon docking. Strum box is required to filter out large sized and
non-biodegradable wastes before entering the sludge tank. Two separate tanks are
required to store oily bilge and dirty oil respectively (Lloyd 2012, 11-42). Sludge tank is
16
used to store dirty oil/lubricant oil from the main engines, meanwhile oily water storage
is used to store oily bilge from various sections in the ship.
Oil dispersant system
The purpose of this system is to transport oil from the dispersant tank to two
dispersant booms at both left/port and right/star board side for cleaning service. Since
most of the oily bilge, waste fluid and grey water are disposed into the sea directly
through overboard, thus the dispersant boom system is required to clean the ships
exterior from these wastes.
Lube oil system
The purpose of this system is to transport lubricant oil from the sump tank to the
main engines in order to ensure the main engines operate smoothly, reliable lubrication
in order to have adequate heat transfer and also to reduce the corrosion rate occurring in
the main engines. According to Lloyd (2012, 11-30), emergency lubrication oil supply
can be installed for the main engines in case of interruption of lubricating oil supply
from the main storage, and besides the lubricant oil treatment is a mandatory for
adequate treatment of the oil via several processes such as filtering, purifiers and
centrifuging.
17
These scheduled site visits contributed knowledge on the piping systems along with
valves and fittings applications implemented in the BPT ships.
2.3 Week 3 (15/12/2014 20/12/2014)
For the third week, few things regarding piping system for ships were learnt which
were summarized as shown in Table 8 below.

Date
15/12/201
4
Time
Duration
9.00 am
3 hours
2.00 pm
2 hours
8.30 am
3 hours
16/12/201
4
17/12/201
4
2.00 pm
piping system analysis.

Comparison between external fire fighting,
firemain and CO2 fire fighting systems.
Site visit on YD408 BPT ships CO 2 fire
2 hours

Teaching & learning session with supervisor on
and 30
the material purchasing technique and procedure
minutes
for valves to be installed for the BPT ships.

Sketch bilge, ballast, firemain & wash deck
8.00 am
2 hours
10.30
1 hour
am
Types of duties
External fire fighting and CO2 fire fighting
piping system based on the schematic diagram.

Site visit on both YD408 and YD409 BPT ships
main engines piping alignment.
18
18/12/201
4
19/12/201
4
20/12/201
4
2.00 pm
2 hours
9.00 am
2 hours
2.00 pm
2 hours
8.30 am
2 hours
2.00 pm
2 hours
9.00 am
2 hours
Material listing for bilge, ballast, firemain &

wash deck system.
Sketch fuel oil transfer piping system based on
the schematic diagram.
Material listing for fuel oil transfer system.
Sketch engine cooling piping system based on
the schematic diagram.
Material listing for engine cooling system.
Site visit on YD408 BPT ships grey water &
black water piping system.
19
External fire fighting system
The purpose of this system is to transport foam from the storage located at below
main deck area to main deck and wheelhouse deck for external fire control purposes.
This system also transport foam to the fire monitor to put out fire on the other ships and
burning/fire zones. Air operated sirens are installed as a part of the external fire fighting
system, to provide warning/emergency sound during emergencies. There are two types
of foam to be used, which are the low expansion foam and high expansion foam. For the
low expansion foam, the ratio volume of foam produced to the mixture of water and
foam concentration supplied must not exceed 12:1, whereas for the high expansion form,
the ratio must not exceed 1000:1 (Lloyd, 12-28).
CO2 fire fighting system
The purpose of this system is to transport CO 2 from the CO2 room located at the
main deck to 12 different positions at the below main deck area for fire fighting purpose.
The difference between this system and the firemain system is that; CO 2 fire fighting
system uses CO2, whereas firemain system uses sea water to put out fire in the below
main deck area. However, firemain is only used as the last resort where CO 2 fire fighting
system fails to put out the fire completely.
20
The aim of this teaching & learning session with supervisor on the material listing
for purchasing technique and procedure of piping materials was to make quantitative and
qualitative analysis on choosing valves and materials for the piping systems based on the
schematic diagram. Drawing review on materials basis was required to ensure the
material list provided by the designers is accurate. To conduct material listing, few
criteria are required, such as items, size, material, allowable pressure drop and materials
purchased reference number (JIS). The reference numbers are usually referred to the
supplier such as Sun Korea Co., LTD. (2005) and Najin Corp. (n.d.) Material listing for
all of the 10 systems based on the schematic diagram were and tabulated in Section 3.1.
2.4 Week 4 (22/12/2014 27/12/2014)
For the fourth week, the daily duties given and conducted were summarized as
shown in Table 9 below.

Date
Time
Duration
8.00 am
4 hours
2.00 pm
3 hours
22/12/201
4
8.00 am
3 hours
2.00 pm
3 hours
23/12/201
4
Types of duties
Check the construction progress of YD409 BPT
ships pipeline piping system.
Sketch and conduct material listing for domestic
fresh water & sea water system based on the
schematic diagram.
Check the construction progress of both YD408
&YD409 BPT ships pipeline piping system.
Sketch and conduct material listing for oily
bilge & dirty oil piping system based on the
schematic diagram.
21
Conduct material listing for grey water & black

9.00 am
2 hours
24/12/201
water and oil dispersant system based on the

schematic diagram.
Check the construction progress of both YD408
4
2.00 pm
25/12/201
4
26/12/201
4
27/12/201
4
2 hours
9.00 am
2 hours
2.00 pm
2 hours
8.00 am
3 hours
& YD409 BPT ships firemain and fuel oil

piping system.
None, due to public holiday (Christmas)
Literature studies on the BPT ships Daihatsu
main engines.
Hands on BPT ship main engines fittings
arrangement based on the manual.
Sketch and conduct material listing for lube oil
piping system based on the schematic diagram.
As for week 4, material listing and block diagram sketching activities were
continued for the remaining piping systems. Apart from that, checking and updating the
piping construction progress for both YD408 and YD409 BPT ships were conducted to
ensure
the
construction
progress
ran
smoothly.
All
of
the
construction
progress/supervisory work were summarized in Section 3.2.
Since the ships main engines piping system is the most crucial system, a literature
studies on the main engines was conducted. The main engines used are Daihatsu main
engine, built in Osaka, Japan, with the function to provide both mechanical and electrical
energy for the ship at maximum continuous output of 1920kW @ 750RPM. In order to
understand the piping mechanisms of the main engines, the arrangement of the main
engines fitting and the relevant piping system are required. The piping systems involved
in these Daihatsu main engines are ballast system, domestic fresh water & sea water
22
supply system, engine cooling system, fuel oil transfer system, oily bilge & dirty oil
system and lastly lube oil system. The fitting arrangements are like lube oil inlet &
outlet, fresh water inlet & outlet, fuel oil inlet & outlet and other fittings. Once the main
engines fittings arrangements are recognized, the alignment for the involved piping
systems can be conducted.
A hand on BPT ship main engines fittings arrangement based on the manual was
conducted. The purpose of this activity is to provide industrial application on the piping
connection in the Daihatsu main engines. In practical, the piping connection throughout
the main engines are mostly welded and flanged with a maximum distance gap of 1.50m.
Daihatsu main engines required lubricant oil, fuel oil, sea water and fresh water in order
to operate smoothly. Lubricant oil is used to provide sufficient oil for smooth mechanical
process; meanwhile fuel oil is used for operating services. Both sea water and fresh
water are used for engine cooling system and also for cleaning service. Although this
activity is more to mechanical engineering applications, one requires this knowledge in
the piping field, so that the piping misalignments can be reduced.
2.5 Week 5 (29/12/2014 3/1/2015)
For the fifth week, the daily duties given and conducted were summarized as shown
in Table 10 below.
23

Date
29/12/201
4
30/12/201
4
Time
Duration
9.00 am
2 hours
2.00 pm
2 hours
9.00 am
3 hours
2.00 pm
2 hours
8.00 am
2 hours
10.30
31/12/201
4
am
2.00 pm
3.00 pm
1/1/2015
2/1/2015
8.00 am
9.30 am
2.00 pm
3/1/2015
1 hour and
30
minutes
40
Types of duties
Conduct material listing for CO2 fire fighting
and external fire fighting systems.
Check the piping construction progress of both
YD408 & YD409 BPT ships.
Revised on the piping systems block diagrams,
processes and descriptions.
Revise on the piping systems block diagrams,
Revised on the piping systems block diagrams,
Task briefing for the upcoming Germanisher
minutes
Lloyd (GL) overboard checking.
1 hour and
Site visit on YD408 BPT ships overboard for
30
the upcoming GL supervision.
minutes
None, due to public holiday (New Year).
1 hour
Literature studies on a BPT ships overboard.
Assist GLs representative on YD408 BPT ships
2 hours
overboard checking.
Revise on the piping systems block diagrams,
2 hours
None, due to public holiday (S.A.W. birthday)
As for week 5, supervisory work for the piping construction progress for both
YD408 and YD409 BPT ships was continued, which were summarized in Section 3.2.
24
All of the piping systems block diagram sketches and the process flow explanation
were revised to meet the ships classification society, Germanisher Lloyd (GL) and also
the constructor standard, Shin Yang Shipyard Sdn. Bhd.
Meanwhile on 2/1/2015, a Germanisher Lloyd (GL) representative Mr. Gan Chee

Kian came to check the overboard position, construction progress for YD408 BPT ship.
To assist the GLs representative, overboards schematic diagram and information such
as size, valve used, location and the height from the Draft Water Level (DWL) are
required. Detailed explanation and working experience were addressed in Section 3.2.
25
2.6 Week 6 (5/1/2015 10/1/2015)
For the sixth week, the daily duties given and conducted were summarized as

Date
Time
Duratio
Types of duties
n
9.00 am
2 hours
2.00 pm
2 hours
8.30 am
3 hours
2.00 pm
2 hours
8.30 am
10.00
1 hour
5/1/2015
6/1/2015
7/1/2015
am
1.30 pm
8/1/2015
9/1/2015
2 hours

Sort out piping equipments of external fire
fighting system for both YD408 & YD409 ships.
Site visit on YD408 ships main engines and its
external fire fighting systems piping alignments.
Check the air test status of YD409 BPT ships
bilge, ballast & firemain system.
Literature studies on exhaust system.
Check the air test status and piping construction
3 hours
progress of YD409 BPT ships fresh water & sea
8.00 am
1 hour
9.30 am
2 hours
water system.
Exhaust system arrangement analysis.
Site visit on YD408 BPT ships main engines and
2.00 pm
2 hours
8.30 am
3 hours
generators exhaust system.

