Marine Instrumentation & Control

Ver 1.1

Prepared by: Prof. Gopalakrishna

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 CONTENTS

1. Automatic Control Theory--------------------------------------------- 3

2. Automatic Controllers--------------------------------------------------- 12
3. Signal transmitting devices & correcting units---------------------14
4. Measuring Instruments & Transducers------------------------------17
5. Control Applications------------------------------------------------------21
6. UMS Operation of Ships-------------------------------------------------23

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 1. Automatic Control Theory
Process Control:

Process Control is an arrangement of devices to closely control a process parameter in the

presence of external disturbances.

Actuator:

Actuator is a device which converts energy into motion. For example, motor.

Feedback Control:

A system in which the value of an output quantity is controlled by feeding back the
value of the controlled quantity and using it to manipulate an input quantity.

Feedforward Control:

A control method in which the correcting signal is applied before the output of a
process.

Open Loop vs. Closed Loop control System:

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 Open Loop system
 Simpler
 Less expensive
 Less accurate
 Performance degradation with aging of components
Closed Loop system
 More complex
 More expensive
 More accurate
 Not much degradation of performance with aging of components

On-Off ( Two Step) Control system:

 Also called 2 step control

 Simplest closed loop control
 On-Off band decides accuracy
o Small band -> accuracy improves, but oscillations increase
o Large band -> accuracy reduces, oscillations reduce
 Hysteresis can be added to improve performance

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Hysterisis:

Hysteresis of an instrument is the maximum difference between readings taken when

moving up scale, to those taken when moving down scale.

Desired Value/Set Value/Set Point:

The input to the control loop is called desired value or set point or set value.

Measured Value:

The output of the control loop is measured and used for control. It is called measured
value.

Proportional Control:

In proportional control, the controller output is proportional to the error signal, which is
the difference between the setpoint and the measured value.

Let Kp = Proportional gain

Let e = error = Set value – measured value

 Proportional Controller Output = Kp * e

 Proportional Control results in Offset (or droop or Steady state error)
 Proportional control output depends upon present value of error
 Proportional Control performance is better than that of on-off control
 Controller tuning is done by adjusting the value of Kp

Offset (Droop or steady state error):

Offset is the sustained difference between desired value (set point) and measured value.
Offset exists in proportional control.

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 Proportional Band:
Proportion Band (PB) is Inverse of Gain of a Proportional controller expressed in
percentage.
PB = (1/Proportional Gain) * 100 %

Integral Control

Let Ki = Integral gain

Let e = error = Set value – measured value

 Integral Controller Output = Ki ʃ e dt

 Also called as “Reset Control”
 Integral Control removes offset but results in oscillations
 Integral Controller output depends upon past values of error
 Integral control is generally used along with Proportional Control ( ie, PI Control),
shown in figure below.
 Integral Controller tuning is done by adjusting the value of Ki

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Derivative (rate) Control:

Let Kd= Derivative gain

Let e = error = Set value – measured value

 Derivative Controller Output = Kd (de/dt)

 Derivative Control removes oscillations but amplifies noise in the system
 Derivative Controller output depends upon future values of error (ie, predictive
control)
 Derivative can not be used alone.
 Derivative control is generally used along with P or PI Control ( ie, PD Control or
PID control).
 Derivative Controller tuning is done by adjusting the value of Kd

Derivative control cannot be used alone.

When error is zero, the controller output which is derivative of error is also zero and hence no
control action. Derivative control amplifies noise in the system.

PID Control:

PID control = (Proportional + Integral + Derivative) Control

Block diagram of a PID control system is shown below.

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 Let e = Error = Set Point – Measured Value
Kp = proportional Gain
Ki = Integral Gain
Kd= derivative Gain
PID Controller Output = Kp * e + Ki ʃ e dt + Kd (de/dt)

 Proportional Control alone results in Offset ( Steady state error)

 Integral control is added to removes Offset.
 Derivative control is added to reduce oscillations.

