HSL- Coffee table book for MoD

A QUEST
TOWARDS INDIGENISATION

& SELF-RELIANCE

Celebrating 76 Years of Glorious Service to the Nation...

Make in India Portal

HSL's Official Website

http://www.hslvizag.in/mii/hslmii.aspx

A user friendly portal for MAKE IN HSL’s future projects and VoP
INDIA has been created as part of the projection for the next 5 years indicating
official website of HSL. material and outsourcing requirement
are also displayed in the portal so as to
The portal caters to the requirements enable prospective vendors to assess
of prospective vendors providing business opportunities with HSL.
information like the Vendor
registration guidelines, items reserved This effort to reach out the maximum
for small scale industrial units and the Indian Vendors for indigenization is
business terms of HSL. yielding appreciable results.

Self-Reliance......

At the forefront

The long journey towards making ships in ‘ The launch of India’s first indigenous steam
India started during the pre-independent ship Jala Usha’ in 1948 after Independence’
years with the founding of the first green-field
shipyard in the year 1941 in the name Scindia
Steam Navigation Co. Ltd by the great
industrialist and visionary Seth Walchand
Hirachand which is today known as the
Hindustan Shipyard Ltd. Strategically located
on the East Coast of the Indian peninsula, at
Visakhapatnam, Andhra Pradesh, HSL has
been catering to the maritime needs of the
country ever since the construction of the
First Ship “JALA USHA” in 1948, sustaining
the efforts till date with the construction of 179
vessels. The shipyard subsequently
diversified into ship repairs, submarine
construction and refits as well as design and
construction of sophisticated state-of-the-art
offshore & onshore structures. Considering
the strategic requirements, the yard was
brought under the administrative control of
the Ministry of Defence on 22 Feb 2010.

Ship Building Achieving self-reliance in shipbuilding is an essential
requirement for the development of a maritime nation.
HSL has accumulated valuable expertise in this
domain, having built 179 ships including 11 wellhead
platforms. The product profile includes:

140 vessels for Maritime sector (Cargo liners,
Bulk carriers, Passenger vessels, Training Ship,
Dredgers, Oil recovery and pollution control
vessel, Ocean Research Vessel and Floating
cranes)

21 Vessels for Defence sector (Offshore platform
vessels, Inshore Platform Vessels, Survey
vessel, Landing Ship Tanks and Tugs)

18 Vessels for Oil Sector (Drill ships, Off shore
platforms and Supply vessels)

Our customers are Indian Navy, Indian Coast Guard,
ONGC, GML, Port trusts, DCI, SCI, Andaman &
Nicobar administration etc.



Ship Repairs Building up self-reliance in Ship repairs is a
critical requirement for sustained maritime
operations. HSL has developed expertise
and successfully repaired many advanced
technology maritime vessels, warships and
submarines. So far, 1951 vessels of various
types have been repaired.

Submarine HSL happens to be the only yard in India other than
Refits Naval Dockyards to have carried out the Medium
Refits of submarines. It undertook Normal Refit of
two Egyptian submarines in 1970-72, Medium refit of
INS Vagli and MRCM of INS Sindhukirti recently. The
Medium Repair-cum-Modernisation of Russian
made INS Sindhukirti, was successfully completed
and handed over to the Navy on 26 Jun 2015.

During the refit of INS Sindhukirti, nearly 46 The submarine achieved a speed of
Tonnes of steel, 100 km of cabling and 30 350 RPM during its very first sea sortie
km of high pressure piping were renewed. for Full Power Trials, a testimony to the
Modernisation included installation of quality of work by the yard. Successful
advanced missile system, new Sonar and completion of this MRCM proves the
other Navigation & Communication Yard’s capability to take up orders for
equipment. construction of next generation
submarines in collaboration.
Incidentally, this was the only instance
where retrofitting of missile system in an
existing submarine was undertaken in the
country.

HSL has been nominated by MoD for
undertaking Normal Refit of INS
Sindhuvir in July 2017, considering
the proven expertise gained in MR &
Modernisation of INS Sindhukirti

Make in India……

The preferred way ahead

HSL- Midhani - BHEL factor….