Check the exhaust system installation progress of
26
10/1/2015
2.00 pm
8.30 am
2 hours
3 hours
both YD408 & YD409 BPT ships.

Problem solving on the main engines exhaust.
Problem solving on the main engines exhaust.
However, a problem encountered within one of the main engines exhaust system
connection and alignment. The problem encountered from the main engines left
side/starboard is that when the expansion joint, bend and the silencer are connected as
shown in Figure 10 in Section 3.3, the drainage system for condensed exhaust vapour
was unable to be installed due to its unsuitability. In order to solve this problem,
knowledge, fittings and the mechanism of the exhaust system are required. Thus,
literature studies, site visit and analysis on the main engines exhaust system were
conducted in order to have better understanding on the exhaust system. Problem solving
for the starboard side main engines exhaust system was addressed in Section 3.3.
As for the exhaust system literature studies, the fittings and the mechanism of the
exhaust system from exhaust piping arrangement schematic diagram (Appendix A) is
summarized as follow. Exhaust system is applied for both main engines and its
generators (genset), whereby the main engines and the genset have their own respective
pipeline, fittings and arrangements. However, they have the same purpose. The purpose
of the exhaust system is to remove exhaust gas from both main engines and genset,
similar to any vehicles. Both main engines and genset are connected with expansion
joint, silencer and lastly exhaust funnel. The function of expansion joint is similar to
flange which connect between pipes for the easy of construction and removal.
Meanwhile, silencer reduces the exhaust sound to the minimal level and lastly the
exhaust funnel channels out the exhaust gas from the ship.
27
This system does not require any valves but require Schedule 40 seamless black
mild steel pipes, except for the exhaust funnels which require Schedule 40 stainless steel
pipes. Besides, both of the main engines and genset exhaust pipe are insulated with
aluminum sheet of 75mm and 50mm thick respectively, with mineral wool in between
the aluminum sheet and the exhaust pipeline for heat insulation purpose.
28
2.7 Week 7 (12/1/2015 17/1/2015)
For the seventh week, daily duties given and conducted were summarized as shown
in Table 12 below.

Date
Time
Duratio
Types of duties
n
3 hours
2.00 pm
2 hours
8.00 am
3 hours
progress
2.00 pm
2 hours
8.30 am
2 hours
progress.
Revised on main engines exhaust drawings.
Site visit on hydraulic power pack machinerys
12/1/2015
13/1/2015
14/1/2015
15/1/2015
16/1/2015
Check both of the ships main engines piping
8.30 am
11.00
am
1 hour
1.30 pm
3 hours
8.30 am
3 hours
1.30 pm
1 hour
3.00 pm
8.30 am
2 hours
3 hours
construction and air test progress.

Assist supervisor in rearrange the pipe connection
due to misalignment in YD408 BPT ship.
Check both of the ships piping construction
and
observe
scupper
installation
fittings and alignment.

Revised on main engines exhaust drawings.
Check and update on the main engines exhaust
new design installation.
Check on the scuppers installation progress on
both YD408 and YD409 BPT ships.
Revised on the material listing for each system.
Check both of the ships piping construction
29
17/1/2015
2.30 pm
2 hours
9.00 am
2 hours
progress and scuppers installation progress.

Revised on the material listing for each system.
Assist supervisor in checking the outstanding
piping construction progress for both BPT ships.
30
On 12/1/2015, scuppers were planned to be installed for both ships main deck, one
on port side and another on the starboard side respectively, as water always accumulated
on the main deck when it rains. Therefore, this task was assigned to the yards welders
and fitters in order to speed up the construction progress and this task was expected to be
completed within 4 working days. Thus, an additional supervisory work was assigned by
supervisor, by checking and updating the scuppers installation progress. This task was
completed on 16/1/2015.
Site visit on hydraulic power pack machinerys fittings and alignment was
conducted on 14/1/2015 in order to have better understanding on the purpose and the
piping connection; as the hydraulic power pack was initially placed on YD408 BPT ship
on 17/1/2015, whereas the hull and piping fitting and alignment will be conducted on
training week 8. The purpose of this hydraulic power pack is to provide hydraulic power
supply to the ships capstan and anchor windlass via two respective control stations. The
function of a ships capstan is to hold the ship in position during docking session by
applying forces on ropes and cables; whereas the function of a ships anchor windlass is
to restrain and control the ships anchor chain for mobility purpose.
31
2.8 Week 8 (19/1/2015 24/1/2015)
For the eighth week, the daily duties given and conducted were summarized as

Date
Time
Duratio
Types of duties
n
8.30 am
3 hours
1.30 pm
3 hours
9.00 am
3 hours
2.00 pm
2 hours
8.30 am
3 hours
2.00 pm
2 hours
8.00 am
2 hours
1.30 pm
1 hour
2.30 pm
2 hours
8.30 am
3 hours
19/1/2015
20/1/2015
21/1/2015
22/1/2015
23/1/2015
Assist supervisor in ships outstanding tasks

distribution to contractors and yards foremen.
Assist main engines engineers (Daihatsu) in main
engines exhaust cleanliness checking.
Site visit on genset testing by Daihatsus
engineers.
Assist main engines engineers (Daihatsu) on the
main engines exhaust second checking.
Check the main engines fuel oil piping progress
for both YD408 & YD409 BPT ships.
Assist supervisor in rearrange YD408 BPT ships
lube oil piping connection due to misalignment.
Site visit on main engines and genset testing by
Daihatsus engineers.
Assist yard foremen in the installation of the main
engines turbo charger in YD409 BPT ship.
Check the main engines piping connection and
alignment progress in YD409 BPT ship.
Check the outstanding compressed air piping
32
connection progress for both BPT ships.

Check air test status of YD408 BPT ships fresh
2.00 pm
2 hours
water & sea water and oily bilge & dirty oil
systems.
24/1/2015
8.00 am
3 hours
Update outstanding piping progress for both ships.
On 19/1/2015, YD408 both port and starboard main engines cleanliness was
scheduled to be inspected by the Daihatsu engineers. In order to assist the engineers, the
expansion joint attached between the two pipelines (turbo charger pipeline and silencer
pipeline) needed to be detached as per referred to the exhaust piping arrangement
schematic diagram in Appendix A. Detailed explanation and working experience were
addressed in Section 3.2. The exhaust cleaning for both of the main engines exhausts
was conducted on the following next day (20/1/2015) as per requested. The Daihatsu
engineers were satisfied with the results and the expansion joint was flanged back to
each of the main engines respectively.
YD408 BPT ship was planned to be delivered to the owner within the first week of
February 2015, thus, several machinery tests were required to be conducted. Gensets
testing was scheduled to be tested and operated on 20/1/2015, whilst main engines
testing was schedule to be tested and operated on 22/1/2015.Thus, the supplier, Daihatsu
33
sent two of their engineers to conduct testing and operated the main engines and gensets
to test the machines efficiency and endurance for a maximum of 4 hours per day.
Therefore, site visits were conducted to observe and to learn on how these machines
were being tested and operated by the engineers.
YD408 BPT ship was scheduled to be delivered to the owner (Nautilus Tug &
Towage Sdn. Bhd.) within the first week of February 2015, all of the outstanding piping
tasks were expected to be completed by the end of January 2015 but all of the
outstanding tasks were completed one week earlier. Since all of the piping construction
for YD408 had completed, therefore all of the supervisory works will be focused on
YD409, which still have 58 outstanding tasks to be completed in three weeks time.
34
2.9 Week 9 (26/1/2015 31/1/2015)
For the ninth week, the daily duties given and conducted were summarized as

Date
Time
Duratio
Types of duties
n
26/1/2015
Assist supervisor and yards foreman in finding
9.30 am
2 hours
2.00 pm
2 hours
copper tubing and copper sockets with supplier.

Participate in YD408 BPT ships yard trial.
Assist supervisor and yards foremen in doing
8.30 am
3 hours
minor piping adjustment for engine cooling in
2 hours
YD408 ship.
Assist supervisor and yards foremen in installing
and 30
copper tubing of air supply from air reservoir to
minutes
control panel and main engines in YD409 ship.

