Samus Shipyard: how to build ships of the Tomsk region

Samus ShipyardLocated in the village of Samus, which is 38 km north of Tomsk, at the confluence of the river Samuski to Tom.Until the mid 90's the company was the main enterprise for the village. It employed more than 1,400 people.

Its history began with the forced parking at the mouth of the passenger and cargo steamer "loon" in 1879. He moved in with a merchant Bijsk load, but was caught by a sudden cold snap. By Tom went ice-slush. The team chose a place to stop and spent the winter. The fact that a safe winter sucks the river fleet — a big problem. Spring break — a big phenomenon, but devastating, and at this point flowing river formed a deep comfortable backwater. Such hiding places on the rivers are rare, and knowledge shall be transmitted throughout the basin. Since then, people began to settle here, and on the shore there was Samus Shipyard.

Now it employs 186 people total. But they are, as before, are engaged in shipbuilding, ship repair, engineering and provision of safe winter lay the river fleet. Of all these activities, shipbuilding takes 84% of the total work.

 

During its existence the factory built 333 different ship types and modifications. Boats and yachts, barges and ferries, pontoons and floating cranes, cargo, passenger vessels and clearing the river fleet … that just does not float over the years. But a special source of pride is the bilge dumb barge capacity 2,800 tons, built in 1993. "Now it is operated on the Rhine River in the Netherlands under the name" Samus "- says Victor Schwartz, director of the plant Gustavovich. — It was the first and only order abroad. River Register took her, and she went out of its course through Samuskov the then Leningrad in Holland. "

Today the factory engaged in the production situational ships. This serial government orders the company received through the action of the federal target program "Development of transport system of Russia until 2015." The first phase of this program — renewal of the fleet maintenance. In the framework of the factory should build 13 ships of project 3050 (three to Novosibirsk, Omsk, Yakutsk, Khabarovsk and Krasnoyarsk for one) and 5 — Project 3050.1 (two to three for the Novosibirsk and Omsk).

3050 Ships of the project:

The task of situational courts — check the condition of the river channel. They are designed to measure the depth of the channel, installation of navigational and bank signs. Their distinctive difference is that the project 3050.1 ships are equipped with two cranes-manipulators in the fore and aft.

Ships of the Project 3050.1:

At this stage of the construction of the housing of the future vessel has already been formed. Now it's time to get up "on board" electricians, pipefitters and finishers to pursue its "saturation." But in general, as well as any big deal begins with the construction of the ship design. The plant does not have its design department, so these jobs entrust external contractors. The project should provide a huge amount of detail, including the thickness of the steel from which the future will be manufactured boat load during operation and even work schedule. Shipbuilding can be compared to building a house. From the initial design to the launching of ships pass from one year to two years.

January 2012, when the plant started the implementation of this government order, was the beginning of a large volume of shipbuilding. His workers sorely lacking, had to apply for assistance to the experts on the side. Fitters, welders, pipefitters, people come from different places, even out of St. Petersburg. To date, the hype was sleeping, the workload is dispersed, and the plant has to cope on their own, and we were able to go and see any of the stages in the construction of the vessel.


Procuring shop.

It all starts with the processing of metal. His purchase at the Magnitogorsk Metallurgical Combine, however, before the special shipbuilding steel plates will be part of the vessel, they must undergo mandatory training. The plant for this purpose there is a whole line.

Metal sheets are captured from the warehouse pneumatic suction cups and fed through the gate in the background:

Next the metal passes through the rolls, which straighten sheet, removing the possible stresses:

For the rolls should be shot blasting, cleaning the metal from rust, scale and other contaminants. Past this processing sheets laid to cover the primer.

It is applied with hand rollers. After priming steel acquires a greenish tint. Hence the metal sheets supplied to various machines, where they are cut and bent by making these kinds of KNITs and frames, stringers and beams in accordance with the project.

There is a factory a few guillotines for cutting metals of different thickness:

Gas cutting machines cut out parts of the curvilinear form:

The edges of the cut parts sanded and transmit fitters.

Or, if the item needs further treatment, she goes to the machine shop.

Machine shop.

Here are concentrated machines, which perform sverlovochnye, turning and milling work. The shop produces a wide range of products, from windows, and ending with propeller shafts.

At the entrance are blanks, which would later become the various couplings, flanges, caps and containers:

The details in the manufacturing process:

Milling machine:

After the bankruptcy, the incident at the plant in 2009, a year or two all the equipment had to put in order. New investors in the face of "Tomsk Shipping Company" and JSC "Siberian Logistics Center" planning this year to begin the modernization of the plant. The action plan envisages the gradual replacement of machinery equipment — plazmorezatelnyh purchase of new cars, modern welding equipment and the replacement of the machines in the machine shop.

