Automation systems

Module 4

Electric propulsion

EP
➢ Introduction .
The operation of a ship comes with a lot fully-automated process, which have to run parallel with
each other. To be able to guarantee a safe and economic operation, all these processes must be
efficiently controlled, consistently monitored and clearly displayed.
All of this is done by the Integrated Alarm, Monitoring and Control System, (IAMCS). IAMCS is a
microprocessor-based system containing all necessary functions for protection and control the
complete ship installation.
In this module we will discuss various aspects of sensors transducers and actuators
We look at Automation control and its application with systems functioning on board our vessels.
Power Management System control and blackout recovered is also discussed. Umbrella safety
systems ie SMCS which incorporates a number of sub systems will be outlined.

Training outcome

➢ Understand functions and main features of different types of IAMCSs;

➢ Understand how sensors and transducers function;
➢ Have a better understanding of Automation Systems
➢ Improved knowledge of Power Management Automation Systems.
➢ Be aware of Umbrella automation systems eg SMCS, ( ESD, FD, PA system).

Automation Definition: The technique of making an apparatus a process, or a system operate

automatically.

Control theory (open / closed loop / components / controller terms)

Process
Control
Monitoring

Class society guidelines: All control systems essential for the propulsion, control and safety of the
ship shall be independent or designed such that failure of one system does not degrade the
performance of another system.

In the case of failure, the control systems used for essential services are to remain
in the last position they had before the failure, unless otherwise specified by these
rules (Class BV).

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Integrated Alarm Monitoring and Control System (IAMCS)

The IAMCS process stations and operator stations, enables the operators to monitor and operate
the majority of the ship’s machinery from a single operator station.
The communication network consists of a redundant process field bus network and a serial point to
point communication.
In the event of an automation failure local manual control is always available.
The IAMCS system has the ability for remote diagnostic, fault finding and Debugging.
The operator workstations usually comprise TFT monitors and operating keyboards with trackball.
The computing capacity is distributed amongst a number of process and operating stations. Process
related programmes are loaded on EPROMs or on battery buffered RAMs in the PLCs. The
programmes cannot be lost or destroyed by an operating mistake or from a total failure.

Process Station
The process station is an independently operating computer station with a redundant process
control station (PCS) for ‘hot back-up’. Each PCS forms a link to the controlled and monitored item of
equipment and it performs the logical functions, mathematical calculations, data collection, alarm
monitoring, etc. The PCS units are independent of any of the central units. The process stations are
essentially PLC controlled input/output terminals receiving and sending data from/to actuators,
starters, sensors, etc. Local processing is carried out via the PLCs located in these process stations. A
number of I/O racks are connected at each station. These I/O racks are the interface between the
equipment being considered and the control system. These provide the analogue or digital input
and outputs to the devices.

Operator Stations
The operator stations, consisting of VDU, keyboard and tracker ball, carry out alarm signaling and
process visualization and operation. The operator stations have their own hard drives to store
configuration data, process data and graphics. The workstation monitor displays system mimics
and information screens. Several hundred process graphics are available to the operator. A process
graphic display consists of a static mimic representing whole or part of the process.

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Printers are connected to the system in the ECR and technical office to enable the printing of
reports, alarms and data logging.

Power Management System (PMS)

On marine vessels the Power Management System PMS is in charge of controlling the electrical
system. Its task is to make sure that the electrical system is safe and efficient. If the power
consumption is larger than the power production capacity, load shedding is used to avoid blackout.
Other features could be to automatic start and stop consumers (e.g., diesel generators) as the load
varies.
Heavy load start program ensuring sufficient generating capacity prior to a heavy load being started;
Automatic load shedding (preferential tripping) of consumers for protection of the 11kV network;

Preferential tripping of consumers for protection of the LV normal and emergency network.

In the event of a blackout, automatic restart of the network with a sequential restart of pumps and
fans.

Interface between the PMS and propulsion control system in order to configure the power plant and
the available power for propulsion. The propulsion control system limits the output of the
propulsion motors to suit the power available from the network (so-called “PLS”).

- Heavy load start program ensuring sufficient generating capacity prior to a heavy load being
started; Automatic load shedding (preferential tripping) of consumers for protection of the
11kV network;

- Preferential tripping of consumers for protection of the LV normal and emergency network.

- In the event of a blackout, automatic restart of the network with a sequential restart of
pumps and fans.

- Interface between the PMS and propulsion control system in order to configure the power
plant and the available power for propulsion. The propulsion control system limits the
output of the propulsion motors to suit the power available from the network (so-called
“PLS”).

