Published: New revised edition published February 2022
This publication provides a comprehensive introduction to onboard automation and operational safety. With high technical and educational value, it is suitable for marine engineers, students and all who wish to deepen their knowledge of a subject that is not only a technology but also a culture.
‘Automation is not only technology, but is, above all, a culture and man is at the centre of this process’ – Alex Stefani.
This publication covers essential topics related to ship automation and control systems, including a brief history of automation on board ships; an introduction to automatic process control; automation systems equipment and technology; automation system design and engineering; alarms and monitoring; measuring devices and final control elements; automation systems project, testing and operation; advanced applications of automation systems; and future views of automation and control.
The book is illustrated throughout with circuit diagrams and component/system schematics. It is an essential source of reference for both ship automation students and onboard engineers.
Table of Contents
Foreword
About the Author
Acknowledgements
Chapter 1 A Brief History of Automation On Board Ships
1.1 Introduction
1.2 The Origin of Automation On Board Ships
1.3 Notable Ships of the Future Projects
1.3.1 ‘QE2’ Project
1.3.2 The ‘Esquilino’ Project
1.3.3 German ‘Ship of the Future’
1.3.4 The Japanese ‘Pioneer Ship Programme’
1.3.5 The Norwegian ‘Operating Vessel of the Future’
1.3.6 The Danish ‘Project Ship’
1.4 The Evolution of Automation Technology
1.5 The Effects of Automation on the Crew
1.6 Future Crew System
Chapter 2 Introduction to Automatic Process Control
2.1 Introduction
2.2 A Brief History of Process Control Systems
2.3 The Control Loop
2.4 Process Control Definitions
2.4.1 Other Process Control Terms
2.5 Automatic Control Systems
2.6 Process Control Characteristics
2.7 Control Modes
2.7.1 Discrete Controllers
2.7.2 Continuous Controllers
2.7.3 Proportional Control
2.7.4 Integral (Reset) Control Mode
2.7.5 Derivative Control Mode
2.7.6 Proportional + Integral + Derivative (PID) Control Mode
2.7.7 Summary
2.8 Advanced Feedback Control Loops
2.8.1 Cascade Control
2.8.2 Split Range Control
2.8.3 Ratio Control
2.8.4 Feedforward Control
2.9 Application Examples of Automatic Process Control Systems
2.9.1 Diesel Engine Temperature Control System
2.9.2 Steam Boiler Control Systems (Boiler Drum Level Control)
2.9.3 Burner Combustion Control for Boilers
2.9.4 Steam Temperature Control
2.9.5 Burner Management System (BMS)
2.10 Process Control Glossary
Chapter 3 Automation Systems Equipment and Technology
3.1 Introduction
3.2 Programmable Logic Controllers (PLCs)
3.2.1 Central Processing Unit (CPU)
3.2.2 The Memory System
3.2.3 The Input/Output System
3.2.4 Power Supply Unit
3.2.5 PLC Operation
3.2.6 PLC Selection
3.3 PLC Programming Languages
3.3.1 Ladder Diagram (LD)
3.3.2 Functional Block Diagram (FBD)
3.3.3 Sequential Function Chart (SFC)
3.3.4 Instruction List (IL)
3.3.5 Structured Text (ST)
3.4 Process Automation Controllers
3.5 Operator Workstations
3.5.1 General
3.5.2 Video Display Unit
3.5.3 Operator Workstation Functional Overview
3.6 Open Control Systems
3.7 Information Management Systems
3.8 Communication Networks
3.8.1 Transport Control Protocol/Internet Protocol (TCP/IP)
3.8.2 Network Topologies
3.8.3 Media Access Control
3.8.4 Network Devices
3.8.5 Industrial Ethernet
3.8.6 Communication of Open Systems: ISO/OSI Layer Model
3.9 Reliability, Availability and Redundancy
3.10 Environmental Conditions
3.11 Interference-free Electronics
3.12 Glossary
Chapter 4 Automation System Design and Engineering
