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ABSTRACT
This paper explores the development of propulsion control systems on board RNLN warships since the advent of gas
turbine driven ships and Controllable Pitch Propellers in the 1970'ties. The requirements for finding new ways of control
with more emphasis on real operational conditions that came from both industry and the Navy are explained. An overview
is given of the research that followed with the successes but also with the inevitable blind alleys that we were entrapped in.
The paper reflects on the deeper differences between the control system proposed and tested recently and the classical
systems that have served us for many years. Also the paper gives an outlook what needs to be done in order to make the step
from proof-of-principle to commercial realisation.
KEY WORDS
Propulsion dynamics, Propulsion Control System, Controllable Pitch Propeller,
In fact in the classic systems the static control was Engine Propulsion Pitch
Control Control Control
achieved by setpoint generators (combinator curves) for System System System
shaft speed and/or fuel flow and for propeller pitch. Disturbances
this is the most important one) but also the rate of change n va vs
÷
n
of the fuel flow setpoint and/or the rate of change of the 1-w
In the meantime Vrijdag [15] proposed that a faster pitch fdem Input θdem
Demand
control in principle could contribute to avoid cavitation System
and as such lower the cavitation noise during operational
conditions in particular in seaway, but also during
manoeuvring: straight sailing or in a turn. This caused the fset θset
RNLN together with the Australian and Canadian Navy to
actuator actuator
embark on a project (Propulsion Control for High
Cavitation Inception Speed: PCS4HICIS) in which the f θ
operation of such a control system had to be demonstrated
Propulsion Plant
on board a frigate. The project was managed by MARIN
who also was responsible for organising the full scale y1 yn
trials. Wärtsilä Propulsion and IMTECH were the
industrial partners. The results were presented in Vrijdag Fig 3 No Control
[20], [21] and [23]. The actual controller development took
place in a PhD project that was running parallel (Vrijdag
[22]).
Command Command
f θ f θ
Command Command
θ Propulsion ndem Input θdem θ Propulsion ndem Input θdem
Control Demand Control Demand
System System System System
f θ f θ
Fig 6 Actual scheme of classical propulsion control for diesel engine drive (left) and gas turbine drive (right)
5. ESTIMATION OF ANGLE OF ATTACK But what is the meaning of this J-value? The mean or calm
water advance coefficient is:
Although the idea to have at least one propeller non-
dimensional parameter as a controlled variable was good,
vA vA 2π ⋅ r
the choice of KT was not. The advance coefficient J was J= = ⋅
rejected because it was then thought that information of the n ⋅ D 2π ⋅ n ⋅ r D
angle of attack i.e. of the propeller load was insufficient,
citing from Stapersma [12]: In analogy a local advance coefficient could be written as:
"At first the advance coefficient or the angle of the flow at v a ,local 2π ⋅ r
J local = ⋅
some distance of the blade seems logical: v t ,local D
vA
J= The axial and tangential wake velocities have a mean
n ⋅D (calm water) component and disturbances:
vA J
β = arctg = arctg
0.7 ⋅ π ⋅ n ⋅ D 0.7 ⋅ π v a ,local = v A + ∆v a, wake distr + ∆v a ,seaway
But these are not a measure of the angle of attack and that
for two reasons. First for that purpose the pitch angle must v t ,local = 2π ⋅ (n + ∆n ) ⋅ r + ∆v t,wake distr + ∆v t ,seaway
be subtracted (which could be done) and secondly it is the
variations of the advance velocity that are causing the all Then also the local J can be written as a mean (calm water)
important load variation of the propeller blade. Now component and a disturbance
although these wake speed variations can, given the sea
state, be predicted nowadays with advanced software, it J local = J + ∆J
seems far away to measure these speeds continuously on
board for the purpose of control. But the effect of angle of After some algebra:
attack (and thus initiation of cavitation) perhaps can be
deduced from a torque or thrust coefficient".