Synergising Competencies

HSL has signed a MoU with major PSUs
(BHEL – specilaised in heavy machinery and
equipment, MIDHANI – specialised in flat
products and forgings of special steel and
non-ferrous alloys, welding materials etc.) to
form a consortium.
This aims to complement the unique strength
of three PSUs in realising indigenous
products as a substitute for Imported items
used in submarine constructions.

Imbibing International
Standards

To strengthen the capability of Indian
shipbuilding industries for achieving the
strategic objectives under the ‘Make in
India policy’, the Indian Govt. has entered
into an Inter-Governmental Agreement
(IGA) with Republic of Korea (RoK) on 21
Apr 17. Considering the strategic location
of HSL, Ministry of Defence has
nominated HSL for Strategic Partnership
under this IGA. M/s Hyundai Heavy
Industries (HHI) has been nominated by
Republic of Korea as the strategic partner
to HSL.

Indian Prime Minister Signs MoU at Hyundai
Heavy Industries - May 2015

This partnership covers
Modernisation of facilities and processes
Design collaboration
On the job training
Technical consultancy
Material supply
Transfer of Technology
Joint construction of future projects

IGA signed on 21 Apr 2017 by Shri Ashok Kumar It is intended to construct the Fleet Support
Gupta, Secy (DP) and Mr Chang Myoung-jin, Ship (6 Nos.) under collaboration with M/s
Minister of Defense Acquisition Program HHI realising the “Make in India vision” of the
Administration, South Korea nation

Indigenisation......

The ultimate agenda

MRCM of Inshore Patrol
INS Sindhukirti Vessel

The refit required very special type of Water jet ducts were newly fabricated
materials and fittings to meet stringent and installed on-board IPVs to suit
technical/ quality norms. the requirement of water jet
propulsion system to the satisfaction
In most cases, material was not of the customer. It was for the first
time these water jet ducts were
available in local market and HSL had to fabricated in-house with meticulous
care and high quality standards.
explore the industries/manufacturers all
It is our constant endeavour, to
over India to meet the material use indigenous material where ever
feasible / permitted by the customer,
requirement. Certain specialist to improve self-reliance and to
decrease FE outflow. Following items
equipment/facilities were procured/ are generally procured from
Indigenous sources only
developed through experienced vendors.
 Ship Building Steel (DMR 249A)
During the refit, 546 purchase orders  Doors & Hatches for ships
 Welding Rods
were placed on 450 different firms for  Welding Rectifiers / Inverters
 Cables
purchase of Material/equipment at a total  Material Handling Equipment
 Switch Gears
cost of Rs 48 Cr.  Lifting Gear and Accessories
 Paints
Many technical issues were also  Transformers
resolved using indigenous expertise
during the refit. The aft conical structure
was found sagging by 45 mm during
alignment check of shaft-line of INS
Sindukirti. Instead of resorting to taking
assistance of Russian specialists, the
corrective work was successfully
completed using local expertise.

In addition, other suitable indigenous
items like filler wires, paints, adhesives,
insulation materials and fittings were
also used thereby avoided importing the
items from Russia, saving precious
foreign exchanges & dependency on
Russia for basic raw material.

Hatch Covers The purpose of a hatch cover is to prevent
ingress of water into a cargo hold. Hatch
HSL has indigenously built the weather covers are moveable structures designed to
tight hydraulically operated Hatch weather tight standard.
Covers for 30,000 DWT and 53,000
DWT bulk carriers for the first time in These hatch covers, constructed with high
India. tensile steel (length of 22.740 m and width
of 6.320 m), encounter critical problem of
distortion during welding. To reduce this
distortion, HSL implemented the best
welding sequence and usage of 98% MAG
welding process with automation like
Automatic travelling fillet welding machine
(MOGGY) and Automatic travelling
Butt/Seam welding machine (KAT
OSCILLATOR).