4.1 Introduction
4.2 Basic Concepts
4.3 Structure
4.4 Propulsion Remote Control System
4.4.1 Automatic Operation Mode
4.4.2 Advanced RCS Architecture
4.5 Remote Control System for Controllable Pitch Propeller
4.5.1 Pitch Control
4.5.2 RPM Control
4.5.3 Pitch–RPM Command (Combinator or Constant Speed Mode)
4.5.4 Load Control
4.5.5 Load-increasing Program
4.5.6 Load Sharing Program
4.5.7 Pitch Indication and Back-up Control of Pitch/RPM
4.5.8 Pitch Back-up Control
4.5.9 RPM Back-up Control
4.5.10 Manoeuvre Responsibility System
4.6 Bridge Remote Control System of Electric Propulsion Systems
4.6.1 Power Limitation System
4.6.2 Torque and Speed Control
4.6.3 Crash-stop
4.6.4 Electric Propulsion Control Alarm System
4.6.5 Electric Propulsion Safety System
4.7 Power and Energy Management System (PMS and EMS)
4.7.1 Introduction
4.7.2 Marine Power System
4.7.3 Power System Redundancy
4.7.4 Power Management System
4.7.5 PMS Functional Design Specification (FDS)
4.7.6 Automatic Diesel Generator Start and Stop Sequence
4.7.7 Diesel Generator Safety System
4.7.8 Automatic Power Restoration Sequence Program
4.8 Energy Management System
4.8.1 Event-based Fast Load Reduction
Chapter 5 Alarm and Monitoring
5.1 Introduction
5.2 Alarm Colour Coding
5.3 Alarm Management
5.3.1 Alarm Suppression
5.3.2 Clear and Understandable Alarm Messages
5.3.3 Recommended Corrective Action
5.4 Other Monitoring and Control Functions
5.5 Data Communication with Other Control Systems
5.5.1 Other Communication Protocols
5.6 Software Assessment
5.6.1 Tests and Evidence
5.6.2 Testing
5.6.3 Software Duplication and Changes
5.6.4 Software Maintenance Management
5.7 Control Rooms and Operator Workplaces
5.7.1 Ergonomics
5.8 Alarm Management Glossary
Chapter 6 Measuring Devices and Final Control Elements
6.1 Introduction
6.2 Measuring Devices
6.3 Temperature Measurement
6.3.1 Non-electric Temperature Sensors
6.3.2 Electric/Electronic Thermometers
6.3.3 Installation Considerations
6.3.4 Role of Signal Conditioners
6.4 Pressure Measurement
6.4.1 Mechanical Pressure Gauges
6.4.2 Electromechanical Pressure Sensors
6.4.3 Trim, List and Draught Measurement with Pressure Transmitters
6.5 Level Measurement
6.5.1 Float Switches
6.5.2 Magnetic Level Gauges
6.5.3 Capacitive Level Gauges
6.5.4 Conductive Level Gauges
6.5.5 Ultrasonic Level Gauges
6.5.6 Hydrostatic Level Gauges
6.5.7 Microwave Level Gauges
6.5.8 Level Measurement by Bubbler Pipes
6.6 Flow Measurement
6.6.1 Flowmeter Types
6.6.2 Selecting a Flowmeter
6.6.3 Installation and Maintenance
6.7 Other Types of Sensors
6.7.1 Torque and Power Meters
6.7.2 Conductivity and pH Meters
6.7.3 Gas Analysis
6.7.4 Angular Speed and Limit Value Sensors
6.7.5 Limit Value Sensors
6.7.6 Oil Mist Detectors
6.7.7 Viscosity Meters
6.7.8 Water Ingress Detectors
6.7.9 Measurement of Electrical Quantities
6.7.10 Wireless Sensors and Networks
6.8 Control Valves
6.8.1 Seat Valves
6.8.2 Butterfly Valves
6.8.3 Ball and Ball Segment Valves
6.8.4 Valve Sizing
6.8.5 Valve Characteristics
6.8.6 Valve Cavitation, Noise and Vibration
6.8.7 Actuators and Positioners
6.9 Sensors for Exhaust Gas Cleaning Systems
6.9.1 Turbidity
6.9.2 pH
6.9.3 Polycyclic Aromatic Hydrocarbons
6.9.4 Exhaust Gas Analysis
6.10 Glossary
Appendix
A6.1 Degrees of Protection for Electrical Equipment
A6.1.1 IEC Classification
A6.1.2 NEMA Classification
A6.1.3 Conversion of NEMA Enclosures Type to IEC Classification Designations
A6.2 Hazardous Area Classification – Europe
A6.2.1 Zones
A6.2.2 Gas Groups
A6.2.3 Protection Types
A6.2.4 Temperature Codes
A6.3 ATEX Directive
Chapter 7 Automation Systems Project, Testing and Operation
7.1 Introduction
7.2 Classification Society Rules
7.2.1 Registro Italiano Navale (RINA) Rules for Automation Systems
