Singapore Maritime Academy
Superintendent’s Course
Prepared by
DAVID TAY
Superintendent’s Course
Shipboard Control Systems
e to this o n on
o m ati
Welc ess Autom
n on Proc ips!
le s s o rd s h
e- b oa
We will cover 3 topics as
follows:
1. Introduction to Automatic
Control
2. Pneumatic Controller
3. Shipboard Control
Systems
Part 1
INTRODUCTION
to
Automatic Control
Classification of Automatic Control
Closed Loop Control Open Loop Control
• Automatic • Automatic (no feedback)
• Control action based on feedback signal • Control action based on timing
• Accuracy depends on tuning & modes of & sequence
control. • Accuracy depends on
• Modes: on-off, P, PI, PD or PID calibration & age.
• Applications: Process control systems. • Applications: Purifier
• 4 basic elements- Process, Transmitter, desludging, E.G.E soot blowing.
Controller & Final control element.
• Other application: Kinetic control
systems
iv id e d into 2
c C o n trol is d O P and
m a ti LO
Auto
L O S ED & OPEN lated as
C tabu
types - s ti cs a re
erlined
ch ar a cteri r e u n d
the
e k e y f ocus a
Th
shown. and in R
ED
Basic block diagram of a
closed loop control system
The basic closed
control loop
comprises 4 basic
blocks as shown
On-Off Control is one in which the output
signal changes from one fixed value to
another when preset values are reached.
Usually, this signal is either 0% or 100%.
It is also known as Two Step
Control
This is the first automatic
control mode. Because signal
is either ON or OFF –
comprising 2 steps
Here is an example of When heater is turned ON, liquid around the
the simple ON-OFF heater heats up. Heat then spread out to the
control other parts via convection after some time. The
thermometer sense the temperature rise.
This temperature rise
is transmitted to the
ON-OFF controller. As
water temperature
reaches the set
temperature or set
point, the controller
turns the heater OFF.
Heater starts to cool
down but will still emit
heat. It will take some
time for the heater to
really cool down.
Dead-zone or
Overlap or Water temperature continues
to rise then tapers off.
Deadband
After that the temperature
Overshoot begins to fall.
At the set temperature 55
deg C, the controller turns
heater ON again.
Undershoot Again the heater takes time
to heat up, water
temperature drops further
before starting to rise
towards set temperature 60
deg C again.
Hence, you see the overshoot
Heater at higher set temp. 60 deg C
and undershoot at lower set
temp 55 deg C in the graph.
This phenomenon gives rise to an overlap zone of 5 degrees where the controller is
not effecting any controller.
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Advantages Disadvantages
• Simple and cheap • Oscillatory
• Easy to adjust behaviour
• High wear and
tear
• High maintenance
Thus lifespan of on-off equipment tend to be short
• Inaccurate
How to prolong the lifespan of on-off equipment?
By selecting the highest possible overlap to
reduce frequency of oscillation to
minimum.
Q: When is on/off control recommended?
A: It is recommended when:
• the process variable need not be kept
within
close limits and
• oscillatory response is acceptable.
Q: What if oscillatory response is
not
A: Useacceptable?
continuous modes of control
There are 3 continuous modes
Proportional, Integral and Derivative Actions
Proportional action is that
mode of control in which the
change in output signal (Vp) is
directly proportional to
deviation, .
i.e. Vp
We will explain this action with a simple
arrangement of tank and float-operated
lever controlled valve in the next slide
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Assume initial conditions:
1.Valve is 50% open
2.Supply = demand
3.MV = SP = 50%,
ie Error = 0
4. Normal load condition
How does MV versus time
graph looks like?
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Under normal load
condition, there is
no deviation.
How does the deviation
occur? We explain next.
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lever
2. Water level falls,
lever follows
4. Water level
reaches new
equilibrium
3. Valve opens more
to supply water 5. Offset
to tank float
results
1.
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How can offset be reduced in P-
only control?
Offset is steady-
state deviation (or
error)
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How can offset be reduced in P-
only control?
By increasing controller gain or sensitivity:
1. Increase proportional gain, Kp or
2. Reduce proportional band, PB (%).
change in
PB X
input
= 100%
change in
output
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Offset is reduced
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To reduce offset,
which way to move
the fulcrum?
? ?
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PB>10 PB=1 PB<10
0 00 0
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Is there any precautions when
increasing gain?
Yes! Increase gain with care
because excessive gain can
lead to instability of control
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What is the output
equation for a P-only
controller?
V Vo Vp
V Vo Kp
V controller output (Valve opening )
Vo normal load output
Vp proportion al output
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Deviation (or error) is the
difference between the set point
value (SP) and the measured
value (PV).
PV SP....(DA)
SP PV .....(RA)
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100% PB: An input change of
100% causes the controller
What
What is change
output is
to 100% byPB?
Proportional
100 %.
Band ?
100%
Fulcrum
100%
What then is 50% PB?
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50% PB: An input change of
50% causes the controller
output to change by 100 %.
100%
Fulcrum
50%
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Δoutput 100%
ΔInput 50%
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input output
PB x100% Kp
output input
So what is their relationship?