Various heating techniques like Triangular
heating, Line heating and Spot heating
were used to straighten the hatch cover
within the permissible limits for the smooth
functioning of Hatch covers on the vessel.

Skilling India......

Empowering the next
generation

The yard has adopted the Govt.
ITI, Visakhapatnam for boosting
skill development initiative of the
govt. Support is extended in
terms of donation of equipment,
offer of HSL facilities and its
employees to impart training.

HSL has been doing yeomen service to
industries in Andhra Pradesh by
providing training for technical personnel
since inception of the company. All
training requirements of yard, at workers
and supervisor level, are being met in-
house. Thousands of technical
personnel, from semi-skilled to graduate
engineers have been trained in yard from
late sixties. Every year, hundreds of
apprentices (ITI, Diploma and Graduate
Engineers) are being trained in this yard.
Students from various engineering
colleges and polytechnics are also
undergoing internship in HSL as part of
their curriculum.

Vendor Development......

Supporting MSEs & Start-ups

In order to develop and build-up a robust Measures taken for promoting indigenous
supply chain, efforts are being made to Defence manufacturing in the MSEs
identify potential indigenous vendors in sector:-
line with “Make in India” initiative of
Government of India. Introducing purchase preference
clause (to Indian manufacturer over
The objective is to create a strong vendor Foreign manufacturer)
base which can support indigenous
warship construction projects. Towards Assurance of orders for future
this, various Vendor development requirement in 5 years on the same Indian
initiatives have been taken. firm which executed import substitute order
successfully

Relaxation of norms for MSEs and
Start-ups in all public procurements subject
to meeting quality and technical
specifications

Provision of advance payment to MSEs

"Vendors are our partners in
writing success stories"

Support to HSL has been a lead industry in
Ancillary shipbuilding, Ship Repairs and
Industries Submarine Repairs.

The Shipyard has also been
instrumental in training large no of
Young Engineers and Workers. The
shipyard has thus made significant
contribution earning a name for itself
as a shipbuilder of repute.

Apart from providing substantial
employment to locals, the Shipyard
has been a catalyst in the rise of a
large no of ancillary industries in and
around Visakhapatnam District

HSL provides the following Test Quality
Facilities to private sector entities to Control Test
encourage them to take up high-end Facilities
technology jobs:-

 Calibration of pressure gauges up
to 600 bars

 NDT (Non-Destructive Test)

 Facilities

 DPT (Dye penetrate testing)

 MPT (Magnetic particle testing)

 USG (Ultra Sonic Gauging)

Innovation & Creativity......

An alternative
manufacturing process

Enhancing in-house Design

HSL has a well-equipped Design Department, The complete suite of Naval Architecture
which has been catering to design
requirement of different categories of Ships. calculations (hydrostatics &
This design department has been recognized
as in-house R&D unit by Department of hydrodynamics) is undertaken using the
Scientific & Industrial Research (DSIR),
Ministry of Science & Technology. design module. The hardware in design

HSL's design capability embraces wide department has been augmented in 2016-
spectrum of general and special purpose
vessels. In anticipation of the requirement of 17, to the state of the art configuration with
state-of-the-art resources for taking on the
complex design support for the assured an expenditure of Rs 5.5 Cr.
orders for SOVs and FSS, Design
Department has been upgraded in the recent The following Research & Development
past with sufficient number of licenses for activities were undertaken:-
Aveva Marine as well as for Auto CAD
Mechanical under modernisation program. Optimization of powering for survey
vessel (large) for Indian Navy
With these tools, the design office has
mastered the art of producing composite Preliminary design of caisson gate
drawings which would enable adoption of for ND (V).
integrated modular construction methodology
with a high level of pre-outfitting of blocks- Re-engineering of main engine
modules. exhaust for project VC 11184 for the
improvement of backpressure.

3D modeling of Structural
foundations and complete modeling
of HVAC and modifications in piping
and cable trays for VC 11184

Nesting drawings for block drawings
for 10Ton Bollard Pull Tugs.