PID Controller tuning

Tuning means adjustment of values of Kp, Ki and Kd to get required performance.
Tuning Procedure:
 Make Ki and kd zero.
 Start with Small value of Kp and adjust it to get best response
 Start with small value of Ki and adjust to remove offset
 Start with small value of Kd and adjust it to kill oscillations in response.

Split Range Control:

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  Control for output is split and sent to 2 or more actuators
 Splitter defines how each actuator is sequenced for output from o to 100%
 For Example,
 for 0 to 50% , one control valve is used
 for 50 to 100% another control valve is used
 If pressure increases, fluid discharged to flare to adjust pressure
 If pressure decreases, fuel gas introduced to adjust pressure

Cascade Control

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  Used for better performance
 But requires multiple sensors
 Outer Master Control loop and inner Slave Control loop(s)
 Gives faster corrections
 Shields against component degradation
 Tuning starts with inner most loop first and then outer loops one by one.
 Faster inner loop, slower outer loop

Step and ramp inputs:

 These are the standard inputs to a control system.

 These inputs completely characterizes the behavior of control system in time
domain.
 Sine wave input is used in frequency domain analysis.

Transfer Function:

Transfer Function is the ratio of the Laplace Transform of output to the Laplace Transform of
Input, with all initial conditions zero.

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 Transfer Function = H(s) = Y(s) / X(s)

System response

System Response is the output of plant for a given input.

Distance Velocity lag:

Distance Velocity lag is the time delay between a change in process condition at the
actuator and the arrival of this changed condition at the sensor.

Measurement lag & Transfer lag:

 This delay is similar to the behavior of a RC network.

 It is due to sensor arrangement.

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 2. Automatic controllers

1. Pneumatic PID Controller using Nozzle-Flapper

 Uses Nozzle flapper with feedback bellows and Integrator bellows

 Nozzle flapper separation decided Proportional gain
 Integrator bellows valve decides Integral gain
 Feedback bellows valve decides Derivative gain

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2. Relay (Pneumatic Amplifier)

 Used for additional amplification of pressure to operate control valves

 Amplification factor upto 15 can be obtained
 Pressure balance type
 If Diaphragm pressure increases, leakage to air reduced, output pressure high
 If diaphragm pressure reduces, it cuts off supply, no output pressure.

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 3. Signal transmitting devices & correcting units

Flapper Nozzle system

 A transducer or amplifier
 Converts displacement to pressure
 Flapper motion changes air flow
 Small movement results in large change in pressure
 Has a limited linear range of operation as shown below

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Valve positioners

 A valve positioner is a device used along with a control valve to ensure that it is
at a correct position of opening as per the control signal.
 Valve positioner provides an additional feedback for correct operation of control
valve.
 Minimizes the effect of valve friction and hysteresis
 It can provide additional amplification required to operate control valve

Actuators
Control valve has two parts – actuator and valve body

1. Pneumatic Actuators

(a) Diaphragm actuator

 Part of control valve used for providing force to drive valve stem
 Made of flexible synthetic rubber diaphragm
 Diaphragm movement is opposed by a spring
 Movement transmitted to stem of valve

(b) Piston actuator

 Used for high stem force
 Ease of direction reversal
 Fail safe – ‘open’ or ‘close’ or ‘as is’
 Fail safe means ability to fail in a safe state depending on application

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2. Hydraulic Actuators
 Gear pumps
 Screw pumps

3. Electric Actuators
 AC motors
 DC motors
 Solenoids

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 4. Measuring Instruments & Transducers
Transducers for Temperature:
(i) Liquid Gas thermometer
 Mercury or alcohol is used
 Bulb contains liquid, expands in capillary tube

(ii) Liquid in metal Thermometer

 Bulb with liquid under pressure
 Bourden gauge shows readings

(iii) Gas Expansion thermometer

 Uses inert gas
 Gives faster response

(iv) Bimetallic strip thermometer

 2 metals with very low and very high temperature coefficients
 As temperature changes, twisting occurs

(v) Resistance Thermometer

 Conductor resistance increases with temperature
 Platinum or Nickel used
 Wheatstone bridge is used

(vi) Thermistor
 Semiconductors used
 Negative temperature coefficient

(vii) Thermocouple
 Uses Seeback effect
 Small size
 Faster response
 Medium range

