APSTIPRINĀTS
Novikontas Jūras koledžas Padomes sēdē
ar 14.07.2015. prot. Nr. 3-1-1/2015/14
NOVIKONTAS MARITIME COLLEGE
Subject name: Ships Electronics and Automation 6 sem
Exercise number: 5. Manipulator elements
Teacher: Deniss Krasovskis
Student: Sergejs Boiko
Date: 23.01.2021
Ship Particulars.
1. Observe on board pneumatic system (you may choose any of the
ships systems and define it with ships specific):
1.1. List the advantages of the system?
1.2. Sketch the diagram of the main system components?
1.3. How can the controlling system be operated?
1.4. What does the turn down ratio mean?
What kind of advantages have these type of system?
Advantages
1. Not affected by ship’s power supply variations for short term.
2. No heat generated and hence no risk of fire.
3. Actuators are cheaper and accurate than electric systems.
4. Simple control air piping system.
Disadvantages
1. Require air compressor and associated systems.
2. A clean, dry and oil free supply of good quality air is essential for satisfactory operation of
the system.
3. Good quality air require driers, filters with drains, etc. which increases maintenance.
4. May have transmission lags in large systems.
Sketch the diagram of the main system components?
How the controlling system can be operated?
The opening or closing of automatic control valves is usually done by electrical, hydraulic or
pneumatic actuators. Normally with a modulating valve, which can be set to any position between fully
open and fully closed, valve positioners are used to ensure the valve attains the desired degree of opening.
For continuously modulated control, a feedback controller is used to automatically control a process
or operation. The control system compares the value or status of the process variable (PV) being
controlled with the desired value or set point (SP), and applies the difference as a control signal to bring
the process variable output of the plant to the same value as the set point.
What is means turn down ratio?
Turndown ratio refers to the width of the operational range of a device, and is defined as the ratio
of the maximum capacity to minimum capacity. For example, a device with a maximum output of 10 units
and a minimum output of 2 units has a turndown ratio of 5. The term is commonly used with measurement
devices and combustion plant like boilers.
2. Study the controlling devices of the main working parts of the
pneumatic system (please use your ships data and manufacturer manuals):
2.1. What is a positioner in the system?
2.2. Describe the features of a positioner?
2.3. List the manufacturer’s recommendations for troubleshooting?
What it is positioner in the system?
The Pneumatic Valve Positioner is an instrument working on force balance principle to position the
Control Valve stem in accordance to a pneumatic signal received from a controller or manual loading
station, regardless of packing box friction, actuator hysteresis or unbalanced forces on the valve plug.
Thus, the positioner ensures a reliable and accurate operation of Control Valve.
Describe the features of the positioner?
The Valve Positioner is force balance device which, ensure the position of the plug, which is
directly proportional to the controller output pressure. The Positioner compares the forces generated by the
control signal and the control valve stem through the motion connector and the feed back cam, and
accordingly it feeds or bleeds the air going to the valve actuator.
The manufacturer recommendations for resolving troubleshooting?
Troubleshooting
Positioner does not respond to the input signal.
• Check supply pressure level. The level must be at least 1.4 kgf/cm2
• Check if input signal is properly supplied to the positioned.
• The signal should be 3-15 psi.
• Check if the positioner’s nozzle has been blocked. Also, check if the pressure is
• supplied to the positioned and the pressure is being exhausted through the nozzle.
• If the nozzle has been blocked by any substances, please send the unit to YTC for
repair.
• Check if feedback lever has been installed properly.
The pressure of OUT1 reaches exhausting pressure level and does not come back down.
• Check A / M switch. If the switch has been damaged, replace the switch or pilot relay
valve.
• Check for a gap or damages between the nozzle and the flapper.
• If damaged, please send the unit to YTC for repair.
• The pressure is exhausted only by A / M switch.
• Check if the positioner’s nozzle has been blocked. Also, check if the pressure is
supplied to the posiioner and the pressure is being exhausted trough the nozzle. If the
nozzle has been blocked by any substances, please send the unit to YTC for repair.
Hunting occurs.
• Check if safety spring has been displaced. <Next to pilot relay valve>
• Check if the size of actuator is too small. If so, insert an orifice in order to reduce the
pressure flow rate.