Structural modeling and generation
of drawings of 50 Ton BP Tugs

Receiving Raksha Mantri’s
Award for Innovation

HSL has received Raksha Mantri’s Rear Admiral LV Sarat Babu, NM, IN (Retd),
award for excellence in the category of Chairman & Managing Director and Shri Ch
Innovation for the year 2015-16 for the Srinivasa Rao, Addl. General Manager,
following works:- Engineering Department, Shri N Appa Rao,
Addl General Manager, Ship Repair
Innovative shafting work Engineering Department and Shri D Srinivasa
Rao, Addl General Manager Shipbuilding
Innovative rudder carrier bearings Division attended the award function at New
modification Delhi on 30 May 2017 and received the award
on behalf of HSL.
Innovation in welding techniques
The Board of directors has placed on record
their appreciation for the commendable efforts
put forth by the C&MD, functional directors

and concerned employees.

Innovative Shafting Work

Presently, a 15000 T Vessel is under With this process, the launch schedule
construction at HSL for the Indian Navy. was met cutting down on the time
The build strategy for a vessel to be frame by 2 months and cost saving of
constructed is decided based upon the approximately 50 lakhs.
method and sequence of propulsion shaft
installation. Conventionally, as per the The innovative process involved a low
build strategy, the shafting work bed transporter, in-house designed jig,
commences with the lowering of the shafts alignment tools and load/stability
on the bearing blocks located inside the checks. The three shaft weight varied
shaft tunnel using the overhead crane. from 15 T to 35 T with asymmetric
loading. For inserting the shafts, the
Delivery of the shafts of this project got low bed transporter (a material
handling equipment), normally used in
delayed due to accidental damage to shaft broad roads to shift large structural
panels on ground, was lowered into
during overseas transhipment. Progressing the building dock to facilitate the
planned process.
construction as per the original build
A special jig was designed to
strategy would have resulted in deferment of undertake the fine adjustments of rake,
vertical displacement and eccentric
many sequential activities scheduled to be loading of the hub to enable smooth
travel of the shaft piece into the shaft
undertaken after shaft lowering and tunnel avoiding any scoring of the
shaft or damage to the stern gear/stern
impacted the time lines of the project of tube of the ship with clearances of
about 1.5 mm.
National importance. Following
The movement of shafts within the
conventional method of shipping in of tunnel was arranged using grouped
pneumatic blocks and tackles for
delayed shafts by cutting decks would have smooth and controlled movement.

led to restricted progress of work on above This activity was undertaken
successfully by meeting all quality
decks, extensive fabrication and erection requirements and was accepted by the
owner and the classification society.
works leading to both time and cost

overruns.

Hence, HSL revised the build strategy for
insertion of all the shafts through the stern
tube and progressed with the erection of
the steel blocks and equipment outfit
inside and above the engine room and aft
sections of the ship

As against, a timeline of 8 weeks planned for shaft
mounting following the deck cut and vertical lowering, the
entire job was completed in 3 days thus accruing a saving
of two months in timeline. The saving of manpower was of
400 mandays as most of the operation was automated.

Creative Picks This innovative ‘Multi Degree Freedom Shaft Insertion
Approach’ enabled yard to address the issue of shaft
lowering with minimum impact on concurrent progress
while meeting all the quality requirements. All activities
were completed on time and the vessel was launched as
per the schedule.

This innovative process with available resources could as
well be a preferred alternative process for major platforms
to maximize on accrued savings in time and cost.

Rudder Carrier
Bearing Modification

Rudder carrier bearings of INS Kesari, a vessel under refit, were
to be replaced with modified bearings to overcome the ‘Rudder
drop’ defect. This defect rectification required disconnection of
rudder stock from tiller as well as from rudder blade for carrying
out necessary machining works on stock for fitment of modified
carrier bearing. The challenge was to detach the tiller from
rudder stock, which was of H7/s6 interference fit, within the
restricted clearance between tiller top and steering
compartment deck head. Hitherto this work was undertaken in
other yards by cutting the deck head of the steering
compartment and removing the structure to create space around
tiller. This enabled creating space for accommodating pullers to
disconnect the tiller from rudder stock. This methodology
involves extensive degutting of Electrical & Hydraulic systems
and major hot works in deck head. In order to avoid major hot
works and extensive degutting of Electrical & Hydraulic systems
in the steering flat, it was decided to find an alternative
methodology for disconnecting the tiller from rudder stock.
Accordingly, special pullers were designed and manufactured to
suit the limited and constrained work space available between
tiller top and steering compartment deck head. Further
strengthening was undertaken to withstand anticipated heavy
load of about 700 tons.