7.3 Failure Mode Effect Analysis
7.3.1 FMEA Regulations
7.3.2 FMEA/FMECA Procedure
7.4 International Standards
7.4.1 IEC 61508: Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems
7.4.2 ISO 17894:2005 – Ships and marine technology – Computer applications – General principles for the development and use of programmable electronic systems in marine applications
7.4.3 ISO 13407:1999 Human-centred design processes for interactive systems
7.5 Automation Systems Project
7.5.1 System Basic Requirements
7.5.2 System Detailed Engineering and Specification
7.5.3 Functional Design Specification
7.5.4 Factory Acceptance Test
7.5.5 System Installation
7.5.6 System Testing
7.5.7 Maintenance and Service
7.5.8 Spare Parts
Chapter 8 Advanced Applications of Automation Systems
8.1 Condition-based Maintenance Systems
8.1.1 Overall Equipment Effectiveness
8.1.2 Maintenance Management
8.1.3 Vibration Monitoring
8.1.4 Vibration Measurement
8.1.5 Oil Analysis
8.1.6 Thermography
8.1.7 Engine Performance Monitoring
8.1.8 Electrical Equipment Condition Monitoring
8.1.9 Integration of CBM with the Automation System
8.1.10 Measuring the Performance of CBM
8.2 Electronic Control of Diesel Engines
8.2.1 Control Functions
8.2.2 Electronic Governor Applications
8.2.3 Multi-channel Tacho (MCT) System
8.3 Dynamic Positioning (DP)
8.3.1 History of DP
8.3.2 Basic Principles of DP
8.3.3 Modelling and Filtering
8.3.4 Elements of a DP System
8.3.5 Examples of DP Operations
8.3.6 DP Vessel Operations
8.3.7 Worksite Approach
8.3.8 Final Setting-up
8.3.9 Failure Modes and Effect Analysis (FMEA)
8.3.10 Classification Society Notations
8.3.11 Consequence Analysis
8.3.12 Watchkeeping
8.3.13 Checklists
8.3.14 Dynamic Positioning Operator (DPO) Training
8.3.15 Conclusions
Chapter 9 Future Views of Automation and Control
9.1 Introduction
9.2 Global Vessel Management System
9.2.1 Navigation System
9.2.2 New Performance Standards of INS, a Further Step to Digital Navigation
9.2.3 Bridge Navigational Watch Alarm System (BNWAS)
9.2.4 INS – Conclusions
9.3 Integrated Safety Management (ISM)
9.4 HVAC Control
9.5 Design Considerations
9.6 Functional Integration
9.6.1 Information Layers
9.6.2 Machinery Condition Monitoring
9.6.3 Fast Load Reduction
9.6.4 Thruster Torque Control
9.6.5 Simulation Models
9.6.6 Advisory Systems
9.6.7 Onboard Training System
Chapter 10 Final Guidance and Conclusions
10.1 Introduction
10.2 Identified Problems
10.3 Guidance for Crew Operating Automatic Control Systems
10.4 Guidance to Shipowners and Shipmanagers
10.5 A Design Model for an Integrated Automation System
10.6 Selection Criteria of the Automation System Supplier
10.7 Conclusions
Chapter 11 MARINE 4.0: The Dawn of the Next Generation Ships is Now
11.1 Introduction
11.2 The Enabling Technologies
11.2.1 Internet of Things
11.2.2 Big Data and Data Analytics
11.2.3 Connectivity
11.3 Augmented Reality
11.4 Horizontal and Vertical Integration
11.5 Additive Manufacturing
11.6 Blockchain
11.7 Cyber Security
11.8 Cloud Computing
11.8.1 Infrastructure as a Service (IaaS)
11.8.2 Platform as a Service (PaaS)
11.8.3 Software as a Service (SaaS)
11.9 Artificial Intelligence
11.10 Digital Twin
11.11 Radio-frequency Identification (RFID)
11.12 The Path to the Autonomous Ship
11.12.1 Levels of Automation and the Sheridan Scale
11.12.2 Human-centred Automation
11.13 Digital Applications
11.13.1 ABB
11.13.2 Wärtsilä
11.13.3 Kongsberg Maritime/Rolls-Royce Marine
11.14 Rules, Regulations and Standards
11.14.1 International Maritime Organization
11.14.2 Classification Societies
11.14.3 Bureau Veritas
11.14.4 Lloyd’s Register (LR)
11.14.5 IMO Resolution MSC.302(87) (2010)
11.14.6 OneNet
11.15 Conclusions
11.16 References