(viii) Radiation Pyrometer

 Higher range
 Non-contact type

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Transducers for Pressure
(i) Manometer
 Balance the pressure to be measured against a column of Mercury
 Measures Gauge pressure
(ii) Mercury Barometer
 Uses glass capillary tube sealed at one end
 Filled with mercury
 Gives absolute readings

(iii) Bourden Tube gauge

 Widely used for Gauge pressure measurement
 Uses elastic deflection of metal tube
 Tube displacement convertefd to readings on scale
(iv) Diaphragms & bellows
 Uses elastic property of metals

Transducers for Flow

(i) Orifice

 Differential pressure between 2 ends gives flow rate

 Thin SS metal plate with hole at centre
 Placed between flanges in pipeline

(ii) Venturi

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  Differential pressure between 2 ends gives flow rate
 Conical convergent entry tube
 Cylindrical centre tube
 Divergent conical outlet
 Expensive, but more accurate

(iii) Rotameter

 Height of the float gives flow rate

 Float moves freely in a variable area tube
 Slowly rotates
 External magnetic pickup external

Transducers for Speed

(i) DC tacho generator
 Small precision generator
 Driven by shaft whose rpm is required to be measured
 Output voltage is proportional to rpm

(ii) Mechanical tacho

 Based on action of centrifugal force

Transducers for Torque

(i) Strain gauge torsion meter
 Torque is proportional to strain

(ii) Magnetic stress torsion meter

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Water purity measurements
(i) Salinity (conductivity) measurement
 Salinity is proportional to Conductivity of water
 Conductivity of water is measured between 2 platinum electrodes
(ii) Acidity (alkalinity or pH) measurement
 Uses 2 special electrodes (reference and measurement electrodes)
 pH is proportional to potential difference between 2 electrodes
(iii) Presence of oil measurement
 1st method:
 Uses UV light fluorescence
 Oil fluorescences more than water
 Uses emission from molecule that absorbed light
 For example, Bailey oil content monitor

 2nd method
 Uses scattered light
 Oil molecules scatters light
 IR light is passed through water perpendicular to water flow
 Both straight light and scattered light are measured using
detectors

Oil Mist Detector

 Oil mist in crankcase of an engine due to oil vaporization caused by a hotspot can
be dangerous
 Works on the principle that oil mist density is proportional to optical obscurity.
 Samples are measured in a measuring chamber with light source at end and
photo-cell at other end
 Photo-cell output is a measure of oil mist which is compared to threshold level
from a reference set earlier
 Alarm generated on crossing threshold indicating engine slow down

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 5. Control Applications
1. Boiler Level Control ( using 3 element method)

 Reaction of steam and water in modern boilers give problem in boiler level control
 As load changes, steam flow changes.
 Load changes result in ‘swell effect’ and ‘shrinkage effect’.
 Hence 1 sensor is not adequate, normally 3 sensors are used (ie, 3 elements)
 1: Boiler level sensor, 2: Steam flow sensor, 3: Feed water flow sensor
 Generally a PI controller is used for Boiler level control

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2. Piston (jacket) cooling system
 Outer loop uses sea water(raw water), Inner loop uses fresh water(treated water)
 Hot fresh water from engine jacket is cooled in a cooler(heat exchanger) by incoming
sea water
 Fresh water is recirculated to engine after cooling
 1 sensor is used for measuring temperature of fresh water from engine block
 Controller adjusts recirculation of fresh water
 PI controller is used to remove offset

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 6. UMS operation of Ships

Requirements of Unmanned Machinery Spaces (UMS)

 Bridge Control of propulsion machinery
o For emergency control action
o Simple Control & instrumentation required
 Centralized Control & Instrumentation
o Controls must be easily reached
 Automatic Fire detection system
o Quick response detectors required
 Fire extinguishing system
o Remote control fire station in addition to hand extinguishes
 Alarm system
 Automatic bilge high level fluid alarms and pumping units
 Automatic start emergency generator
 Local hand control of essential machinery
 Adequate settling tank storage capacity
 Regular testing and maintenance of instrumentation

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