PB(%) Gain(
K) 1
100 100
kp 50 2
PB 25 4
10 1
0
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o ntrol
on d c Action
h e sec egral
T
e is Int
mod
Integral (or Reset) Control is one in
which the controller output (Vi)
changes at a rate directly proportional
to deviation ie
dVi
dVi dt dVi dt
dt
Vi dt
We go back to the same
water tank system, now
adding I-action
Assume initial conditions:
1.Valve is 50% open
2.Supply = demand
3.MV = SP = 50%,
ie Error = 0
4. Normal load condition
V Vo K p K i dt
Assume the same initial
conditions:
1. Valve is 50% open
2. Supply = demand
3. MV = SP = 50%,
ie Error = 0
4. Normal load condition
V Vo K p K i dt
Advance the slide to see
animation of the operation
Assume initial conditions:
1.Valve is 50% open
2.Supply = demand
3.MV = SP = 50%,
ie Error = 0
4. Normal load condition
V Vo K p K i dt
3 lever follows,
valve opens
2 level falls,
float follows
3 P-action
opens control
valve
V Vo K p K i dt
3 lever follows,
valve opens
4 fluid flow
3 P-action to push
opens control piston up
valve
5 I-action opens
spool valve a
bit more
V Vo K p K i dt
8*
7 water level
return to SP
6#
6.# Control valves reaches a larger opening - a new equilibrium position.
8.* Lever return original position and spool valve closes
How to adjust I-action in a PI controller?
-By I.A.T knob or
-By Ki knob
V Vo K p K i dt 1
K i
I . A.T
1
V Vo K p
I . A.T dt
What is I.A.T (integral action time)?
It is the time in sec/min taken by I-action of a PI
controller to repeat the proportional output in
response to constant deviation.
Relationship between Ki and
I.A.T.
1
Ki (R / M )
I . A.T
Ki (R/M) I.A.T(M/R) I.A.T(S/R)
0.1 10 600
0.5
1
2
10
Relationship between Ki and
I.A.T.
1 1
Ki (R / M )
I . A.T I . A.T ( M / R )
Ki (R/M) I.A.T(M/R) I.A.T(S/R)
0.1 10 600
0.5 2 120
1 1 60
2 0.5 30
10 0.1 6
rd
th e3
e is o d e
M od rol M
ve on t
ti
iva ous C
e r
D tinu
con
is usually incorporated with
Proportional mode to reduce
overshoot and undershoot of the
controlled variable when the
system is subjected to large and
sudden load changes.
Derivative action is a mode of
control in which the output is
proportional to the rate of change
of deviation, i.e.
d
Vd
dt
For a PD controller:
d
V Vo K p D. A.T .
dt
We will use the same simple tank
and valve system to explain except
now we use a dashpot
arrangement
Advance the slide to see the animation
How can D-action be adjusted?
Q: How is D-action adjusted in a PD controller?
A: By D.A.T knob
d
V Vo K p ( D. A.T . )
dt
What is D.A.T (Derivative action time)?
It is the time in sec/min taken by P-action of a PD
controller to repeat the derivative output in response to
constant rate of change of deviation.
PID control In PID
de m a Contr
n d ol, wh
takes ch a en
place st nges, D ac
action 1 , fo tion
and t llo w
hen I ed by P
action
.
Process Characteristics
• Distance-Velocity or Transportation
lags or Dead Time
• Transfer Lags (first- & second-order)
When working with automatic process
control, one needs to know that there exists
some characteristics that will affects the
effects of control action on the systems and
these are as mentioned here.
Distance-Velocity lags = distance/speed
Proportional
& Integral Temperature
Temperature
PI TT Transmitter
Controller
Thus, the effect of control action is not
immediate but will take some time to
reach a steady state.
Let’s first examine the
Pneumatic Controllers
Part 2
Pneumatic
Controllers
Displacement Detector
Elementary Flapper Nozzle Mechanism
As you left click to advance the slides, the animation
shows the action of the flapper- nozzle mechanism
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Displacement Detector
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Displacement Detector
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Displacement Detector
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Displacement Detector
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Displacement Detector
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Elementary Flapper Nozzle Mechanism
is too sensitive for practical use.