Finally, both the tillers were successfully separated from the
rudder stocks with the alternative & innovative methodology with
the help of specially designed pullers by using special gas
torches for controlled heating of tiller and applying hydraulic
pressure as per the plan in steering compartment. For refitting
the tillers, induction heating method was adopted successfully.

This innovative design of pullers enabled
the yard to address the issue of
eliminating major hot works for cutting,
removal & re-welding of deck head and
extensive degutting / regutting of
Electrical & Hydraulic systems in steering
flat normally required for disconnecting
the tiller from rudder stock to complete the
Rudder Carrier Bearing modification
works. This has resulted in avoidance of
major expenditure of about Rs. 20 Lakhs
and hot work & reduction in refit duration
by about 20 days.

Innovative Welding Technique

Corrosion resistant Cu-Ni (Cupronickel)
piping is used in highly corrosive flow
systems and GM (gunmetal) flanges are
used in joining the pipes together. The
existent and established welding
procedure for joining Cu-Ni (90/10) Pipe
to LG4C GM Flange involves Brazing
Process with Silver brazing electrode
grade BaCuAg 16A containing high
percentage (43%) of Silver(Ag) metal.
The 43% grade silver brazing rod is very
expensive, costing Rs 25,000/- per Kg,
depending on bullion rate prevailing on
that date.

HSL took initiative to develop a new welding
technique to join Cu-Ni piping with GM
flange and conducted trials way back in 2012
following its application. This resulted in a
better weld quality and substantial reduction
in cost.

A Detailed study of the melting temperatures
and weldability of Cu-Ni with LG4C Gun
Metal along with the service condition of
piping system was carried out.

The joining of the Cu-Ni to Gun metal flange by Tungsten Inert Gas welding process was
proposed using a high melting point non-ferrous alloy with minimum Silver content to
economise the cost. A 2% silver bearing electrode from a leading manufacturers of Silver
brazing alloys was chosen for the purpose.

Based on the trials conducted in the
presence of Indian Register of Shipping
(IRS) and destructive testing at a NABL
approved lab, IRS approved the weld
consumables and Welding Procedure
Specification (WPS) / Procedure
Qualification Record (QPR)

The major benefit achieved by adopting
the new TIG welding process instead of the
existing brazing process is the reduction in
cost of the filler material. Cost of the earlier
Filler material is about Rs 23000 to 27000/-
per KG. Cost of newly Inducted Filler
Material is only Rs 1620/- per KG.

The cost benefit that was achieved during
the year 2015-16 was to the tune of 5.00 Cr
and it will be accruing continuously. It is
established that this innovative welding
process is much stronger, superior and of
higher quality than the existing brazing
process. The process is very easy to follow,
operator friendly and fast. This also
enables better quality, faster process and
ease of operation.
.

Critical Technologies.......

Imbibing through initiative &
involvement

HSL has submitted citations for SODET’s award for excellence in the category of
Technology Development and Technology Innovation for the year 2015-16 for the following:

Design of ship side exhaust for Main Engine and Diesel Alternators
Installation of Major Sensor and Dome on the Ship

Design of ship side exhaust for Main Engine and Diesel
Alternators:

The work has been undertaken on the Fleet Conventional Exhaust Layout of a ship
Support Vessel under construction in HSL.
Generally, in a ship the exhaust of the Main
engine and the Diesel Generators are
routed through the funnel, which finally
ends in the superstructure. The initial
design also considered the same
arrangement. However, when yard
commenced preliminary design and the
binding data became available, it became
apparent that arrangement would need
review since the ship’s sensitive sensors
were located on the upper deck which
would get affected by the high temperature
of the exhaust and soot. Additionally the
location of the sensors also precluded
fitment of a funnel.