∆J =
1
n⋅D
( )
⋅ ∆va, wake distr + ∆va ,seaway −
J
2π ⋅ n ⋅ r
( ) J
⋅ ∆v t, wake distr + ∆v t , seaway − ⋅ ∆n
n
So that is how we arrived at KT. The hint to look at angle
of attack was taken up by Vrijdag [20]: Now the tangential velocities change during one
revolution, i.e. are shaft frequent, they will cancel out in
It can be derived that the local angle of attack contains the mean value and essentially (as was shown by Schulten
pitch θ, flow angle β and a correction for the shock free [14]) will cause a shift of the KT-J diagram and thus an
entry angle αi as follows: error. Also the circumferential distribution of the axial
wake is shaft frequent. Neglecting the error one still is able
α eff = θ − β − α i to observe the variations in J due to axial flow variations
caused by seaway and the resulting response of the shaft
Working this out gives: speed:
~
P c1 ⋅ v A J = J + ∆J meas
α eff = arctan 0.7⋅R − arctan − αi
0. 7 ⋅ π ⋅ D 0.7 ⋅ π ⋅ n ⋅ D
144 42444 3 144424443 with:
θ β
f θ
where θ0 is the zero thrust pitch-angle and θnom is the
nominal pitch angle, while ' n' represents the actual shaft Propulsion Plant
speed. Onboard, the actual realised virtual rpm is n
constantly calculated and presented via measurement of θ
pitch and shaft speed via above formula". T
But that means that the pitch actions to optimise angle of Fig 7 Propulsion control according to Vrijdag [22]
attack must be compensated such that virtual shaft speed
will be maintained. The result will be that the rigid choice
of the combinator curve (i.e. combinations of shaft speed The results of the control system are presented in Vrijdag
and pitch) will effectively be replaced by an adaptive [21], [22] and [23]. In general it can be concluded that:
control.
- Cavitation during linear acceleration and deceleration
The principle of the control system as it was tested on is almost completely avoided in the relevant ship speed
board an M-frigate is shown in Fig 7. On the right hand domain.
side the measured thrust T, shaft speed n and propeller - Cavitation in seaway slightly improved but since the
pitch θ are fed into the alfa estimator incorporating bandwidth of the hydraulic servo system was not yet
calculation of KT, reading of J, calculation of vA and increased more improvement is to be expected.
subsequently α. During the tests the data base was simply - By proper tuning of KP and Ki the trajectory through
the estimated middle of the cavitation bucket, but given the engine characteristic was such that the diesel engine
more knowledge this could be expanded to a sophisticated was not overloaded
database that could be dependent on more inputs. The - The α-control of the pitch also prevented windmill
controller for the setpoint of propeller pitch was a simple during deceleration
proportional controller with gain Kp, calculating a - In case of resistance increase through seaway or sailing
correction of the propeller pitch to be added to the actual in a turn, pitch is reduced automatically and shaft speed
pitch. is automatically increased..
In Fig 7 on the left hand side the actual shaft speed 'n' and Where in the classical control system a host of fuzzy
propeller pitch θ serve to calculate the actual virtual shaft function blocks were required to fulfill all these tasks, in
speed which is compared to the demanded value and fed the new control system the two controllers carry out all
into a controller to generate a shaft speed setpoint for the jobs at once.
governor. During the test this was a simple integrating
controller with gain Ki to calculate a shaft speed 6. FUTURE IMPROVEMENTS
increment. For the initial value of this integrator still the
The driver of the propeller shaft (diesel engine, gas turbine
"old" combinator curve was used (not shown in Fig 7).
or electric motor) "feels" the propeller law or stated in
Tuning of KP and Ki determines torque and speed of the
terms of non-dimensional propeller quantities, is sensitive
engine and therefore the trajectory through the driver
to the instantaneous value of torque coefficient:
characteristic.
Q
When one compares Fig 7 with the classic control in Fig 6, KQ =
apart form the active control of propeller pitch by the α- ρ ⋅ n 2 ⋅ D5
estimator, the combinator curve effectively has
disappeared and is replaced by the virtual shaft speed error It could be considered to calculate KQ from a measurement
feeding a controller. of torque and speed and somehow adapt KP and Ki. In
general the two controllers need to be optimized and
proper stability checks need to be carried out. Also the
database for the demanded value of α must be filled and be
expanded with hydrodynamic knowledge.
