NASSCO S New Panel Line Sarah Sarnecki General Dynamics NASSCO Assistant Manager, Steel

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1 NASSCO S New Panel Line Sarah Sarnecki General Dynamics NASSCO Assistant Manager, Steel 1

2 Introduction Sarah Sarnecki Assistant Manager, Steel at GD NASSCO BS in Mechanical Engineering 5+ Years Shipbuilding Experience 2

3 NASSCO Shipyard Stages of Construction Plates SOC 1 Shapes SOC 3 Assembly SOC 4/5 Grand Block SOC 6 Erection SOC 2 Subassembly 3

facilities from around the world to identify the components that would allow

4 SOC 3 Panel Assembly Lines New panel line adds 71,000 sq. ft. to SOC 3 Our team scouted thin plate welding technology and processing facilities from around the world to identify the components that would allow NASSCO to stay at the forefront of shipbuilding manufacturing technology - NASSCO President, Kevin Graney 4

mechanized SAW Profiles welded with mechanized FCAW Additional parts welded manually Distortion corrected

5 The Old vs. The New Previous Practices No relief of internal stresses within plates prior to paneling Panel welded with mechanized SAW Profiles welded with mechanized FCAW Additional parts welded manually Distortion corrected through line heating and panel breakers New Panel Line Plate straightening Panel welded with automated HLAW Profiles welded with automated HLAW Robotic Welding No line heating/panel breakers are required 5

Automation Each station* requires only one operator Laser Systems run by Welding Engineers Systems are driven by uploaded files Mainly text files

6 Automation Each station* requires only one operator Laser Systems run by Welding Engineers Systems are driven by uploaded files Mainly text files ESAB Telerex: CNC files Robot Welding: RinasWeld No manual data entry Parameters developed by suppliers *With exception to Stations 4 and 5, Manual Fit 6

7 Design for Automation 7

3B 6 Robotic Welding This facility, the only one in the world with this unique combination of technologies, is already

8 General Arrangement 0A Plate Stripping 0B 0A 4 5 0B Mangler 1 Plate Milling/Hybrid Laser Seam Welding 2 Telerex (ESAB) Profile Fitting and Hybrid Laser Welding 1 2 3A Profile Milling 3B Profile Blasting 4 Manual Fitting 5 RT-1 3A 3B 6 Robotic Welding This facility, the only one in the world with this unique combination of technologies, is already beginning to transform our business while reducing energy consumption and emissions - NASSCO President, Kevin Graney 8

9 Plate Stripping Station 0A: ESAB Suprarex Function: Cut Plate Length and Width Features: 2 Plasma Torches Downdraft Table Plate Size: Length m, Width: m Before: Raw Plate as Purchased After: Plate Length and Width Stripped 9

10 Plate Straightening Station 0B: Haeusler Mangler Function: Flatten and Relieve Internal Stresses Features: 9 Straightening Rolls Mangle plates 5 10mm thick Pass through >10mm thick Before: Plate Warped After: Plate Flattened 10

11 Panel Milling & Welding Station 1: Graebener Milling & IMG Hybrid Laser Arc Seam Welding Function: Mill and Weld Panel Seams Features: Two-sided Simultaneous Milling 1 16kW Laser Hybrid Welding Carriage 1 GMA Tandem Welding Carriage Before: Individual Plates After: Plate Joined into Panel 11

12 Panel Marking & Cutting Station 2: ESAB Telerex Function: Grind Welds, Blast & Mark Layout Lines, Cut Penetrations & Perimeter Features: Belt Grinder Vacublast 2 Plasma Markers Plasma Cutting Torch Downdraft Table Panel Marked and Cut 12

Laser Hybrid Welding Carriages (2 4kW, 2

13 Profile Welding Station 3: IMG Hybrid Laser Arc Profile Welding Function: Load, Fit, and Weld Stiffeners to the Panel Features: Profile Positioning System 4 Laser Hybrid Welding Carriages (2 4kW, 2 8kW) Pre-Stressing Unit Stiffeners Welded to Panel 13

Conveyors and Sorting Gantries Cassette Buffer Area

14 Profile Preparation Station 3A/B: IMG Profile Preparation Line Function: Mill and Blast Profile Edges Features: Graebener Profile Edge Milling Machine Munk & Schmitz Blast Unit In/Outfeed Conveyors and Sorting Gantries Cassette Buffer Area Before: Profiles as Purchased After: Bottom Edge Milled 3mm and Blasted 14

15 Manual Fit Station 4/5: IMG Manual Fit & Rotate Table Function: Manually Load & Fit Frames, Girders, and Small Parts Features: T-Cassette Bridge Loading Gantry Traverse Gripper 4 Basket Weld Machines Panel Rotate Table Additional Parts Tacked in Place 15

16 Robotic Welding Station 6: Kranendonk Robot Welding Function: Weld Out of Frames, Girders, and Small Parts Features: 2 Gantries 4 GMAW Robots (2 ea. Gantry) Liftable I-beam Weld Bed Parts Welded Out 16

17 Engineering Design Design for Producibility The more the better! Build location is limited to facility parameters Parameters were set based on Engineering input Continuous Learning Facilities Manual Updates 17

18 Questions? Sarah Sarnecki General Dynamics NASSCO Asst. Mgr. Steel, Panel Line

Guide to Pipe Beveling

Guide to Pipe Beveling Make Weld Ready Bevels on Pipe to Fit Your Application When welding two pieces of pipe together the ends of the pipe must be properly prepared to obtain the best possible weld joint.