Assist supervisor and contractor in doing minor
3 hours
piping adjustment for chain wash at YD408 ship
27/1/2015
2.00 pm
9.00 am
28/1/2015
1.30 pm
3 hours
9.30 am
2 hours
29/1/2015
2.00 pm
2 hours
firemain system.
Check the piping construction progress of YD409
BPT ship.
Check and update the YD408 BPT ships main
deck penetration of air vents, soundings and filling
tanks.
Assist supervisor in reconfirm the air vents size
and position on YD408 BPT ships main deck.
35
Assist yards foremen in doing piping adjustment

8.30 am
3 hours
30/1/2015
31/1/2015
2.00 pm
2 hours
8.00 am
3 hours
for the rexpeller cooling system for both BPT

ships.
BPT ship.
BPT ship.
Since YD408 BPT ship had completely constructed and passed all of the machinery
tests, the ship was scheduled to undergo yard trial for 2 hours on 26/1/2015. The purpose
of this yard trial is to check and test the overall ships performance on river with the
minimum depth of 15m. After passing the yard trial, the ship will undergo sea trial which
takes places at the wide open sea area, which is to check and test the overall ships
performance under sea condition. However, on the way back to the site, the YD408
experienced some vibration at the port side rexpellers shaft due to less tighten of bolt
and nut. This vibration will cause fatal problem if not taken seriously. Thus, the ship
required to undergo some modifications. Since there was a problem detected on the
ships, therefore the ship need to undergo second sea trial which was scheduled to be on
3/2/2015.
36
Although the YD408 BPT ship had fully constructed, however minor piping,
fittings and electrical modifications were conducted to resolve for any problems
encountered during and after the yard trial. As for piping, the minor adjustments were
made on the engine cooling pipelines, rexpeller cooling pipelines and the hawse pipe
wash down pipelines. On 27/1/2015, minor piping adjustment for engine cooling in the
YD408 ship was conducted due to main engines unbalance pressure. Meanwhile, on
28/1/2015, the chain wash pipe of firemain system in YD408 ship was reallocated to
allow the bollard installation on the main deck. Whilst, on 30/1/2015, rexpeller cooling
system pipelines in both BPT ships were readjusted as per requested by the Daihatsus
engineers.
37
2.10 Week 10 (2/2/2015 7/2/2015)
For the tenth week, the daily duties given and conducted were summarized as

Date
Time
Duratio
Types of duties
n
9.00 am
3 hours

alignment progress and also the copper tubing
2/2/2015
2.00 pm
2 hours
installation of air supply from air reservoir to both

control panel and main engines in YD409 BPT
3/2/2015
9.00 am
7 hours
9.00 am
3 hours
2.00 pm
2 hours
8.00 am
3 hours
2.00 pm
2 hours
8.30 am
2 hours
2.00 pm
2 hours
4/2/2015
5/2/2015
6/2/2015
ship.
Participate in YD408 BPT ships second yard trial.
Update the exhausts expansion joint reinstallation
in YD409 and butterfly valve tightening in YD408.
alignment progress in YD409 BPT ship.
Assist yards foremen in doing minor modification
of soundings for both BPT ships.
Check the soundings modification progress of
both BPT ships.
Check the soundings modification progress of
both BPT ships.
Assist supervisor in checking and updating any
38
7/2/2015
8.00 am
and 30
outstanding piping construction tasks for YD409
minutes
BPT ship with contractors and yards foremen.

Assist supervisor in checking and updating any
3 hours
outstanding piping construction tasks for YD409

BPT ship with contractors and yards foremen.
On 3/2/2015, a yard trial for YD408 BPT ship was conducted at 9.00 am. The first
phase of the trial was conducted to travel back and forth from PSSB to Shin Yang
Dockyard Sdn. Bhd. which is about 3km far, which minimum water depth of 15m for 4
times. Then, the ship docked at Shin Yang Dockyard Sdn. Bhd. or also known as
Shipyard 1, for fresh water filling, which took about 3 hours to fully fill the fresh water
tanks. At 3.30pm, the ship departed from Shipyard 1 and docked safety at PSSB at 4.00
pm. This yard trial considered as a successful yard trial as no machinery problems were
encountered throughout the entire trial, only a minor leakage occurred for standby main
engines cooling pump was detected. The leakage problem was solved on 4/2/2015, by
tightening the butterfly valve along the pipeline.
On 3/2/2015, main engines exhaust cleanliness checking was conducted by the

Daihatsus engineers for YD409 BPT ship. This inspection was conducted during the
night time. Similarly with YD408 BPT ship, dirt was detected surrounding the exhaust
39
pipeline, which required cleaning. On the next day 9.00 am, second inspection was
conducted and the Daihatsus engineers were satisfied with the exhaust cleanliness. The
expansion joint was installed back to the main engines exhaust, completed at 11.00 am.
On 5/2/2015, minor modification was made to 5 soundings located on the main

deck by fabricated an adapter in between current sounding cap and the sounding pipeline
for each of the soundings for both of the BPT ships. The purpose of adding this adapter
for each of the soundings is to ensure the soundings are having the same height level
with the main deck flooring board, in order to prevent water being accumulated around
the soundings due to height difference. This task was completed on 6/2/2015 for YD408
BPT ship and 7/2/2015 for YD409 BPT ship.
2.11 Week 11 (9/2/2015 14/2/2015)
For the eleventh week, the daily duties given and conducted were summarized as

Date
9/2/2015
Time
Duratio
Types of duties
8.30 am
n
3 hours
Check the lube oil piping systems welding and
40
2.00 pm
2 hours
9.00 am
2 hours
10/2/2015
minor piping modification for both of the BPT

ships external fire fighting systems pump.
Check the YD409 BPT ships main engines fuel
2 hours
8.30 am
2 hours
1.30 pm
3 hours
minor piping modification for YD408 BPT ships
9.00 am
2 hours
2.00 pm
2 hours
fresh water pipeline.

Follow up yards foremen tasks progress.
8.30 am
2 hours
2.00 pm
2 hours
8.30 am
3 hours
13/2/2015
14/2/2015
(Marpol and decks penetration) for YD408 ship.

2.00 pm
11/2/2015
12/2/2015
connection progress for YD409 BPT ship.

Check the main deck piping construction progress
oil piping construction progress.

Check and update the ships external fire fightings
pump piping modification with yards foremen.
oil piping alignment and connection progress.

Assist yards foremen in relocating the chain wash
pipeline of YD409 ships firemain system.
Assist supervisor in updating any outstanding tasks
for YD409 BPT ship with contractors.
As for week 11, supervisory work for the piping construction progress both YD 408
and YD409 BPT ships was continued, which were summarized in Section 3.2.
Few piping modifications were made throughout this week due to minor technical
problems or as per suppliers request. On 10/2/2015, minor piping modification was
made for both BPT ships external fire fighting systems pump as per required by the
supplier, FITECH Engineering Pte. Ltd. This modification was conducted by removing
41
all of the pipes connected to the fire fighting pump as well as the pump itself. This is for
the ease of the installation of additional device on the pump and along the pipelines. This
task was partially completed on 12/2/2015, whereby the firefighting pump and the pipes
were removed from its position, whereas the additional device was not installed yet as it
had not arrived yet and was expected to arrive on 13/2/2015. Thus, this task was
completed on 14/2/2015 and underwent fire hydrants testing at 3.00 pm.
Apart from external fire fighting system, minor piping modification was conducted
on 11/2/2015 for one of the YD408 BPT ships domestic fresh water system pipelines
(main decks washrooms pipeline). With the current fresh water pipeline, there was
tendency for the fresh water to flow back into the water tank. To solve for this problem,
a bronze swing check valve was installed along the pipeline, after the gate valve. The
purpose of installed an additional swing check valve is to ensure the fresh water flow in
one direction only, which is to the washrooms. The installation of the swing check valve
can be checked by referring to the domestic fresh water & sea water supply systems
schematic diagram in Appendix A. This task was completed on 12/2/2015. This
modification was applied to YD409 BPT ship and was scheduled to be conducted on
16/2/2015.
The chain wash pipeline for YD409 was reallocated on 13/2/2015 to allow the
bollard installation on the main deck and was completed at 4.00pm.
42
2.12 Week 12 (16/2/2015 21/2/2015)
For the twelfth week, the daily duties given and conducted were summarized as

Date
Time
8.30 am
16/2/2015
2.00 pm
Duratio
Types of duties
n
2 hours
and 30
minor piping modification for YD409 BPT ships
minutes
fresh water pipeline.

Follow up yards foremen tasks progress and
2 hours
check the YD409 BPT ships main engines fuel oil
8.30 am
2 hours
2.00 pm
2 hours
9.00 am
2 hours
2.00 pm
3 hours
19/2/2015
20/2/2015
21/2/2015
8.00 am
3 hours
17/2/2015
18/2/2015
piping alignment and connection progress.

oil piping alignment and connection progress.
Literature studies on corrosion control and paint
system.
Check the YD409 BPT ships hydraulic piping
connection progress.
Literature studies on corrosion control and paint
system.
None, due to public holiday (Chinese New Year).
None, due to public holiday (Chinese New Year).
43
44
As for week 12, supervisory work for the piping construction progress YD409 BPT
ship was continued, which were summarized in Section 3.2.
Since the all of the minor piping modifications for both piping and fittings had
completed, YD408 BPT was set off for sea trial on 16/2/2015, 1.00 pm. The sea trial was
conducted at the sea area with the sea depth of more than 60m and safe location away
from subsea cables for 5 days continuously. The sea trial program for YD408 BPT ship
was listed as shown below:
1. Anchor dropping and hoisting test @ 100% Maximum Continuous Rating
2.
3.
4.
5.
6.
7.
(M.C.R) of main engines.

Steering gear test @ 100% M.C.R of main engines.
Turning circle test @ 100% M.C.R of main engines.
Crash stop test @ 100% M.C.R of main engines.
Inertia test
Straightness checking with vessel astern at 7knot and rudder at 00
Speed trial & endurance trial
Operates at 25% M.C.R.
Auto pilot test to verify and accept conformance by ship officer.
Navigation and communication equipments to verify and accept
conformance by ship officer.

8. Escort trial to perform test for
Verify the speed for assisted vessel speed during full scale trial.
Verify the maneuvering time needed to shift indirect towing from an oblique
angular at stern of assisted vessel to mirror position at other side.