NOMENCLATURE
When sailing at high virtual shaft speed the α-estimator D Diameter propeller
could reduce pitch such that shaft speed needs to be higher f fuel rack
than maximum speed: then the situation is too "heavy" to J Advance coefficient
maintain demanded virtual shaft speed. When sailing at Ki Gain integrator action
low virtual shaft speed and the α-estimator still requiring Kp Gain proportional action
relatively high pitch, the required shaft speed needs to be KQ Torque coefficient
lower than minimum speed. Then either the demanded KT Thrust coefficient
virtual shaft speed cannot be achieved or the ideal angle of n rotational (shaft) speed
attack must be given up. P Propeller pitch
Q Torque
Somewhat more radical: in the present control of the diesel
R Outer radius propeller
engine there is still a governor. Wouldn't it be possible to
r radius
get away with the governor and rely on fuel (rack)
T Thrust
schedules as used in aero derived gas turbines? This could
v velocity
be beneficial for fuel saving but also for emissions and
vA Advance velocity
probably also for engine wear.
va axial velocity
The control scheme for sailing on main gas turbines still vt tangential velocity
has to be developed where it must be decided to maintain
the primarily fuel scheduled control as shown in the right α Angle of attack
hand side of Fig 6 or rely on closed loop shaft speed β Flow angle
control as for the diesel engine (the latter as said having θ Pitch angle
disadvantages for fuel consumption and emissions) ρ Seawater density
Furthermore a gas turbine can withstand much larger
torque deviations (or deviations of non-dimensional KQ), dem demand
but of course the excess thrust (or deviations of non- eff effective
dimensional KT) could well be the determining factor. nom nominal
set setpoint
On the hardware side there need to be some major virt virtual
developments before the system can be supplied 0 zero
commercially:
ABBREVIATIONS
- Improvement of bandwidth of CPP hydraulics
APCS Automatic Propulsion Control System
- Further development of thrust sensor
CODOG Combined Diesel or Gas Turbine
CODAG Combined Diesel and Gas Turbine
7. CONCLUSIONS COGOG Combined Gas turbine or Gas Turbine
In general the authors believe that no design of control CPP Controllable Pitch Propeller
systems is possible without going back to first principles, ICMS Integrated Control & monitoring System
in this case propeller hydrodynamics. DYLOPROPS Dynamic Load on Propellers
LCU Local Control Unit
Controlling the effective angle of attack of the propeller is MARIN Maritime Research Institute Netherlands
an effective way to simultaneously decrease propeller NLDA Netherlands Defence Academy
cavitation, prevent engine overloading and to improve PCS Propulsion Control System
manoeuvring behaviour. This can be realised without the PCS4HiCIS PCS for high Cavitation Inception Speed
original complexity of a lot of fuzzy function blocks. RNLN Royal Netherlands Navy
TUDelft Delft University of Technology
The proof-of-concept of this system was tested full scale, WPNL Wärtsilä Propulsion Netherlands
the way to commercial production lies ahead.
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BIOGRAPHY AND CONTACT
INFORMATION Presented at the Fourteenth International Ship Control
Systems Symposium (SCSS) in Ottawa, Canada, on 21-
Douwe Stapersma graduated in 23 September 2009.
1973 at Delft University of
Technology in the field of gas
turbines, joined NEVESBU - a
design bureau for naval ships - and
was involved in the design and
engineering of the machinery
installation of the Standard frigate.
After that he co-ordinated the
integration of the automatic propulsion control system for
a class of export corvettes. From 1980 onward he was
responsible for the design and engineering of the
machinery installation of the Walrus class submarines and
in particular the machinery automation. After that he was
in charge of the design of the Moray class submarines in a
joint project organisation with RDM. Nowadays he is
professor of Marine Engineering at the Netherlands
Defence Academy and of Marine Diesel Engines at Delft
University of Technology. Douwe Stapersma can be
reached at D.Stapersma@nlda.nl