• Check if there is any friction between the valve and the actuator. If so, increase
actuator’s size or reduce the friction level.
Actuator only operates by on / off.
• Check pipe connection
• Check cam direction
Linearity is too low.
• Check if the feedback lever is properly installed. Especially check if the feedback
lever is parallel to the around at 50% point.
• Check if zero and span has been properly adjusted, that is not too low or not too high.
• Check if supply air pressure level is stable from the regulator. If the level is unstable,
replace the regulator.
Hysteresis is too low.
• In case of double acting actuator, check if seat adjustment has been properly done.
• Please contact YTC for any further inquiries regarding the seat adjustment.
• Backlash can occur when feedback lever and lever spring is loosen. To avoid
backlash, adjust the lever spring.
• Check if the connection bar to the feedback lever is tightly fastened.
3. Describe the circumstances when piston actuators, butterfly valve
might be used (study any systems on board your vessel and prepare a
photo report)?
On board our vessel such type of valves “ Butterfly valve with actuator “ are used only in ballast
system, but might be met on modern ships also in cooling systems, sea water systems, cargo systems and
etc.
4. Temperature range:
4.1. What is a normal temperature range in the pneumatic control system and what
temperature range in the pneumatic control system do you have on board your vessels?
4.2. What kind of electronic temperature control elements are used in the pneumatic system?
In my understanding, the manufacturer must specify the restrictions and requirements of operating
liquid and temperature in such systems. I think that approximately from the temperature of freezing water
and the boiling point. ( from 3-5 to 85-90 degrees ).
Talking about temperature of compressed air – it must be between 20-60 degrees. Therefore cooler
is used to reduce the temperature of the compressed air. The water vapour or moisture in the air is
separated from the air by using a separator or air dryer.
The air treatment can be divided into three stages. In the first stage, the large sized particles are
prevented from entering the air compressor by an intake filter. The air leaving the compressor may be
humid and may be at high temperature. The compressed air from the compressor is treated in the second
stage. In this stage temperature of the compressed air is lowered using a cooler and the air is dried using a
dryer.
What kind of electronic temperature control elements are used in the pneumatic system?
A temperature controller - often called a PID controller is an instrument used to control temperature.
The temperature controller takes an input from a temperature sensor and has an output that is connected to
a control element such as a heater. To accurately control process temperature without extensive operator
involvement, a temperature control system relies upon a controller, which accepts a temperature sensor
such as a thermocouple or RTD as input. It compares the actual temperature to the desired control
temperature, or setpoint, and provides an output to a control element.
5. Servomotors in a ship’s systems.
5.1. How is a servomotor used in the ship’s systems?
5.2. Describe a dc servomotor and explain how it varies from the common motor?
5.3. When servomotor is used in ac machine, what kind of problems can occur using three
phase connection?
How is used servomotor in the ships systems?
Servomotors on board the ship are used in stabilizing systems, steering gear systems, CPP, hydraulic
systems, anywhere where Motion Control feedback and accuracy is important.
Describe a dc servomotor and explain how it varies from the common motor?
Generally, the servo motor is an association of four things, namely a DC motor, a control circuit, a
gearing set, and also a potentiometer usually a position sensor.
The servo motor position can be controlled more precisely than those of typical DC motors, and
generally, they have three wires like power, GND, and control. Power to these motors continually
applied, with the servo motor control circuit changing the draw to drive the servo motor. These motors are
designed for more exact tasks where a motor position needs to be clear precisely like moving a robotic
arm or controlling the rudder on a boat or robot leg within a particular range.
These motors do not alternate easily like a standard DC motor. In its place, the rotation angle is
partial to 1800. Servo motors obtain a control signal that signifies an o/p position and applies power to the
DC motor until the shaft goes to the precise position, decided by the position sensor.
PWM (pulse width modulation) is used to control the signal of a servo motor. But, unlike DC
motors it’s the period of the positive pulse that controls the position, somewhat than speed, of the servo
shaft. The value of the neutral pulse depends on the servo keeps the shaft of the servo motor in the middle
position. Increasing the value of the pulse will make the servo motor turn clockwise, and a shorter pulse
will switch the shaft anticlockwise.