Verify maximum steering force.
Verify towing wince damping system.
45
Similarly with YD408 BPT ship, minor piping modification was conducted on one
of the YD409 BPT ships domestic fresh water system pipelines (main decks
washrooms pipeline) with the same problem encountered whereby the fresh water had
the tendency to flow back into the fresh water tank. Thus, a bronze swing check valve
was installed along the pipeline, after the gate valve to ensure that the fresh water flows
directly to the washrooms only. The installation of the swing check valve can be checked
by referring to the domestic fresh water & sea water supply systems schematic diagram
in Appendix A.
There are many types of corrosion tend to occur on any part of the ships, especially
hull and pipelines. Table 18 below summarized the common corrosion and its
description that occurred on the pipes of any ships, whereas Table 19 shows the
common prevention for the corrosion listed in Table 18.
Table 18: Several types of common piping corrosion

Type of corrosion
Description
A common type of corrosion which depends on the relative
Atmospheric
humidity, oxygen and salt content that occurs widely on pipes on
corrosion
deck, in bilge and ballast tanks and pipes that are exposure to rain
(Eyres 2001, 299).
A localized breakdown of the inert protective surface layer that
Pitting corrosion
protect the mild steel and stainless steel from corrosion (Murdoch
2012, 22). A prolong condition may caused the formation of
cavities on the pipes surface.
Cavitation damage caused by frictional force occurred between
Erosion
turbulent fluid flow and the pipes inner surface (Eyres 2001, 304).
Graphitic damage
Severe condition may occur when sea water flows within the pipes.
A common type of corrosion which often found at cast iron bends
46
and elbows, whereby fluid often accumulates at that area due to

different in velocities (Murdoch 2012, 25).
Table 19: Corrosion and its preventions

Type of corrosion
Atmospheric
corrosion
Pitting corrosion
Prevention
Protection by using paints
Cathodic and anodic protection
Cathodic and anodic protection

Use higher alloys for increased resistance to pitting corrosion
Reduce the occurrence of turbulent flow by using larger
Erosion
Graphitic corrosion
diameter pipes and reduce the pumping rate; to reduce the
fluid flow rate (Eyres 2001, 304).

Inspect every cast iron pipe or fittings that have a connection
to the sea during docking session (Murdoch 2012, 25).
In PSSB, the corrosion preventive method widely practiced for pipes are applying
blast cleaning, followed by pickling and lastly paint application on the pipes surfaces.
Initially all of the welded pipes will undergo blast cleaning, whereby sand is thrown into
the pipes surfaces at high velocity by using an impeller wheel plant. The purpose of
blast cleaning is to brush of any rust on the pipes surfaces. After blast cleaning, the
pipes will undergo pickling process. Pickling process is defined as an immersion process
of metallic pipes in an acid solution, such as hydrochloric acid or sulphuric acid. The
purpose of pickling process is to remove rust and millscale which are unable to be
removed by the blasting process and also to remove the excess sand from the blasting
process. Both blasting process and pickling process serve as a surface preparation for the
pipes to ensure successful painting on the pipes. The common types of paints applied on
the pipes are alkyd resin paints and oleo-resinous paints. Alkyd resin paints are paints
made from alcohols and acids which provide enhanced drying time and film forming
47
properties of drying oil. This paint is only applicable for indoor use. Oleo-resinous paints
are paints made from natural or artificial resins into drying oil protective layer, which is
applicable for any pipes exposed to weather such as main decks and wheelhouse decks
pipes and also for underwater service.
48
2.13 Week 13 (23/2/2015 25/2/2015)
For the twelfth week, the daily duties given and conducted were summarized as

Date
Time
Duratio
Types of duties
n
Check the completion status for all of the drainage
9.00 am
2 hours
23/2/2015
24/2/2015
25/2/2015
2.00 pm
2 hours
8.30 am
2 hours
2.30 pm
2 hours
8.30 am
3 hours
pipelines for the grey & black water system of

YD409 BPT ship.
Check the main engines exhaust joint and
connection progress of YD409 BPT ship.
Check the misc fittings of YD409 BPT ship.
Revise corrosion control and paint system
applications with assistant paint coating engineer.
As for week 13, supervisory work for the piping construction progress YD409 BPT
ship was continued, which were summarized in Section 3.2. YD408 BPT ship had been
successfully delivered to the owner on 22/2/2015. Meanwhile, YD409 BPT ship was still
under construction and was expected to be completed by early March 2015.
49
50
Chapter 3: Working Experience
In this section, the working experiences gained throughout these 12 weeks are case
studies on the piping systems in harbor tug ship, site visit on harbor tug ships
(YD408/BPT Larut and YD409/BPT Lumut), material listing for each of the piping
systems, literature studies on machines, supervisory works and problem solving.
3.1 Project Carried Out
One of the projects carried out during the 13 weeks of industrial training is
conducting case studies and analysis on the piping systems in PBBSs Bollard Pull Tug
(BPT) ships. Most of the pipeline implemented in both YD408/BPT Larut and
YD409/BPT Lumut practiced these exercises (Lloyd 2012, 11-2):
1. Welds on pipe shall be with full penetration.
2. The usage of galvanized bolts and nuts.
51
3.
4.
5.
6.
The usage of long radius elbows for curves in the pipeline.

All pumps are installed with pressure gauge, vacuum gauge and relief valve.
Corrosion inhibitor is added to the cooling system of the diesel engines.
All service tanks and non structural tanks are installed with level indicators;
meanwhile all storage tanks are installed with sensor.

7. All equipment designed to work with any type of oil shall be fitted with trays
with drains.
8. Prohibited to use any piping materials with low heat resistance (melting point
below 9250C), as it will cause outflow of flammable liquids.
9. All valves require open/shut off indicator.
52
Since there are 10 main piping systems in the BPT ships that had been explored,
simplified block diagrams were drawn based on the schematic diagrams (Appendix A)
in order to have preliminary understandings and concepts on the piping systems.
Bilge, ballast, firemain & wash deck system
Figure 2 shows the summarized schematic diagram for bilge, ballast, firemain and
wash deck piping system for below main deck area via block diagram. The bilge system
transport non/low level toxin waste fluid (bilge) within the ship into manifolds and later
discharged those bilge into the sea via overboard compartment. Manifold act as a mixer
whereby it accumulates all the bilge from different sections. Sea water strainer is used to
remove most of the sodium chloride, NaCl contain to reduce corrosion rate in the pump.
Overboard is a section where the waste water and bilge are discharged from the ship to
the sea. SDNR valves are widely used to ensure the bilge flow in one direction only.
As for the ballast system, the fresh water is used to balance the ships weight and
coordination by filling up the ballast tank. The excess water transported from the fresh
water tanks can be further used for domestic usage in the main deck area and cooling
reagent for heat exchanger for the ships engines in the below main deck area. Butterfly
valves are used to regulate low pressure fresh water flow rate. Sea water strainer is used
53
for emergency purpose, just in case sea water is used for the ballast piping system. Gate
valves are used to minimize pressure drop across the valve in fully opened condition.
The firemain system uses sea water for firefighting purpose in below main deck
area, in case for fire activities. Excess water is discharged back to the sea via overboard.
SDNR valves are used to ensure the excess sea water is flown back to the sea directly
and the fire hydrant valves are used for emergency situations where sea water is released
in the engine room to put out fire. For this bilge, ballast, firemain & wash deck system,
the pipes used are Schedule 80 hot dipped galvanized mild steel.
54
55
Figure 2: Bilge, ballast, firemain & wash deck system block diagram
56
Table 21 shows the material listing for bilge, ballast, firemain & wash deck system
based on the schematic diagram in Appendix A.
Table 21: Material listing for bilge, ballast, firemain & wash deck system
Item
Size
Gate valve (V1)

Gate valve (V2)
Gate valve (V3)
Gate valve (V4)
Gate valve (V5)
Gate valve (V6)
SNDR valve (V7)
SNDR valve (V8)
SNDR valve (V9)
Butterfly valve (V10)
Swing check valve (V12)
SNDR valve (V14)
Angle screw down check
valve (V15)
Pressure
Material
Quantity
JIS
300A
50A
65A
50A
50A
25A
80A
65A
50A
300A
50A
65A
40A
50A
(bar)
10
5
5
5
5
5
5
5
5
5
5
5
5
5
Cast steel
Cast steel
Cast iron
Cast steel
Bronze
Bronze
Cast iron
Cast iron
Cast iron
Cast steel
Cast iron
Bronze
Bronze
Cast steel
1
2
3
1
4
2
1
8
6
2
9
4
2
2
F7366
F7363
F7363
F7363
F7367
F7367
F7353
F7353
F7353
F7371
F7371
F7353
300A
Cast steel
F7354
F7121
F7121
F7203
Galvanize
Sea water strainer (SW1)
300A
d mild
steel
Galvanize
d mild
steel
Galvanize
d mild
steel
Galvanize
d mild
steel
Galvanize
65A
Mud box (M1)
65A
Strum box (SB1)
65A
Bell mouth (B1)
50A
d mild
5
5
steel
Bronze
Cast iron
6
2
Fire hydrant valve (FH)

Hand pump (P3)
Fuel oil transfer system
50A
40A
57
Figure 3 shows the summarized schematic diagram for fuel oil transfer system for
both main engines and generators via block diagram. This system transports fuel oil to
the two ships main engines and to two ships generators from two identical fuel oil
services tanks. By referring to the generator fuel oil supply line block diagram, it is
observed that the fuel oil is transported from the fuel oil services tank directly to the
generator by passing through two racor filters. The excess fuel oil is then recycled back
to the storage tank. This system applies to the second generator too. Racor filters are
installed to remove impurities contained in the fuel oil.
By referring to the main engine fuel oil supply line block diagram, fuel oil is
transported from the fuel oil services tank to manifold, then passes through mercury
filter for mercury removal then lastly to the main engine. Excess fuel oil is then recycled
back to the storage tank by passing through air separator, with the purpose of releasing
the confined vacuum pressure in the recycled fuel oil via air vent. Dirty used fuel oil is
transported to the sludge tank for disposal. Emergency fuel oil services pipeline is
installed to provide fuel oil for the main engines in case of emergency situations via
stand-by fuel pump operating at 25m3/hr @ 30m head. This cycle applies to the second
main engine too.
Several valves are used for this system, such as gate valve (to minimize pressure
drop across the valve in fully opened condition), swing check valve (to ensure the oil
flow in one direction only, back to the storage tank) and flange end ball valve (to
regulate the oil flow rate to the main engine, in-case the oil is isolated to prevent the oil
been isolated in the pipeline). Several quick closing valves are installed along the fuel oil
storage tanks pipeline to shut off the fluid transportation immediately in case of
emergency situation, especially when there is a fire breaks out. For this system, the pipes
used are Schedule 40 black and seamless mild steel pipes.
58
Figure 3: Fuel oil transfer system block diagram
59
Table 22 shows the material listing for fuel oil transfer system based on the
schematic diagram in Appendix A.
Table 22: Material listing for fuel oil transfer system
Item
Size
Gate valve (V1)
100A
Gate valve (V2)
Pressure
Material
Quantity
Cast steel
50A
Cast steel
Gate valve (V3)
50A
Bronze
Gate valve (V4)
40A
Bronze
Gate valve (V5)
25A
Bronze
SNDR valve (V6)
80A
Cast iron
SNDR valve (V7)
50A
Cast iron
Quick closing valve (V8)
50A
Cast steel
13
Spring loaded valve (V9)