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ESD (Emergency Shut Down System)

In order to provide protection of human life and property, as well as adhering to governing
regulations, an operational and highly effective ESD is an essential asset.
In the case of emergency, reliable operation of the ESD system is of highest importance.
Main task of ESD solution is to prevent escalation of hazardous events by Shutdown and control of
integrated equipment and systems, running the automated and predefined Cause & Effect charts,
providing the status and alarms of equipment and systems, supporting the decision making and
displays and propose activities during emergency situations.

- Shutdown and control of integrated equipment and systems

- Running the automated and predefined Cause & Effect charts
- Providing the status and alarms of equipment and systems
- Supporting the decision making
- Displays and propose activities during emergency situations

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SMCS (Safety Management Control System)

The safety management system (SMS) is an organized system planned and implemented by the
shipping companies to ensure the safety of the ship and marine environment.

SMS is an important aspect of the International safety management (ISM) code and it details all the
important policies, practices, and procedures that are to be followed in order to ensure the safe
functioning of ships at the sea. All commercial vessels are required to establish safe ship
management procedures. SMS forms one of the important parts of the ISM code.

The safety management system (SMS) therefore ensures that each and every ship comply with the
mandatory safety rules and regulations, and follow the codes, guidelines, and standards
recommended by the IMO, classification societies, and concerned maritime organizations.

System (SMCS) is a computer network based control system which provides single point access and
status monitoring to all the major safety systems on board the vessel. The SMCS is deemed an
essential system for the Safe Return to Port (SRTP), it needs to remain operational after a fire or
flooding casualty. The SMCS system monitors and controls several sub-systems, some of which are
considered an essential system. Among the interfaced sub-systems are the Emergency Shutdown
system (ESD), Fire Detection System (FDS), Watertight Doors (WTD), which are considered essential
systems. Redundant interfaces connect the sub-systems to the SMCS server and are arranged in such
a way as to avoid a single failure from affecting the communications between the systems.
This system acts in a supervisory capacity to all the safety sub-systems, such as fire detection, fire
doors, etc, and can integrate and co-ordinate the actions of these systems. The system can be used
to manually trigger individual actions in any of the linked systems, and is capable of automatically
executing safety strategies across several independent systems in line with stored scenarios in its
database.
The SMCS detects alarms from the sub-systems and displays those using graphic interfaces
in a strategic and co-ordinated way to enable the operator to see the overall safety situation. The
system then allows the operator to decide the course of action and will carry out actions as
necessary by sending commands to the sub-systems. The operator can choose several different
displays; fire zones, decks, multi-deck, etc.

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 A module built PLC

The PLC is structured around a Central Processing Unit (CPU), a power supply (from AC or DC
voltages) and modules according to the application needs

PS – Power source
CPU – Central processing unit
IM – Interface module
SM – Signal module
FM – Functional module
CP – Communication process

Power source module makes it possible to connect the PLC to several power sources.
The central processing unit is selected depending of the process and the amount of code in the
program. If there is a lot of code, you might select a faster CPU or one with more memory.
The interface module is used for connecting devices on RS 232 or RS 485 like (label)printers,
scanners and so on. Signal modules are used to get a hardwired connection with sensors and
actuators in the field. Explained later in Inputs and Outputs. Functional module are used for critical
processes which are controlled independent of the cycle time of the CPU. Examples are positioning
tasks, motion control, closed loop control, etc. The communication process module is used to
connect to other networks and bus systems, like Profibus-DP, CAN-bus. This makes it possible to
communicate with control panels, other PLC’s and other networks.

PLC’s are still developing and getting smaller and smaller. Some manufacturers have combined
several modules into one. The CPU is equipped with two communication ports and a power source.

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PLCs differ from computers in their reliability and ease of maintenance. Modules can be very quickly
replaced and PLC restart is very fast. It’s high flexibility in use offers many advantages throughout
every stage in the lifetime of a plant.

Process Control

Engineering Watch keepers, ETO’S play an important part in the human-machine dialogue. They
must use the information they have to perform actions that makes the ships and installations run
properly without endangering safety and availability. It is therefore crucial that the interfaces and
dialogue functions are designed to ensure that operations can be performed reliably in all
circumstances.

Distributed control network.

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Distributed Control System

DCS is an abbreviation for Distributed Control System.

The controlling elements are not in one central location but are distributed throughout the ship.
Each controlling element is controlled by one or more controllers. The entire system of controllers
and control element is connected by networks for communication and monitoring.

Network Bus Communication examples on some Carnival, Costa, Princess

PAC (Programmable Automation Controller)

A programmable automation controller (PAC) is a compact controller that combines the features and
capabilities of a PC-based control system with that of a typical programmable logic controller (PLC).
PACs are most often used in industrial settings for process control, data acquisition, remote
equipment monitoring, machine vision, and motion control.
Additionally, because they function and communicate over popular network interface protocols like
TCP/IP, OLE for process control (OPC) and SMTP, PACs are able to
transfer data from the machines they control to other machines and components in a networked
control system or to application software and databases.

