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PRODUCTION FACILITIES BASIS
Presently Zaliv is a leading shipyard & shiprepair not only in Ukraine, but also in CIS countries in construction of middle tonnage tankers of 85,000 t water displacement, which are exported since 1988. Totally 9 units were exported.
During construction of a nuclear powered LASH vessel and tankers (Panamax type) Zaliv has significantly increased the level of technology and methods, and now they comply with European standards.
During the last 5 years shipbuilding production was completely modernised after the projects and with assistance of Western companies.
About US $ 35 MM were invested to introduce new technologies, equipment resulting in significant increase of quality, shortening of construction period - main parameters of competitiveness of vessels in the world market.
Only during the last three years following were put into operation :
- automated shotblasting and priming line;
- automated block and panel line;
- a new paint shop, complying with European standards.
Zaliv has all necessary facilities, technical possibilities, all kinds of production to construct and repair vessels.
Production facilities of Zaliv include :
- a graving dock complex, providing for construction of vessels up to 340 m long, 54 m beam and launching weight up to 50,000 t,
- two horizontal slipways, 400 m long each, providing for construction of vessels up to 150 m long, 22 m beam and launching weight up to 5,500 t,
- two deep water outfitting quays, 278 m and 240 m long respectively with two cranes 32 t capacity and one crane 50 t capacity,
- quay, 186 m long for unloading of metal with a crane, 80 t capacity,
- all facilities, necessary for ships construction and repair.
- port, providing for handling of general cargoes.
Hull processing production
Hull processing production is located in 4 bays of a block of hull shops and includes :
- metal pre-treatment shop with a ware-house. Equipped with a GUTMANN plate and profile automatic shotblasting and priming line. The line was put into operation in 1995 and provides for shotblasting and priming of steel to international standards;
- plate gas-cutting production area with automatically controlled machines KRISTALL and GRANAT for cutting of steel plates;
- profile cutting automatic machines PROFISEC and VERTISEC
- bending area with a 5,000 t press.
- sorting area.
Production capacity of a hull processing shop is 70,000 t of steel per year.
Welding-assembly production
Welding-assembly production area is located in 5 bays of hull construction block of shops. It is equipped with a TTS (Norway) block and panel line, welding equipment of ESAB (Sweden) company, put into operation in 1994.
The line provides for fabrication of panels up to 12 m x 18 m, weight up to 100 t, hull blocks 18 x 24 m, weight up to 300 t.
Since the line started to operate, up to 80% of sections and blocks of a hull are fabricated on it (except bow and aft sections.
The shops have cranes, lifting capacity up to 200 t and trolleys to transport sections up to 350 t, sufficient number of indoor building areas, and it is possible to assemble blocks up to 300 t and organise work in two shifts at the shops.
Total production capacity of welding-assembly facilities is up to 60,000 t of hull constructions per year.
The shipyard has investigated further possibilities to increase production potential, namely automation of units assembly and welding, usage of universal devices to fabricate sections and blocks, bow and aft sections.
Zaliv is certified by GL and MRS to fabricate hull constructions.
Graving Dock and Building berths
The graving dock (364 x 60 x 13.2 m) is serviced by two gantry cranes, 320 t capacity each and 5 portal cranes, 80t capacity. The cranes enable to assemble a hull from large sections and blocks weighing up to 600 t.
It is possible to divide the graving dock into two spaces by a caisson and repair vessels in parallel with ship construction.
To implement large block technology of ship construction within the frames of modernisation a dock-lift vertical transportation system is being constructed in the dock and alongside. Commissioning of this system will enable the shipyard to assemble hulls of blocks of 2,000 t each.
Zaliv has two horizontal building berths, 400 m long with following cranes : 80 t x2, 32 t x 3, 16 t x 4. Both slipways have launching arrangements with trolleys, 1,500 t capacity. Vessels weighing from 1,500 to 5,000 t are launched via a floating dock.
Pipe production
Pipe production is located in 4 bays of one pipe-shop. Pipes are bent and cut with a highly productive equipment: cutting of big sized pipes - by a gas-cutting machine BUG-2, bending - by pipe-bending machines TGSV-1/2. All pipes are processed by the shipyard, without subcontractors.
Pipe shop has facilities to flush pipings of hydraulic systems and to test hydraulically pipes and fittings.
Capacity of pipe production satisfies the requirements of Zaliv and capacity of a galvanic treatment area satisfies requirements of shiprepairing yards of the town, which have no galvanic facilities of their own and amounts to 1200 t/year or abt.70 000 pipe lengths.
Coating works
Coating works at Zaliv are a completely new production, which complies with European standards. Instead of temporary blasting and coating shelters, which didn’t comply with necessary technological requirements, ecological and labour safety, a modern paint shop, purchased at KIESS company, was erected with all necessary technological equipment.