Swing check valve
25A
Bronze
50A
Cast iron
25A
Bronze
20A
Bronze
50A
Cast iron
12
1
-
25A
Bronze
50A
1330
Mild steel
13
5
5
5
Bronze
Cast iron
Galvanize
2
1
1
F720
(V10)
Swing check valve
(V12)
Flange end ball valve
(V14)
Bell mouth (B1)
Flat sight glass (SG1)
Kamlock (K1)
Hand pump (P2)
Duplex strainer (Y1)
mm
80A
50A
100A
(bar)
JIS
F736
3
F736
3
F736
7
F736
7
F736
7
F735
3
F735
3
F739
9
F737
2
F737
1
F737
60
d mild
steel
Galvanize
Duplex strainer (Y1)
25A
d mild
steel
Galvanize
Racor filter (Y3)
50A
d mild
F720
8
steel
61
Engine cooling system

Figure 4 shows the summarized schematic diagram for engine cooling piping
system for below main deck area via block diagram. This system cools the ships main
engines by regulating the sea water flow rate via built-in generator pump and valves into
the heat exchanger and then discharge the output hot water to the sea through the
overboard. This system also provides seawater to the air condition condensing units for
air cooling system throughout the ship via air-cond cooling pump operating at 30m 3/h @
30m head.
Sea water strainers are used to remove most of the NaCl contains and impurities in
the sea water, in order to reduce the corrosion rate in air-cond cooling pump, generators
built-in pumps and the heat exchangers. Emergency cooling system pipeline from ballast
system is installed to provide cooling system for the main engines in case of emergency
situations via gate valves.
Several valves are used such as gate valves (to minimize pressure drop across the
valve in fully opened condition), check valves (to ensure the cooled water from the airconditional cooling pump flow in one direction only, to the air condition condensing
units), butterfly valves (regulate the low pressure fresh water for air ventilation purpose)
and lastly angle SDNR valve (to ensure the hot water exit from the heat exchangers;
located in below main deck area to flow upwards to the main decks overboard in one
direction only for water discharge purpose). Shut off valves are required at the outlet and
inlet for both of the heat exchangers (Lloyd 2012, 11-35). For this system, the pipes used
are Schedule 80 galvanized mild steel pipes.
62
Figure 4: Engine cooling system block diagram
63
Table 23 shows the material listing for engine cooling system based on the
Table 23: Material listing for engine cooling system
Item
Size
Gate valve (V1)
200A
Gate valve (V1)
Pressure
Material
Quantity
Cast iron
100A
Cast iron
13
Gate valve (V3)
80A
Bronze
Gate valve (V4)
65A
Cast iron
Gate valve (V5)
50A
Cast iron
Gate valve (V6)
15A
Bronze
Angle SNDR valve (V7)
100A
Cast steel
80A
Cast steel
65A
Cast steel
50A
Cast steel
SDNR valve (V11)
200A
Cast iron
SDNR valve (V12)
100A
Cast iron
SDNR valve (V13)
50A
Cast iron

200A
100A
80A
80A
5
5
5
5
Cast iron
Cast iron
Cast iron
Galvanize
2
6
1
1
Angle SNDR valve

(V10)
(bar)
d mild
JIS
F736
3
F736
3
F736
7
F736
3
F736
3
F736
7
F735
4
F735
4
F735
4
F735
4
F735
3
F735
3
F735
3
F712
1
64
steel
Galvanize
50A
d mild
steel
F712
1
65
Domestic fresh water & sea water supply system

Figure 5 shows the summarized schematic diagram for domestic fresh water & sea
water transfer system for below main deck area via block diagram. This system
transports fresh water from the fresh water tanks and from ballast system into filing
manifolds and suction manifolds, then further transport the fresh water throughout the
whole ship for domestic activities via Pump 1 and Pump 3. Filling manifolds act as the
distribution centre, whereby fresh water supply is distributed throughout the whole ship
when in need. External fresh water supply can be transported into the ship via external
pumps, just in case of insufficient fresh water supply. Apart from fresh water, sea water
is also transported from the sea into the ship for washroom purpose via Pump 2.
Three pumps are operating for this system, a pair of identical pumps; fresh water
pump (P1) and sea water pump (P2) operating at 3.8m3/h @ 35m head and another fresh
water pump (P3) operating at 25m3/h @ 30m head. A basket strainer is used to filter out
any impurities from the fresh water supply for safe and clean consumption.
Gate valves are widely used in this system; to ensure that the fresh water does not
change its fluid flow direction and also to stop the flow completely in case the fresh
water supply is contaminated or due to emergency situations. Two SDNR valves are
used to ensure that the fresh water flowing out from the pump does not flow back to the
pump. UV light device is recommended to be installed after P1 to kill bacteria contained
in the fresh water. Since the fresh water can be transported via two directions, pumps are
required to justify the flow direction. For this system, the pipes used are Schedule 80
galvanized mild steel pipes.
66
Figure 5: Domestic fresh water & sea water supply system block diagram
67
Table 24 shows the material listing for domestic fresh water & sea water system
based on the schematic diagram in Appendix A.
Table 24: Material listing for domestic fresh water & sea water supply
Item
Size
Gate valve (V1)
65A
Gate valve (V2)
Pressure
Material
Quantity
Cast iron
50A
Cast iron
Gate valve (V3)
32A
Bronze
15
Gate valve (V4)
25A
Bronze
SDNR valve (V5)
50A
Bronze
SDNR valve (V6)
25A
Bronze
SDNR valve (V7)
15A
Cast iron
32A
Bronze
(bar)
JIS
F736
3
F736
3
F737
6
F737
6
F730
9
F730
9
F735
3
F737
1
Galvanize
Bellmouth (B1)
32A
d mild
steel
Galvanize
Y strainer (Y1)
d mild
steel
Galvanize
Two way cock (FC)
d mild
F722
0
15
steel
Galvanize
Spectacle flange (S1)
Spectacle flange (S2)
32A
25A
d mild
steel
Galvanize
d mild
68
Kamlock (K1)
65A
steel
Bronze
Galvanize
Basket strainer (BS)
65A
d mild
steel
2
1
F712
1
69
Grey water & black water system

By referring to the ships grey water & black water system schematic diagram as
shown in Appendix A, the piping system is installed at both main deck and below main
deck. For the main deck area, the grey water is discharged directly to the sea through
overboard by using angle storm valve for each overboard. Angle storm valve transport
the gray water from the source area down to the main decks overboard sections. The
black water is transported to the sewage treatment plant located in the below main deck
area.
As for the below main deck area, both of the gray water and black water from the
washrooms are transported to the sewage tank via check valves for each pipeline. These
check valves are used to ensure that both of the grey water and black water do not flow
back to the washroom.
In the sewage treatment tank, the accumulated waste water in the sewage tank can
only be discharged to the sea through the below main decks overboard at least 3 nautical
miles from the nearest land, otherwise during docking cleaning session. Two check
valves are used after the sewage treatment plant, to ensure that the treated water either
flows directly to sewage tank or below main decks overboard respectively, without
flowing back to the sewage treatment plant. Several gate valves are used to ensure the
treated/waste water flows continuously to the desired location, otherwise is stopped
completely in case of emergency situations. For this system, the pipes used are Schedule
40 galvanized carbon steel pipes.
70
Table 25 shows the material listing for grey water & black water system based on
the schematic diagram in Appendix A.
Table 25: Material listing for grey water & black water system
Item
Size
Angle storm valve (V1)
100A
Angle storm valve (V2)
Pressure
Material
Quantity
Cast steel
50A
Cast steel
Gate valve (V3)
100A
Cast iron
Gate valve (V4)
50A
Cast iron
Check valve (V5)
100A
Cast iron
Check valve (V6)
0A
Cast iron
(bar)
JIS
F306
0
F306
0
F736
3
F736
3
F737
2
F737
2
Galvanize
Bellmouth (B1)
50A
d mild
steel
Galvanize
Scupper (S1)
50A
d mild
steel
71
Oily bilge & dirty oil system