Innovative approach Innovative Concept
to overcome challenge
As the hot gases have tendency to rise, the
This design challenge was taken up by the chimney effect is normally used in the stack
Yard and an alternative was found which design. The exhaust routed through the
was far removed from the comfort zone of funnel stack thus is maintained vertical or
the conventional design. As locating, the close to vertical. This was not possible in
exhaust on the upper decks was not this design approach, as the exhaust had to
possible the only option was to undertake a be led to the ship’s side. The exhaust duct
design to provide the exhaust on the ship’s was required to be given a 180° bend after
side above the waterline. However, this reaching the main deck to bring it down till
concept was compounded by several unique the waterline exhaust at shipside.
features of this ship some of which are
The innovative approach was to create a
• High Capacity engines gooseneck above the damage control deck
to meet the damage stability criteria and
• Limitations caused by damage control design the exhaust duct size and with
requirements bends to meet the total pressure drop
criteria. If this pressure drop takes place,
• Limitations caused by pressure drop required power cannot be obtained from
because of the bends arising in the main engine, which finally results in
system. reduction of speed of the vessel.

• Requirement of ensuring that water does With the pressure drop criteria as the
not enter the exhaust from the seaside. design condition, a route with admissible
duct sizes was made with a 180° goose
• Extreme high temperature of the exhaust bend in the exhaust line and the final outlet
meeting the surface close to sea water of the exhaust just above the waterline of
the ship.
The yard proposed to follow a non-
conventional technology to route the While optimisation of the duct route, sizes
exhaust through the side shell after and components led to meeting the head
overcoming all these limitations. Being the loss criteria, the goose bend above the
first ever for a ship of this size and the damage control deck met the damage
complement, the proposal was put through flooding criteria. To arrive at this optimised
protracted deliberations with the owner’s design, analytical duct loss calculation and
experts and finally it was jointly agreed to CFD analysis using advanced numerical
progress with the unconventional tools had to be used. This CFD analysis
technology of ship side exhaust. established the efficacy of the design.

Special Operation Vehicles

SOV is a mini submarine to carryout This would also entail a transfer of skill
covert operations of launching and and technology in design and
recovery of Marine Commandos construction apart from utilisation of the
(MARCOS) and also to carry out extant indigenous material and
close-in surveillance & attack in equipment in this project.
shallow waters / anchorage.
Even though there is no Offset clause
Construction of Special Operation condition in this project, HSL will
Vehicles, the midget submarines, a endeavour its best to use indigenous
project being taken up by HSL will be products and Technology transfer to the
a big milestone in Make in India maximum extent possible. Once the
initiative. This will be a first time in shipyard develops the capability to build
India project. SOVs, there will be a possibility to build
and export these products to South East
HSL has been nominated to construct / South Asian Navies in future.
02 nos SOV for Indian Navy. HSL will
tie up with foreign a collaborator who
is capable for design of submarine /
SOV for construction of this project.

Technology Up-gradation

HSL has partnered with M/s Tech Mahindra Ltd as System
Integrator (SI) to implement SAP ERP and integrate with
PLM design software products in order to have a seamless
flow of information and to bring in best practices adopted in
other Indian and foreign shipyards. This would be first time
in any Indian Shipyard that PLM Design software would be
integrated with any ERP software. In fact not many
shipyards in the world have this feature included in the ERP.

Geared for growth

Apart from our commitment towards achieving self
reliance through indigenization HSL has been
continuously striving to meet the requirements of the
maritime sector. The turnover achieved during the last 5
years is as indicated in the figure. In FY 2016-17, the yard
clocked highest turnover of Rs 629 Cr since its inception
75 years ago with an associated net profit of Rs 54 Cr.

“To be an internationally competitive
shipyard for Building & repairs of
Ships & Submarines”

RAdm LV Sarat Babu, NM

Chairman & Managing Director