Besides the main factory is engaged in ship repair activities. Soon to come from Novosibirsk ship "Tide". It will be used here to put a Chinese engine:

And this domestic engine Yaroslavsky Engineering Plant:

These engines are mounted on the MAZ. Now the mechanics of it are preparing to install Project 3050 on the ship.

About the size of another motor, located here in the repair can be judged by these connecting rods:

These details will then portholes on the ship:

Tanks for water, fuel and waste are doing in the first shop and then brought here, where they are welded machined parts, primed and tested.

Rudder for the ship project 3050. In the future, it will control the direction of the boat:

The process of making the propeller shaft for the same ship:

The anchors have to be purchased, as they cast, and the plant does not have its foundry:

The flow of production, beginning in the blank and the machine shop, comes together in shipbuilding plant.


Ship-building workshop.

The vessel is assembled from several blocks. We are fortunate that the plant is running on a serial order, so that we were able to see how it goes through various stages of construction. First, "korpusniki" as they are called here, is welded flat sections, which are then collected volume units. Further units are joined together, thus forming the ship's hull. Details are interconnected by means of semi-automatic and manual welding.

Here on the assembly stand is assembled first and second block of the ship 3050.1:

Working first cooked and collected a flat section of the deck, and then set it on a metal frame, which now welded shell plates:

The fifth unit is ready to ship, and stands on the pillars next to the assembly jig, waiting for the primer:

The third block made earlier and had already primed:

Primer finished parts:

Thus, gradually, there is a formation of the hull:

It must be said that the shipbuilding hall is impressive for its size. It was built by the Finnish company ASPO in 1988, and it was immediately provided full cycle of the ship in covered areas. New gas boiler, built after bankruptcy can not stop the work in the winter. Even in the most extreme cold in the shop is worth zero temperature.

In the last stage start building, piping, electrical and other work. The vessel is already installed crane:

And here ends up cutting and assembly of interior living spaces:

The engine room has established the main engine and two support:

When all is finished, the operation will last — the final painting. After his ship rolling out of the shop, is launched and start its tests. And only after that, it will pass to the customer.

Sucks fleet and ship repair.

Outside, outside the plant, an area of several kilometers are on winter sucks and repair large and small vessels from around the pool. We managed to visit the factory at a time when the river was about to be uncovered from the ice, and the entire fleet was still on the beach.

In winter you can settle up to 100 units of the fleet. Now almost all of them went to the place of registration.

Some vessels spend the winter in a safe backwater, and some pick up on shore to repair underwater. Every summer the plant is gaining portfolio of such orders. The fleet on the river the old, the past twenty years, virtually no new ships were built, many of them in need of repair.

These trim inserts, marked in white, changed:

So check all the welds for leaks on one side seam smeared with lime, and the other — kerosene. Kerosene has the property to penetrate very deeply into the metal through tiny capillaries and cracks, making it superior to other fluids, and on the white plaster, it will be clearly seen. Thus, if it is tread on the rear side casing, this means that the seam has a through defect.

Teams ships spend the winter close to their ships. Living in a dorm at the factory. If the repair of propeller shafts, propellers and underwater hull, their working businesses, all other work — to repair the engine, open the deck planks, etc. — Executes the command.

Of water vessels weighing up to 800 tonnes and up to 97 meters raises special ship lifting facility — SLIP.

With the help of boats are on the beach. It also brings them back into the river.

Primed hulls away waiting for their customers, serving as a reminder of the kind of bankruptcy that happened just at the time of their construction:

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"At that time there were almost single orders — says Victor Gustavovich — serial river shipbuilding in the country actually was not. Federal program for the development of the transport system earned only in 2012 and is designed to update the state of the fleet. At the moment, the industry is loaded by 25-30%. The fact that the shipbuilding — an expensive proposition. Vessels that are building the plant, are from 30 to 100 million. The most expensive project was the yacht "Baiterek" $ 500 million for the Ulbinsk mining and metallurgical complex in Kazakhstan.

At the moment, most of the fleet came to be written off, but to find the money to re-equip it, shipowners have almost none. And speaking of borrowing, the high interest rates in banks increase the payback period for vessels so much that he almost approaches to the life — 25-35 years. Such a long-term investment with a vague prospect of their return no interest from private shipowners. Thus, without government support in the renewal of the fleet simply can not do. "

Today the plant is guaranteed a job for another year, so we are optimistic about the future: Federal Programs, we have proven themselves reliable shipbuilders, so there will come other orders. Our task now is to block other work time between government contracts over which we are working. We are negotiating, so no matter, I think, will not sit. "


Text, photo Eugene Mytsyk.

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