The servo control pulse is typically recurrent every 20 ms, fundamentally telling the servo motor
where to go, even if that means remaining in the similar position. When a servo is commanded to move, it
will move to the position and hold that position, even if the external force pushes against it. The servo
motor will fight from moving out of that position, with the max amount of resistive force the servo motor
can use being the torque rating of that servo.
When servomotor is used in ac machine, what kind of problems can occur using three phase
connection?
AC servo motors are basically two-phase squirrel cage induction motors and are used for low power
applications. Nowadays, three phase squirrel cage induction motors have been modified such that they can
be used in high power servo systems.
The main difference between a standard split-phase induction motor and AC motor is that the
squirrel cage rotor of a servo motor has made with thinner conducting bars, so that the motor resistance is
higher.
6. When keeping a watch please find the two phase servomotor on
board your ship:
6.1. Make a picture and develop a report - explaining how such features can vary?
6.2. Provide examples of the applicate equipment.
The stator of the Two Phase AC Servo Motor has the two distributed windings which are displaced
from each other by 90 degrees electrical. One winding is known as a Reference or Fixed Phase, which is
supplied from a constant voltage source. The other one is known as Control Phase, and it is provided with
a variable voltage
The connection diagram of the two Phase AC Servo motor is shown below.
The control phase is usually supplied from a servo amplifier. The speed and torque of the rotor are
controlled by the phase difference between the control voltage and the reference phase voltage. By
reversing the phase difference from leading to lagging or vice versa, the direction of the rotation of the
rotor can be reversed.
The rotor of the Drag cup servo motor is made of a thin cup of the nonmagnetic conducting
material. A stationary iron core is placed in the middle of the conducting cup. This arrangement completes
the magnetic circuit. As the rotor of the motor is made of thin material, its resistance will be high, which
results in the high starting torque.
7. Find a hydraulic servomotor on the existing working systems and
briefly explain the main arrangements.
How servo hydraulic amplifiers work
There are three main components of the linear
amplifier: the pilot motor (normally a stepper motor
however could be a DC motor or AC servo motor); the
NC-valve; and the hydraulic cylinder.
A flexible coupling is fitted between the pilot motor
shaft and the control shaft exiting the NC-valve. At
the other end of the control shaft is a
thread which enables the
movement of the control shaft
into/out of the NC Valve. On the
control shaft is fitted a spool which is kept in location
by a spring inside the spool and around the control
shaft. This spring positively locates the spool against a
thrust washer at the threaded end of the control shaft.
The rotation of the pilot motor is converted into a linear movement of the spool within the NC-
valve using the control thread on the control shaft. As the spool moves either the 'tank' or the 'pressure'
ports are opened up. The flow of hydraulic medium is controlled into/out of both the piston area and
piston ring area.
The closed-loop within the linear amplifier is achieved mechanically via a feedback spindle located
within the piston. Located at the NC-valve end of the feedback spindle is a bush. The feedback spindle
(which has an opposite thread to the control shaft thread rotates in the same direction to the pilot motor
input due to the resulting movement of the piston. This rotation moves the spool to it's neutral position.
When in the neutral position the piston will once again be stationary.
Diagram A) shows the linear amplifier in it's stationary state i.e. the 'pressure' and 'tank' ports are
closed. The piston is stationary.
Diagram B) shows the pilot motor rotating a small distance anticlockwise. This causes the control
shaft and spool to move in the direction of the motor, causing the flexible coupling to compress. This
movement opens up the piston area to the 'Pressure' and the piston ring area opens up to 'Tank'. The piston
the extends out of the cylinder. As piston extends the resulting rotation of the feedback spindle (also
anticlockwise) results in the spool being moved back to it's neutral position and the piston stops moving.
Diagram C) shows the pilot motor rotating a small distance clockwise. This causes the control shaft
and spool to move in the direction of the cylinder, causing the flexible coupling to expand. This movement
opens up the piston ring area to the 'Pressure' and the piston area opens up to 'Tank'. The piston the retracts
into the cylinder. As piston retracts the resulting rotation of the feedback spindle (also clockwise) results
in the spool being moved back to it's neutral position and the piston once again is stationary.