a p p er
t h e fl in a
n t of sults hus
ve me zzle re sure t
The gap here is very small a ll mo the no e pres
Sm ards in th sitive
tow change oo sen
re at it is t
g
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Flapper Nozzle
3-15 psi
0.0125 mm
04/21/2025 ALARM CIRCUITS 63
Negative feedback bellows So we
add a
reduce sensitivity of flapper count be
er the llows to
Nozzle amplifier hence
ne g
effect
feedb ative
ack
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As le
ft
you a click on
dvan mo u
the a ce se
nima the slide
the a tion sh s,
ction ows
feed
back of the
bello
ws
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Let us now examine what a DA pneumatic proportional
controller is
Explain the operation of a Direct-acting
Pneumatic Proportional Controller
Assumptions:
• Normal load condition
• A.T.C control valve is 50% open
• PV = SP
• Kp = 1 (or PB =100%)
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PNEUMATIC D.A. PROPORTIONAL CONTROLLER
Direct Acting - DA
Air To Close
Valve
Measured input signal Set point
When PV > SP, the flapper moves TOWARDS the nozzle , reducing the
gap, block air leak, thus air signal pressure is increased causing the
ATC valve to CLOSE to reduce the process fluid flow
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PNEUMATIC D.A. PROPORTIONAL CONTROLLER
V Vo Vp
V Vo Kp
V Vo Kp ( PV SP )....DA
V controller output (Valve opening )
Vo normal load output
Vp proportion al output
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PNEUMATIC R.A. PROPORTIONAL CONTROLLER
Reverse Acting - RA
Air To Open
Valve
Set point Measured input signal
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PNEUMATIC R.A. PROPORTIONAL CONTROLLER
When PV > SP, the flapper moves AWAY from the nozzle ,
increasing the gap, air leaks, thus air signal pressure is reduced
allowing the ATO valve to close to reduce process fluid flow
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PNEUMATIC R.A. PROPORTIONAL CONTROLLER
V Vo Vp
V Vo Kp
V Vo Kp ( SP PV )....RA
V controller output (Valve opening )
Vo normal load output
Vp proportion al output
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Which valve is Air-to-Open?
A.T.C
A.T.O.
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m e nts,
ati c instru sually
um re u
In pne tic relays a owing
a foll
pneum ed for the
includ reason.
Pneumatic relay is used
to reduce transfer lag
and so speed up the
response of control
valve.
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Pneumatic D.A. P+I controller
Left click on the mouse to see how the DA PI and PD
Pneumatic Controller works
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Pneumatic D.A. P+I controller
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Pneumatic D.A. P+I controller
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Pneumatic D.A. P+I controller
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Pneumatic D.A. P+I controller
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Pneumatic D.A. P+I controller
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Pneumatic D.A. P+I controller
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Pneumatic PD controller
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Pneumatic PD controller
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Pneumatic PD controller
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Pneumatic PD controller
P-action
D-action
Constant rate of
change of deviation
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I.A.T Knob
D.A.T Knob
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D.A.T Knob
This wi
ll
looking be the final p
into Pro art
System cess Co –
s on b o ntr
ard shi ol
ps.
Part 3
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We will examine some common systems on board while
differentiating the single and the two element systems
Shipboard ME Control
Systems
• Single Element Control Systems
• M/E Fuel Oil Viscosity control
• M/E LO inlet temp control
• M/E Jkt CW outlet temp control
• Two Element Control System
• M/E Jkt CW outlet temp control
• M/E Piston cooling oil outlet temp
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What is a ‘single element’ control system?
• A Single element Control System is
one in which closed loop control
action is based on feedback signal
derived from a single transmitter.
What is a ‘Two element’ control system?
• A two element Control System is
one in which closed loop control
action is based on feedback signals
derived from two transmitters.
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Explain operation
Assumptions: M/E on normal load, PV
=SP, CV = 50%
DA
c e s s V a riable
PV = Pro re d va lue of)
(meas u
(d e s i re d value)
Point
SP = Set Acting
D i re c t
DA = g
= R e ve rse Actin
RA e
E = M a i n En g i n
M
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If M/E load increase → F.O. flow through
heater increases → fuel temp drops →
Viscosity increases
→ PV increases → D/A controller output
increases
→ ATO CV opens more → Steam flow
increases
→ temp increases →Viscosity decreases
→ PV decreases toward SP within about 2.5
cycles due to I-action, as shown below.
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Response of PI Fuel Oil viscosity
control system
Fuel Oil Viscosity
Load
incr
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Single Element
M/E LO inlet Temperature Control Loop
RA
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Assumptions: M/E on normal load,
PV = SP, CV = 50% open
If M/E load increase
RA
a ir to
T C CV = trol
A con
clos e
valve
TT = temp.
transmitter
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If M/E load increase → engine L.O. temp
increase → engine inlet L.O. temp.
increase
→ TT (Temp. Transmitter) senses the
increase → PV increase → R/A controller
output decrease → ATC CV opens more
to cooler
→ L.O. flow to cooler increase → engine
inlet L.O. temp decrease →TT senses
temp decrease → PV decreases toward
SP within about 2.5 cycles due to I-
action, as shown below.
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Response of P+I M/E LO inlet
temperature
control system
M/E LO inlet temperature
Load
incr
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Single Element Jacket outlet Temperature
control system
RA
A.T.
C
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Assumptions: M/E on normal load, PV=SP, CV
50%
M/E load
increases,
RA
A.T.
C
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If M/E load increase → engine JCW
outlet temp increase → TT (Temp.
Transmitter) senses the increase → PV
increase → R/A controller output
decrease → ATC CV opens more to
cooler → JCW flow to cooler increase
→ reduce JCW inlet temp to engine
→ engine JCW outlet temp decrease
→ TT senses temp decrease → PV
decreases toward SP within about 2.5
cycles due to I-action, as shown below.
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Response of P+I M/E JKT CW outlet
temperature control system
JKT CW outlet
temperature
Load
incr
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Thank
You
Please confirm your attendance by completing
the online quiz and assignment.
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