The new paint shop put into operation sections and blocks can be coated with temperature and humidity strictly controlled independent of environmental conditions.
The paint shop enabled to increase the scope of coating works performed before erection in the dock from 25% to 75% of all painting works.
The shipyard has mastered a technology of coating cargo and ballast tanks, inner surfaces of cargo pipes.
Production capacity is 410,000 sq.m per year.
The Modern paint shop and shot-blasting and priming line is a specific feature of Zaliv shipyard among other Ukrainian shipyards.
Mechanical-assembly Production
Mechanical-assembly production is located in several areas. There is a separate area for assembly of the ME in the scope of 100% at the shop. About 70% of all machinery is installed on board in assembly.
Outfitting of newbuildings
Outfitting of vessels after launching is performed at two deep water outfitting quays, serviced by cranes : 32 t x 2 and 50 t x 1, 1 x 80 t. The shipyard has outfitting shops in charge of insulation, panelling of pipes and a hull.
To provide for dock and sea trials Zaliv has its own floating facilities : a floating crane of 100 t lifting capacity, a tug and a diver’s boat.
Zaliv has its own oxygen, acetylene and compressed air stations, providing for the shipyard’s needs.
Zaliv has a test and analysis laboratory, a welding laboratory, a measurements laboratory. Laboratories have a Quality Certificate of MRS.
Laboratories provide for monitoring and measurement of following parameters:
- chemical composition of metals and materials (paints, oils, gases incl.);
- mechanical properties of metals and welds;
- monitoring of welded metals and alloys;
- dimensions;
- parameters of el.current;
- parameters of air.
Machine building Production
The scope of machinery on modern vessels varies from 12 to 16%, that’s why machine-building production is necessary for any shipyard. Machine building production also provides the yard with technological equipment and instruments.
Machine building production of Zaliv is located on production areas of machining, forging, machine assembly, assembly of ship’s fittings for other yards.
Facilities include 700 tools, 51 of them are CNC.
Product mix of this production includes :
- machinery for newbuildings;
- technological equipment;
- instruments;
- equipment for newbuildings and machinery for other yards.
Zaliv shipyard fabricates following ship equipment and machinery, which can be delivered to Ukrainian shipyards :
- sewage plant ЭОС-5 for ship’s sewage water, capacity 5 cu.m/h;
- fire monitors for water and foam ship fire-fighting systems;
- foam generators;
- accomodation ladders;
- vertical and inclined ladders;
- fire doors;
- bollards, rollers;
- companion covers for COT;
- foam smothering bottles;
- IG scrubbers;
- cargo system filters;
- ventilation covers for ship’s vent systems;
- thread and union connections, dia 3 - 32 mm;
- pipe branches for pipelines;
- water filtering plant VFS-10 for the Army;
- a stacking crane for warehouses, 5 t lifting capacity;
- KT-84, KT-100Y, KT-106 units.
As analysis of the product mix of machine building shows, the potential of this production can satisfy not only Zaliv’s requirements, but also those of other customers.
SUMMARY :
The shipyard has powerful enough facilities and equipped with modern equipment.
During the last years a lot was done to increase Zaliv’s competitiveness.
Production-technological potential of Zaliv provides for :
· construction of middle-tonnage vessels up to 340 m long, beam 54 m, launching weight up to 30 000 t;
· construction of small-tonnage vessels up to 150 m long, beam 22 m, launching weight up to 5 500 t on horizontal building berths;
· shiprepair (specialising in hull, coating, docking works);
· fabrication of fittings and ship’s equipment for other yards;
· fabrication of consumer goods (furniture, accessories, gas-cookers);
· production of energy-carriers : oxygen, acetylene, carbon dioxide for own consumption and for outside consumers;
· status of a shipyard-port enables Zaliv to receive and dispatch cargoes by sea;
All stages of ships’ production are modernised and provide for European quality and level:
· shot blasting and priming is effected by an automated line;
· plate cutting is effected by CNC machines;
· sections and blocks (up to 80% of hull constructions) are fabricated on Western block and panel line;
· shops of welding-assembly production are equipped with powerful cranes and trolleys, providing for fabrication of blocks up to 300 t in shops;
· a completely new paint shop of West-European level provides for surface treatment and coating up to international standards. The scope of coating works before assembly in a dock is increased up to 70% and coating works are performed now independent of weather conditions.
· Zaliv is advantageously geographically located in a natural bay between two seas on the shore of the Kerch strait;
· All technological lines and production is located mainly indoors, inside shops;
· Zaliv’s products are well known in the world market and were exhibited at International exhibitions “Ukraine-America-93” in the USA, and “Ukrainian Industry-94” in UAE, “Posidonia-94,-96, 2000” in Greece,
Ukrainian Shipbuilding 97, 2000.
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