8. Describe the main principles of a swash plate pump.
A swashplate consists of a disk attached to a shaft. If the disk were aligned perpendicular to the
shaft, then rotating the shaft would merely turn the disk with no reciprocating (or swashplate) effect. But
instead the disk is mounted at an oblique angle, which causes its edge to appear to describe a path that
oscillates along the shaft's length as observed from a non-rotating point of view away from the shaft. The
greater the disk's angle to the shaft, the more pronounced is this apparent linear motion. The apparent
linear motion can be turned into an actual linear motion by means of a follower that does not turn with the
swashplate but presses against one of the disk's two surfaces near its circumference. The device has many
similarities to the cam.
9. List advantages and disadvantages of a high pressure hydraulic
system.
Higher pressures mean higher force and torque is available from smaller components. And because
these components are smaller in displacement, higher speeds are possible from smaller flows. Smaller
flows mean pipework, valving and even the tank can be made smaller.
So the power density of individual components and the system as a whole increases with
pressure. But there are a number of disadvantages with higher operating pressures:
The inherent heat dissipation of the system is lower because the surface area of the tank (it's
smaller in volume), pipework and components are less. In other words, a bigger heat
exchanger is required for a high-pressure system of the equivalent power and efficiency.
Greater variation in fluid volume (compression) at higher pressures means reduced stiffness
of the system and less favorable dynamic response.
Higher noise levels as a result of higher peak pressures and greater energy transmission for a
given mass.
The potential for greater friction and wear, resulting from heavier loads on bearings and
sliding surfaces, and more severe damage resulting from aeration, cavitation and micro-
dieseling due to higher compression ratios.
In the majority of applications though, the advantages presented by higher operating pressures
outweigh the disadvantages. Which is why for several decades now, we've seen the average operating
pressures of hydraulic equipment increase. But clearly, it comes with some design problems.
Here's a few that spring to mind:
Heavier hose construction, i.e., less flexible lines, longer bend radii and possibly, special
fittings and assembly methods.
Heavier valve bodies, actuators, pumps, pipes -- or the use of more exotic, and expensive,
materials in their construction.
More advanced seal materials, new groove designs and closer tolerances will be required to
ensure sealing integrity doesn't suffer.
Greater attention to reservoir configuration, conductor selection and component locations to
accommodate components resonating with more energy and emitting higher sound pressure levels.
10. Please explore and describe the hydraulic ram servomotor.
Ram type Steering gear
Ram type steering gear is one of the commonly used steering gear construction and is quite
expensive in construction. The basic principle is same as that of a hydraulically-driven motor engine or
lift.
There are four hydraulic cylinders attached to the two arms of the actuator disc, on both sides. These
cylinders are directly coupled to electrically driven hydraulic pumps which generate hydraulic pressure
through pipes. This hydraulic pressure field present in the pumps imparts motion to the hydraulic
cylinders, which in turn corresponds with the actuator to act upon the rudder stock. As we know, rudder
stock is an indispensable part of the entire steering gear arrangement of ships and dictates the exact
behaviour of the rudder response.
The sense of turning the rudder is guided by the action of the hydraulic pump. The physics behind
its function can be explained better with the help of the following figure.
Ram type steering Gear
Here the cylinders denoted A and C are connected to the discharge side of the pump. This
generates a positive pressure in the piston cylinders. On the contrary, the other two cylinders B and D are
connected to the suction side of the pump. This creates a negative pressure in the cylinders. The resultant
forces create a clockwise moment in the rudder. To put it simply, positive and negative pressures from
pumps generate lateral forces on the rams which create a couple for turning the rudder stock.
Similarly, to put it in a anticlockwise turning sense, the reverse is carried out, viz. the discharge ends
of the pumps are connected to the cylinders B and D, while the suction side of the pumps are to A and C.
This reverse pressure flow from hydraulic pumps is achieved with the help of control valves operated
from the wheelhouse.
The ram type steering gear arrangement produces a considerably high value of torque for a given
applied power. The hydraulic oil pressure varies from 100 bars to 175 bars depending on the size of the
rudder and torque required.