Figure 6 shows the summarized schematic diagram for oily bilge & dirty oil system
for below main deck area via block diagram. The purpose of this system is to transport
oily bilge from four different locations (three from strum boxes and one from holding
tank) and dirty oil from the main engine lubricant sump tank into a sludge tank for
disposal purpose. The oily bilge will be accumulated in a manifold which later been
filtered via a simplex strainer then pump into an oily water storage and finally to the
sludge tank when the disposal process is ready. As for the dirty oil, the waste lubricant
oil from the main engines will be pumped to the sludge tank directly via semi rotary
pump. Strum box acts both filter and storage for the oily bilge.
Swing check valves are used for the oily bilge transportation to ensure that the oily
bilge flow to the manifold and oily water storage directly. Swing check valves are used
for the dirty oily transportation before the semi-rotary pump to ensure the dirty oil flow
in one direction only, which is to the semi-rotary pump and also to shut off the valve
when necessary to prevent the semi-rotary pump from overloaded with the dirty oil.
During the oil disposal process, the accumulated waste oil will be pumped out from
the sludge tank and gate valve is used to ensure that the waste oil flows continuously to
the desired location, otherwise is stopped completely in case of emergency situations.
For this system, the pipes used are Schedule 40 mild steel pipes.
72
Figure 6: Oily bilge & dirty oil system block diagram
73
Table 26 shows the material listing for oily bilge & dirty oil system based on the
Table 26: Material listing for oily bilge & dirty oil system
Item
Size
Gate valve (V1)
40A
Gate valve (V2)
Pressure
Material
Quantity
Bronze
25A
Bronze
40A
Bronze
SDNR valve (V4)
25A
Bronze
12
(bar)
Galvanize
Simplex strainer (S1)
40A
d mild
steel
Galvanize
25A
d mild
steel
Galvanize
Strum box (SB1)
25A
d mild
JIS
F736
7
F736
7
F737
1
F735
1
F720
9
F720
9
steel
Galvanize
Bellmouth (B1)
25A
d mild
steel
Galvanize
Bellmouth (B2)
40A
d mild
Hand pump (P3 & P4)
40A
steel
Cast iron
74
Oil dispersant system

By referring to the ships oil dispersant system schematic diagram as shown in
Appendix A, this system transport fuel oil from the dispersant tank (located at below
main deck area) to the dispersant boom (located at main deck area) via detergent pump
operating at 50m3/hr @ 30m head for cleaning the ships body from discharged waste
fluid and bilge. The transported fuel passes through SDNR valve and swing check valve.
These valves are installed to ensure that the oil flow directly to the desired locations. Sea
water is also transported into the detergent pump for cleaning purpose. For this system,
the pipes used are Schedule 40 galvanized seamless carbon steel pipes.
Table 27 shows the material listing for oil dispersant system based on the schematic
diagram in Appendix A.
Table 27: Material listing for oil dispersant system
Item
Size
Gate valve (V1)
65A
SNDR valve (V2)
Pressure
Material
Quantity
Cast iron
65A
Cast iron
65A
Cast iron

Angle valve (V5)
300A
300A
5
5
Cast iron
Cast iron
Galvanize
2
2
65A
d mild
(bar)
steel
Galvanize
300A
d mild
steel
JIS
F736
3
F735
3
F737
2
F712
1
F712
1
75
Lube oil system

Figure 7 shows the summarized schematic diagram for lube oil system for below
main deck area via block diagram. This system transport lubricant oil from sump tank to
the main engines, while undergoing filtering process; to ensure the lubricant oil is clean
and free from unwanted particles. The excess lubricant oil from the main engines will be
recycled back to the sump tank. Check valves are used in this system to ensure that the
lubricant oil flow directly to the desired location without flowing back to the origin. A
relief valve is installed for each main engine; to regulate lubricant oil flow rate at a
required pressure so that the lubricant oil filters and main engines are not destroyed due
to excess pressure. The pipes used are Schedule 40 black seamless carbon steel pipes.
Table 28 shows the material listing for lube oil system based on the schematic
Table 28: Material listing for lube oil system
Item
Size
SNDR valve (V1)
100A
SNDR valve (V2)

SNDR valve (V3)
Pressure
Material
Quantity
Cast iron
125A
Cast iron
80A
Cast iron
(bar)
Stainless
Ball valve (V4)
15A
Gate valve (V5)
80A
Cast iron
Gate valve (V6)
100A
Cast iron
Gate valve (V7)
15A
Bronze
Relief valve
80A
Cast iron
steel
JIS
F735
3
F735
3
F735
3
F736
3
F736
3
F736
7
-
76
Figur
e 7: Lube oil piping system block diagram
77
External fire fighting system

By referring to the ships external fire fighting system schematic diagram as shown
in Appendix A, this system transports foam from storage tank to water spray system in
both main deck and wheelhouse deck via fire fighting pump operated at 1500m 3/hr @
115m head. Additional two pipelines are installed to transport foam to two fire monitors
located at the wheelhouse deck to put out fire on other ships as well as the burning/fire
areas. The difference between this system and firemain system is that external fire
fighting system puts out fire externally, whilst firemain system puts out fire internally.
Butterfly valves regulate the low pressure foam to the fire monitors at wheelhouse deck.
A SDNR valve is used to discharge the excess foam to the sea directly. Several gate
valves are used to provide on-off service for the entire external firefighting system. For
this system, the pipes used are Schedule 40 galvanized mild steel pipes. Table 29 below
shows the material listing for external fire fighting system based on the schematic
Table 29: Material listing for external fire fighting system
Item
Size
Gate valve (V1)
100A
Gate valve (V2)
Pressure
Material
Quantity
10
Cast steel
65A
10
Cast iron
Gate valve (V3)
50A
16
Cast iron
Gate valve (V4)
40A
16
Cast iron
SDNR valve (V5)
50A
16
Cast iron

P/V valve (V8)
350A
250A
65A
10
16
16
1
2
1
Reducer (R1)
150/250A
Reducer (R1)
100/150A
Cast iron
Cast iron
Cast iron
Galvanize
d mild
steel
Galvanize
d mild
7
-
(bar)
JIS
F736
6
F736
4
F736
9
F736
9
F737
78
Reducer (R1)
50/150A
Reducer (R1)
65/100A
steel
Galvanize
d mild
steel
Galvanize
d mild
steel
CO2 fire fighting system

By referring to the CO 2 fire fighting system schematic diagram as shown in
Appendix A, this system transports CO2 from the CO2 storage room located at the main
deck to the main engines area, located at below main deck. The transported CO 2 is later
further distributed to 12 different locations. To control this system, a manual operated
ball valve is required, whereby the ball valve is installed along the CO 2 rooms pipeline
which transports CO2 to the 12 locations at below main deck area when fire breaks out.
The pipes from the ball valve to CO2 nozzles (12 distribution locations) are to be welded.
For this system, the pipes used are Schedule 40 galvanized mild steel pipes.
Table 30 shows the material listing for CO 2 fire fighting system based on the
Table 30: Material listing for CO2 fire fighting system
Pressure
Item
Size
Ball valve
10A
(bar)
5
Reducer (R1)
110/185A
Material
Quantity
JIS
Cast iron
Galvanize
d mild
steel
Galvanize
Reducer (R2)
110/135A
d mild
steel
Galvanize
Reducer (R3)
Reducer (R4)
110/130A
130/140A
d mild
steel
Galvanize
79
d mild
steel
Galvanize
Reducer (R5)
130/155A
d mild
steel
Galvanize
Reducer (R6)
155/185A
d mild
steel
Galvanize
Reducer (R7)
155/170A
d mild
steel
80
3.2 Supervisory work
Table 31 below shows the supervisory work for the BPT ships' piping
construction progress as per assigned by supervisor throughout these 13 training weeks.
Table 31: Supervisory work for the BPT ships' piping construction progress
Training
Date
YD408 progress
YD409 progress
week
22/12/2014
Installed copper tubing
Installed water sprays
for washrooms for
at both main deck and
both main deck and
wheelhouse deck.
Installed mast water
below main deck.

Installed tubing
sprays
solenoid valve for

fresh water supply to
23/12/2014
24/12/2014
29/12/2014
5/1/2015
Started piping
piping alignment.
alignment for fuel oil
Installed fire monitors
system.
Installed sight glass
Installed water spray
for fuel oil service
tanks.
Completed the
nozzles for external
installation for fuel oil
fire fighting system.

Main engines piping
service tanks tray.

Major piping welding
alignment in progress.
31/12/2014
on wheelhouse deck.
wiper
Started main engines
and alignment for

main engines
Installation for the

main engines
generators
Started the installation
for the main engines
81
generators (genset)
exhaust in progress.
No air tests been
exhaust
Conducted air test for
planned or conducted.
6/1/2015
both bilge and

firemain systems,
7/1/2015
generators (genset)
Installed silencer drain
and exhaust drain for
drain and exhaust
gensets exhaust.
Started the main
pipelines for gensets
engines exhaust
pipeline connection.
8/1/2015
9/1/2015
Major changes
13/1/2015
exhaust.
Completed air test for
fresh water & sea
water system.
Completed fuel oil
implemented for the
supply pipeline and
starboard side main
return pipeline from
engines exhaust
fuel oil tank to main
system due to leakage.
engines generators
Modification for
(and vice versa).

Installed gensets air
starboard side main
breather pipeline to
engines exhaust in
the exhaust funnel.
progress.
Completed the main
engines fresh water

12/1/2015
except ballast system.

Installed both silencer
supply connection.
Installed pressure
gauges for main
engines.
main engines cooling
main engines cooling
and fuel oil systems.

Main engines piping
and fuel oil systems.

Installed gensets
alignment in progress.
Preparation for
exhaust drain and
scuppers installation.
expansion joint.
support for gensets
82

14/1/2015
CO2 fire fighting
engines engine
systems piping
cooling piping
installation in
alignment.
Scuppers and main
progress.
Scuppers installation
engines exhaust
15/1/2015
16/1/2015
Completed main
in progress.
installation in
progress.
Completed scuppers
installation.
Completed all of the
Completed scuppers
installation.
main engines piping
17/1/2015
21/1/2015
connection
Completed fuel oil
Completed fresh
supply to main
water supply to galley
engines.
Completed fuel oil
sink, oily water
return pipeline from
tank and engine room.
main engines to tanks.

Completed fuel oil
piping alignment.
Completed main
engines exhaust joint.

Completed the
separator, expansion
Completed the fuel oil
pipeline for leaked oil
piping connection
from both main
from the tank to both
engines and generators
cargo and filling.

Installed fuel oil
to the sludge tank.

Completed main
service tank overflow
engines compressed
pipeline back to the
air and lube oil
tank.
pipeline
22/1/2015
None, due to Long
Installed main
83
23/1/2015
Range Identification
engines turbo charger
and Tacking (LRIT)
and expansion joint,
test been conducted
whereas the
for 18 hours
connection is still
continuously.
Conducted air tests for
pending.
Major piping welding,
fresh water & sea
grinding and
water and oily bilge &
alignment for the
dirty oil systems.