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PAC (programmable Automation Controller)

Sensors

Definitions of Sensor and Transducer

A dictionary definition of ‘sensor’ is ‘a device that detects a change in a physical stimulus and turns it
into a signal which can be measured or recorded; a corresponding definition of ‘transducer’ is ’a
device that transfers power from one system to another in the same or in the different form‘.
A sensible distinction is to use ‘sensor’ for the sensing element itself and ‘transducer’ for the sensing
element plus any associated circuitry. All transducers would thus contain a sensor and most (though
not all) sensors would also be transducers.

The figure above shows the sensing process in terms of energy conversion. The form of the output
signal will often be a voltage analogous to the input signal, though sometimes it may be a wave form
whose frequency is proportional to the input or a pulse train containing the information in some
other form.

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Transducers can be used to sense a wide range of different energy forms such as movement,
electrical signals, radiant energy, thermal or magnetic energy etc., and there are many different
types of both analogue and digital input and output devices available to choose from. The type of
input or output transducer being used, really depends upon the type of signal or process being
"Sensed" or "Controlled" but we can define a transducer as a device that converts one physical
quantity into another
Devices which perform an input function are commonly called Sensors because they "sense" a
physical change in some characteristic that changes in response to some excitation, for example
heat or force and covert that into an electrical signal.
Devices which perform an output function are generally called Actuators and are used to control
some external device, for example movement.
Both sensors and actuators are collectively known as transducers because they are used to convert
energy of one kind into energy of another kind, for example, a microphone (input device) converts
sound waves into electrical signals for the amplifier to amplify, and a loudspeaker (output device)
converts the electrical signals back into sound waves and an example of this type of I/O system is
given below.

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Analogue and Digital Sensors
Analogue Sensors
Analogue Sensors produce a continuous output signal or voltage which is generally proportional to
the quantity being measured. Physical quantities such as Temperature, Speed, Pressure,
Displacement, Strain, etc. are all analogue quantities as they tend to be continuous in nature. For
example, the temperature of a liquid can be measured using a thermometer or thermocouple which
continuously responds to temperature changes as the liquid is heated up or cooled down.

Analogue sensors tend to produce output signals that are changing smoothly and continuously
which are very small in value so some form of amplification is required. Then circuits which measure
analogue signals usually have a slow response and/or low accuracy. Also analogue signals can be
easily converted into digital type signals for use in microcontroller systems by the use of analogue-
to-digital converters, or ADC's.

Digital Sensors
As its name implies, Digital Sensors produce a discrete output signal or voltage that is a digital
representation of the quantity being measured. Digital sensors produce a Binary output signal in the
form of a logic "1 " or a logic "O", ("ON" or "OFF"). This means then that a digital signal only
produces discrete (non-continuous) values which may be outputted as a single "bit", (serial
transmission) or by combining the bits to produce a single "byte" output (parallel transmission).

Light Sensor used to produce a Digital Signal:

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In the simple example above, the speed of the rotating shaft is measured by using a digital
LED/Opto-detector sensor. The disc which is fixed to a rotating shaft (for example, from a motor or
robot wheels), has a number of transparent slots within its design. As the disc rotates with the speed
of the shaft, each slot passes by the sensor in turn producing an output pulse representing a logic
"1" or logic "0" level.

4 — 20mA versus 0 — 10V analogue signals

4 — 2OmA is generally preferable, because:
➢ less sensitive to interferences and electric noise
➢ automatic detection of wire break (0 mA has no meaning)
➢ Linear relation Range - Signal

Temperature sensors

Temperature Sensor Types

The most commonly used type of all the sensors are those which detect Temperature or heat. These
types of temperature sensor vary from simple ON/OFF thermostatic devices which control a
domestic hot water system to highly sensitive semiconductor types that can control complex process
control plants.
There are many different types of Temperature Sensor available and all have different characteristics
depending upon their actual application. Temperature sensors consist of two basic physical types:

Thermostat
The Thermostat is a contact type electro-mechanical temperature sensor or switch, that basically
consists of two different metals such as nickel, copper, tungsten or aluminium etc, that are bonded
together to form a Bi-metallic strip. The different linear expansion rates of the two dissimilar metals
produces a mechanical bending movement when the strip is subjected to heat. The bi-metallic strip
is used as a switch in the thermostat and are used extensively to control hot water heating elements
in boilers, furnaces, hot water storage tanks as well as in vehicle radiator cooling systems.

The Bi-metallic Thermostat:

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Thermistor
The Thermistor is another type of temperature sensor, whose name is a combination of the words
THERM-ally sensitive res-ISTOR. A thermistor is a type of resistor which changes its physical
resistance with changes in temperature.