Major piping
compressed air
system.
alignment for the

compressed air
24/1/2015
system.
Completed oil
Completed oil
dispersant, hydraulic
dispersant piping
and compressed air
system.
58 outstanding tasks
piping systems.
outstanding tasks.
Conducted minor
27/1/2015
remaining.
Started copper tubing
piping adjustment for
installation for air
engine cooling system.
supply to both control

panel and main
28/1/2015
Conducted minor
engines.
compressed air supply
chain wash pipeline of
piping connection,
firemain system at
except main engines
main deck.
and control panel (to

be completed by
30/1/2015
Conducted minor
yards foremen).
Completed CO2 fire
fighting piping
84
the rexpeller cooling
system.
None
system.
Ongoing compressed
air pipeline
31/1/2015
installation to both
main engines and
10
2/2/2015
control panel.
Completed
minor outstanding
compressed air piping
tasks as per conducted
installation.
Ongoing main
on training week 9.
engines lube oil
4/2/2015
Tighten the butterfly
piping connection.
Reinstalled back the
valve along the
main engines exhaust
pipeline of the main
expansion joint after
engines standby
cleanliness inspection
cooling pump.
by the Daihatsus
engineers.
Completed engine
cooling piping system
5/2/2015
6/2/2015
Assisted in doing the
installation.
Assisted in doing
minor modification for
minor modification
the ships soundings.
for the ships
Completed the
soundings.
Ongoing modification
modification of the
of the ships
ships soundings
soundings.
firemain systems
outstanding piping
tasks.
85
Completed main
engines air vent
connection and sea
water supply
None
connection to pump.
Completed the ships
soundings
modification.
Completed the suction
and discharge pipeline
7/2/2015
of external fire
fighting system and
bilges hand pump
11
None
installation
lube oil system
pipeline connection
9/2/2015
and welding.
decks penetrations
and Marpol
Started the external
firefightings pump
piping modification.
10/2/2015
connection tasks.
Started the external
firefightings pump
Ongoing main
engines fuel oil
piping connection and
11/2/2015
12/2/2015
Ongoing external
alignment.
Ongoing external
firefightings pump
firefightings pump
Partially completed the
Partially completed
86
firefightings pump
the firefightings
Completed the minor
pump piping
piping modification
modification.
Ongoing main
for fresh water
engines fuel oil
pipeline.
piping connection and
None
alignment.
Conducted and
completed chain wash

13/2/2015
pipeline relocation of
firemain system at
14/2/2015
Completed the
main deck.
Completed the
firefightings pump
firefightings pump
oily bilge & dirty oil
None
system
Conducted and
completed the minor
16/2/2015
piping modification
for fresh water
None
12
pipeline.
Completed the main
engines fuel oil
17/2/2015
piping alignment and

connection.
13
None
18/2/2015
hydraulic system
23/2/2015
piping connection.
Completed two out of
None
three of the grey &
87
black water systems

drainage, except for
washing machine and
dryer hose.
Completed main
engines exhaust joint
None
and connection.
misc fittings (vacuum
relief valve, valve
cover, orifice and
water spray nozzles).

Completed the
pipeline installation
from the main engine
lubricant oil sump
tank to hand pump
24/2/2015
and sludge tank and

suction from every
compartment in the
engine room.
Installed pipeline
from sewage
treatment plant to
sewage tank and
terminate sewage
treatment plant air
vent through funnel.

On 2/1/2015, 9.30 am, a Germanisher Lloyd (GL) representative Mr. Gan Chee
Kian came to check the overboard position and construction progress for YD408 BPT
ship. To assist the GLs representative, overboards schematic diagram and information
such as size, valve used, location and the height from the draft water level (DWL) were
required. An outfitting engineer, Mr. Aung Zin Myat assisted throughout the session as
88
Ms. Elizacorina was attending the company meeting regarding the BPT ships
construction progress. During the supervisory progress, Mr. Gan asked three questions
regarding the overboard such as the function of the valves used associated with the
overboard location, the overboard construction progress and the purpose of the
overboard associated with the piping systems. The checking progress went smoothly and
Mr. Gan was satisfied with the overboard construction progress.
On 19/1/2015, 1.30 pm, two Daihatsu engineers came to check on the cleanliness of
YD408 both main engines exhaust. In order to assist the surveyors, four foremen were
assigned to detach the expansion joint; where two foremen are assigned for each main
engine respectively. After detached the expansion joint for both main engines, one of the
engineers went to do the checking. As the result, he was not satisfied with the port side
main engines exhaust cleanliness as it was very dirty, whereby dirt and grease were
found within the exhaust pipeline as shown in Figure 8.
Figure 8: Exhaust pipeline for port side

Meanwhile, he was quite satisfied with the starboard side main engines exhaust
cleanliness, as it was cleaner compared to the port side, although there was few welding
and grinding waste found as shown in Figure 9.
89
Figure 9: Exhaust pipeline for starboard side
In conclusion, both of the main engines exhaust had to be cleaned before the
second inspection, which was on the next following day (20/1/2015). On 20/1/2015, the
second exhaust cleanliness inspection was carried out for both of the main engines and
the engineers were satisfied with the result. Thus, the expansion joints were flanged back
to the origin at 2.30pm leading completion work at 4.00 pm.
90
Table 32 below shows the summary of the construction progress for both YD408
and YD409 BPT ships throughout these 13 training weeks. A tick symbol and date
indicated the completion status for the respective outstanding tasks throughout the 13
training weeks. Whilst, the tick symbol without date indicated that the outstanding tasks
had completed before the industrial training. Empty entry indicates the outstanding tasks
were not completed throughout the 13 training weeks.
Table 32: Summary of the construction progress for both ships
System
Outstanding tasks
Install fire hydrant valve in
engine room
Install hydraulic power pack
cooling to overboard
Firemain
Install fire hydrant at main deck
Add gate valve for sewage tank

for sea water supply
Engine
Conduct air test
Minor piping adjustment for
chain wash pipeline
Bilge
YD408 / Date
(28/1/2015)
Install hand pump at main deck
Repair pipe above manhole

Conduct air test & hydrostatic
test
Main engines generators
cooling pipe
Main engines air vent
cooling
connection
Main engines fresh water
supply connection
Cooling system for rexpeller
YD409 / Date
(6/2/2015)
(6/2/2015)
(6/2/2015)
(6/2/2015)
(6/1/2015)
(13/2/2015)
(7/2/2015)
(6/1/2015)
(16/1/2015)
(6/2/2015)
(12/1/2015)
(4/2/2015)
(4/2/2015)
91
Sea water supply to pump
Install fresh water tanks drains
and sight glass

Install water strainer
Main engines cooling system
(6/2/2015)
connection
Cooling and overboard for
(16/1/2015)
(4/2/2015)
(16/1/2015)
external fire fighting pump

Install pressure gauges for main
(14/2/2015)
engines
Fuel oil
Conduct air test
Minor piping adjustment for
main engine cooling system.

Minor piping adjustment for the
(2/2/2015)
(2/2/2015)
rexpeller cooling system.

Piping connection from the tank
to both cargo and filling
Install tray for fuel oil service

tank
Install fuel oil service tank

overflow pipe back to the tank
(12/1/2015)
Install sight glass for fuel oil

service tank
(12/1/2015)
(12/1/2015)
(21/1/2015)
(29/12/2014
)
(21/1/2015)
(24/12/2014
Fuel oil supply for both main
engines and pump

Fuel oil return from both main
(17/1/2015)
(17/2/2015)
(17/1/2015)
(17/2/2015)
engines and generators

Leaked oil from both main
(21/1/2015)
(17/2/2015)
engines and generators to the
sludge tank
Fuel oil supply pipeline from
92
fuel oil tank to racor filters and
oil tank
Conduct air test, acid cleaning
(12/1/2015)
& flushing
Fresh water, sea water and hot
(12/1/2015)
water supply for washroom at
(22/12/2014
main deck and below main deck

Fresh water supply to main
engines expansion tank

Fresh water supply to engine
room for general services

Fresh water supply to oily water
separator unit
Fresh water supply to sink at
galley
Fresh water supply to washing
machine
Fresh water supply to wiper

along with solenoid valve
Install vacuum relief valve for

water supply to water heater
Grey water
Conduct air test & hydro test
Minor piping modification on
one of the pipelines.

Install grey water pipeline for
washrooms
Install hose/drain for washing
machine and dryer to overboard

Install pipeline from sewage
& black
water
main engines generators to fuel
Fresh water
& sea water
(7/1/2015)
main engines generators

Fuel oil return pipeline from
treatment plant to sewage tank
(7/1/2015)
(17/1/2015)
(17/1/2015)
(17/1/2015)
(17/1/2015)
(22/12/2014
)
(24/2/2015)
(23/1/2015)
(7/1/2015)
(12/2/2015)
(16/2/2015)
(24/2/2015)
93
Close the grey water inlet

flanged connection in the
sewage treatment plant because
the connection is not in used

Terminate sewage treatment
plant air vent through funnel

Install drainage pipeline from
galley/kitchen to overboard
Install and connect the Marpol
connection
Install drainage pipeline from
air handling unit to overboard

Conduct air & flow test
Install pipeline from the oily
water separator to bilge holding
Oily bilge
tank
Install and connect the Marpol
connection
Install pipeline from the main
engine lubricant oil sump tank
& dirty oil
to hand pump and sludge tank

Suction from every
compartment in the engine
room
Oil
Conduct air test
Main deck connection to spray
booms
Repair pipeline in the engine
dispersant
Lube oil
room
(24/2/2015)
(23/2/2015)
(9/2/2015)
(23/2/2015)
(24/2/2015)
(9/2/2015)
(24/2/2015)
(24/2/2015)
(23/1/2015)
(14/2/2015)
(24/1/2015)
(24/1/2015)
(24/1/2015)
Conduct air test
Terminate mist gas through
(24/1/2015)
exhaust funnel
Weld the pipeline from lube oil
(21/1/2015)
(9/2/2015)
94
(9/2/2015)
after filter and recycled pipeline

Final connection to main
(21/1/2015)
(9/2/2015)
engines
Conduct air test & flushing
Suction and discharge pipeline
(21/1/2015)
(9/2/2015)
in engine room.
Install valve cover for fire
fighting 4 way deck head

Install water sprays for both
storage tank to hand pump

Repair lube oil pipe pipeline
main deck and wheelhouse
Install mast water sprays
(24/2/2015)
(22/12/2014
)
deck
(7/2/2015)
(22/12/2014
)
External
fire fighting
Install fire monitors
(24/12/2014
)
Install orifice meter for all of

the water sprays
Install nozzle for each of every

water sprays
Conduct air test

Minor piping modification for
external fire fighting systems
CO2 fire
fighting
pump.
Install pipe distribution from
CO2 manifold
Install relief valve within the
Compressed
air
pipeline inside the CO2 room

Conduct air test
Air supply from air reservoir to
main engines
(29/12/2014
)
(14/2/2015)
(24/2/2015)
(24/2/2015)
(14/2/2015)
(14/2/2015)
(30/1/2015)
(30/1/2015)
(21/1/2015)
(2/2/2015)
95
control panel
(21/1/2015)
(2/2/2015)
bilge, ballast & firemain system

(21/1/2015)
(28/1/2015)
(24/1/2015)
towing hook
(28/1/2015)
horn
(28/1/2015)
oily water separator

(24/1/2015)
(28/1/2015)
fresh water & sea water tanks
(21/1/2015)
(28/1/2015)
sea chest air blow

general service & fire fighting
pneumatic valve
Conduct air test
Complete main engines
exhaust pipeline connection
Exhaust
Install gensets exhaust pipeline
Connect gensets air breather to
exhaust funnel
Install silencer drain for both
main engines & genset
Hydraulic
Install gensets expansion joint
Install gensets exhaust drain
Pipeline connection from power

pack manifold block &
windlass
(28/1/2015)
(21/1/2015)
(28/1/2015)
(17/1/2015)
(23/2/2015)
(7/1/2015)
(7/1/2015)
(9/1/2015)
(7/1/2015)
(13/1/2015)
(7/1/2015)
(13/1/2015)
(24/1/2015)
(18/2/2015)
96
pack to capstan & local panel

pack to rexpeller
Conduct air test & flushing
Install camlock for filling
Install air vent for sea chest

strainer
Tank, vent,
sounding
(Decks
penetration)
Install filling & air vent from

storage tanks to main deck
Relocate ballast tanks air vent
Install trays for all oil air vent
& filling
Minor modification for the
soundings
Scuppers
Install scuppers on main deck
(18/2/2015)
(18/2/2015)
(9/2/2015)
(9/2/2015)
(9/2/2015)
(9/2/2015)
(9/2/2015)
(6/2/2015)
(7/2/2015)
(16/1/2015)
(16/1/2015)
97
3.3 Problem encountered and solving experiences
On 2.00pm, 9/1/2015, a problem encountered on the main engines left

side/starboard, whereby the drainage system for the condensed exhaust vapour was
unable to be installed along the 900 mild steel elbow as shown in Figure 10 below.
Without the drainage system, the condensed exhaust vapour will flow back into the main
engine, causing severe damages on the main engine.
98
Figure 10: Exhaust problem encountered

To solve this problem, a discussion was made between project engineer, yard
manager, supervisor and contractors at 3.00pm on 9/1/2015. Several ideas were given
out and explained in details; however the chosen idea was to install a mild steel box
between the 900elbow. This mild steel box allowed the installation of the drainage
system for the main engines exhaust. Therefore, the first conceptual design was drawn
as shown in Figure 11.
Figure 11: Initial design for the new exhaust arrangement
99
However, another problem was encountered on 12/1/2015 after conducted some

tests on the prototype. From Figure 11, it was observed that a large amount exhaust
vapour/gas emitted from the main engine tended to accumulate at the edge of the mild
steel box, which will cause damages on the main engine when the exhaust condensed
exhaust vapour/gas condensed flow into the main engines turbo charger. In order to
solve this problem, the exhausts design was revised by reducing the length and edges of
the box mild steel box as shown in Figure 12. With the revised drawing, it was
observed, lesser exhaust vapour/gas was accumulated at the edge of the mild steel box
when conducting testing on a prototype. The revised drawing was handed over to the
contractors on 14/1/2015 and the exhaust installation was completed on 17/1/2015.
These changes were implemented on YD409 ships starboard side exhaust system too.
Figure 12: Final design for the new exhaust arrangement
100
Chapter 4: Conclusion
In conclusion, these 13 training weeks mainly focused on the piping systems of

two bollard pull tug ships. Many types of piping systems activities had been conducted
and the activities conducted were literatures studies on piping systems, site visit on
piping systems, assisted supervisor, contractors and yards foremen in hands on the pipes
and fittings, conducted material listing for each of the piping systems, assisted engineers
and Germanisher Lloyd (GL) representative in doing inspection and last but not least
interact with other engineers on solving tasks given by supervisor or any problems
encountered throughout these 13 training weeks. Among of the activities, the major work
performed was checking and updating the piping construction, alignment and connection
progresses for the bollard pull tug ships.
Since there six objectives set for this industrial training, all of the 6 objectives were
achieved. A part of the engineering knowledge learnt in classroom was applied in
throughout this industrial training, which is the application of fluid mechanics
knowledge. Besides, professional engineering practices in the industries were been
exposed too, such as wearing Personal Protection Equipment (PPE) when working on
site. Furthermore, the role and responsibilities as well as code of ethics those engineers
should uphold are practiced too, in such way that piping engineers should be alert and
involve in solving any piping problem encountered efficiently. Apart from that, general
workplace and interpersonal skills were developed such as wearing PPE interact with
others when working on site. Despite that, all piping construction progresses were
recorded and tabulated neatly as a part of the industrial training objective. Lastly, rapport
and network with future employers were built by interacting with them in solving
problems encountered together as well as gaining additional knowledge (other than
piping) with other engineers. As for recommendation, relevant software should be
provided to enhance the understanding of the piping systems and its applications.
101
Reference Lists
Eyres, D. J. 2001. Ship Construction. 5th ed. Great Britain: Butterworth Heinemann.
Lloyd, Germanischer. 2012. Rules for Classification and Construction: Ship
Technology. Hamburg: Germanishcer Lloyd SE.
Murdich, Eric. 2012. A Masters Guide to Ships Piping. 2nd ed. London: The
Standard P&I Club.
Najin Corp. n.d. Marin Valves. 1st ed. Korea: Najin Corp.
Sanguri, Mohit. 2012. The Basics of Pipes and Bends on Ships. Mumbai: Marine
Insight.
Shin Yang. 2013. Piasau Slipways Sdn. Bhd.
http://www.syshippingcorp.com.my/index.php/corporate/ship-building/aboutshipyard
Shin Yang. 2013. Vision & Mission.
http://www.syshippingcorp.com.my/index.php/corporate/vision-mission
Sun Korea. 2005. Valves and Fittings Handbook. Busan: Sun Korea Co., LTD.
Vuthaluru, Rupa (2014). Lecture 6: Valves. PowerPoint Lecture notes.
102
Appendix
Appendix A: Schematic diagrams of

piping systems in a BPT ship
103

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Abstract

Chapter 3: Working Experience...................................................................................36

Chapter 1: Backgrounds of Company

To operate a Modern Integrated shipbuilding base benchmarked for

Adaptability to changes to retain sustained success and steadfast in

Committed to achieve Quality Assurance Management through quality

An integrated and proactive Heath, Safety & Environment Management

Table 1: 55ton Bollard Pull Tug ship details

The supervisor in charge throughout these 13 training weeks is a 2 years

Chapter 2: Summary of Duties

Table 2: Week 1 summary of duties

standard and ship design titled: 55T Bollard Pull

Tug ship, 2012 via AutoCAD software.

Review and amend schematic diagrams

Prepare material list for each piping

If no leakage is presence, the piping

Once the installation is compelete, assist

Send the material list to both project

Assist contractors and check the

Contact suppliers for material purchasing

Contact piping contracors for

Figure 1: Flow chart of shipyard piping engineers roles

Table 3: Pipes and bends in ships

(Sanguri 2012, 4).

flow direction of the medium carried inside it (90 0 Miter bends.

dissimilar pipes (Sanguri 2012, 23).

Table 4: Valves used in ships

2.2 Week 2 (8/12/2014 13/12/2014)

Table 5: Week 2 summary of duties

Table 6: Common fittings used in BPT ships

fuel oil system.

valves, water pressure pumps and deck drums.

hydraulic flow requirements of the system.

pipes for maintenance.

the ease of pipe removal and maintenance.

Table 7: Common valves used in BPT ships

otherwise is stopped completely in case of emergency situations.

the fluid from flowing back to the starting point.

configurations in the control room.

upwards and then move horizontally to the desired location.

the pipeline, which may cause blockage or difficulties in cleaning.

downwards and then move horizontally to the desired location.

time passes by.

fire in the engine room.

Bilge, ballast, firemain & wash deck system

Fuel oil transfer system

Engine cooling system

Domestic fresh water and sea water supply system

Grey water & black water system

Oily bilge & dirty oil system

Oil dispersant system

Lube oil system

2.3 Week 3 (15/12/2014 20/12/2014)

Table 8: Week 3 summary of duties

piping system analysis.

fighting piping system.

the material purchasing technique and procedure

for valves to be installed for the BPT ships.

piping system based on the schematic diagram.

Material listing for bilge, ballast, firemain &

External fire fighting system

CO2 fire fighting system