Thermistors are generally made from ceramic materials such as oxides of nickel, manganese or
cobalt coated in glass which makes them easily damaged. Their main advantage over snap-action
types is their speed of response to any changes in temperature, accuracy and repeatability. Most
types of thermistor's have a Negative Temperature Coefficient of resistance or (NTC), that is their
resistance value goes DOWN with an increase in the temperature but some with a Positive.

Resistive Temperature Detectors (RTD)

Another type of electrical resistance temperature sensor is the Resistance Temperature Detector or
RTD. RTD's are precision temperature sensors made from high-purity conducting metals such as
platinum, copper or nickel wound into a coil and whose electrical resistance changes as a function of
temperature, similar to that of the thermistor. Also available are thin-film RTD‘s. These devices have
a thin film of platinum paste is deposited onto a white ceramic substrate.

Thermocouple
The Thermocouple is by far the most commonly used type of all the temperature sensing devices
due to its simplicity ease of use and their speed of response to changes in temperature, due mainly
to their small size. Thermocouples also have the widest Thermocouples are thermoelectric sensors
that basically consists of two junctions of dissimilar metals, such as copper and constantan that are
welded or crimped together. One junction is kept at a constant temperature called the reference
(Cold) junction while the other the measuring (Hot) junction. When the two junctions are at
different temperatures, a voltage is developed across the junction, which is used to measure the
temperature sensor as shown below.

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Thermocouples can be made from a variety of different materials enabling extreme temperatures of
between -200°C to over +2000°C to be measured.

The output voltage from a thermocouple is very small, only a few millivolts (mV) for a 10 °C change
in temperature difference and because of this small voltage output some form of amplification is
generally required.
In order to prevent measurement errors due to fluctuation of the cold junction temperature,
measurement systems are provided with the so-called «cold junction compensation» function of
electronic type.

Position sensors
The Potentiometer
The most commonly used of all the "Rotational Position Sensors", is the potentiometer because it is
an inexpensive and easy to use position sensor. It has a wiper contact linked to a mechanical shaft
that can be either angular (rotational) or linear (slider type) in its movement, and which causes the
resistance value between the wiper/slider and the two end connections to change giving an
electrical signal output that has a proportional relationship between the actual wiper position on the
resistive track and its resistance value. In other words, resistance is proportional to position.

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Inductive Proximity Sensors
Another type of inductive sensor in common use is the Inductive Proximity Sensor also called an
Eddy current sensor. While they do not actually measure displacement or angular rotation they are
mainly used to detect the presence of an object in front of them or within a close proximity, hence
the name proximity sensors. Proximity sensors, are non-contact devices that use a magnetic field for
detection with the simplest magnetic sensor being the reed switch. In an inductive sensor, a coil is
wound around an iron core within an electromagnetic field to form an inductive loop.
When a ferromagnetic material is placed within the eddy current field generated around the
inductive sensor, such as a ferromagnetic metal plate or metal screw, the inductance of the coil
changes significantly. The proximity sensors detection circuit detects this change producing an
output voltage. Therefore, inductive proximity sensors operate under the electrical principle of
Faraday's Law of inductance.

Rotary Encoders
Rotary Encoders are non-contact optical devices used for converting the angular position of a
rotating shaft into an analogue or digital data code. All optical encoders work on the same basic
principle. Light from an LED or infra-red light source is passed through a rotating high-resolution
encoded disk that contains the required code patterns, either binary, grey code or BCD. Photo
detectors scan the disk as it rotates and an electronic circuit processes the information into a digital
form as a stream of binary output pulses.

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There are two types of encoder:
• Incremental Encoder
• Absolute Position Encoder

Actuators

The Linear Solenoid

A type of electromagnetic actuator that converts an electrical signal into a magnetic field is called a
Solenoid. The linear solenoid works on the same basic principal as the electromechanical relay. A
Linear Solenoid is an electromagnetic device that converts electrical energy into a mechanical
pushing or pulling force or motion.
Solenoids basically consist of an electrical coil wound around a cylindrical tube with a ferro-magnetic
actuator or "plunger" that is free to move or slide "lN" and "OUT" of the coils body. Solenoids are
available in a variety of formats with the more common types being the linear solenoid also known
as the linear electromechanical actuator (LEMA).

They are available as either a holding (continuously energised) or as a latching type (ON-OFF pulse)
with the latching types being used in either energised or power-off applications. Linear solenoids can

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also be designed for proportional motion control were the plunger position is proportional to the
power input.

Electrical Relays
The most common types of actuators or output devices are Electrical Relays. The term Relay
generally refers to a device that provides an electrical connection between two or more points in
response to the application of a control signal. The most common and widely used type of electrical
relay is the electromechanical relay or EMR.

Automation Module will be reinforced during ERM-EP Onsite course, where instructors will introduce
GUNT rig, as by the picture below:

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