AUTO 1

Learning Outcomes

• LO1.1 Explain the various levels of automation as per IMO

guidance and its impact on shipping operation.
• LO1.2 Explain the various aspects of the process control theory
with respect with respect to shipboard applications
• LO1.4 Explain the various types of control .
• LO1.6 Explain the construction and operation of the various
pressure, level, flow and temperature measuring devices
based on industry standards.
 2

Learning Outcomes

• LO1.10 Explain the construction and operation of various analytical

measuring devices for liquid and gas properties based on industry
standards.
• LO1.11 Explain the operation of on-off, proportional, proportional-
integral, and proportional-integral-derivative controllers in response to an
error or deviation from a set point
• LO1.12 Explain the construction and operation of various final control
devices such as: control valves, variable frequency drives, solenoid valves,
stepper and servo motors, base on industry standards
• LO1.13 Explain how various instruments in a process loop communicate
with each other using analog, digital, electrical or pneumatic signal based
on ISA standards.
 3

Topics

• IMO Levels of Automation Guidelines

• Terminology used in process automation, Process Control
Variables, Types of Automation and Control Open and Closed Loop
System On-Off (discrete) and Continuous control Control systems
dynamics Pressure Measurement
• Types of Automation and Control Feedback, feed-forward, ratio
cascade split-range sequential control — Types of Control Systems
and Configuration — Level Measurement
• Process Measuring Instruments
• Level Measurement
 4

Topics

• Flow Measurement
• Temperature Measurement
• Analytical Measurement
• Proportional-Integral-Derivative Control Mode
• Final Control Elements
• Control Loop Signal Processing
IMO Levels of Automation Guidelines 5

The committee has identified four degrees of autonomy for the purpose of the scoping
exercise:
Degree one Ship with automated
processes and decision support:
Seafarers are on board to operate and
control shipboard systems and
functions. Some operations may be
automated and at times be
unsupervised but with seafarers on
board ready to take control.

Degree two Remotely controlled ship with

seafarers on board: The ship is controlled and
operated from another location. Seafarers are
available on board to take control and to
operate the shipboard systems and functions.
IMO Levels of Automation Guidelines 6

The committee has identified four degrees of autonomy for the purpose of the scoping
exercise:

Degree three Remotely controlled ship

without seafarers on board: The ship is
controlled and operated from another
location. There are no seafarers on
board.

Degree four Fully autonomous ship:

The operating system of the ship is able
to make decisions and determine
actions by itself.
 7

Terminology used in process automation

Process Control Variables
Types of Automation and Control
Open and Closed Loop System
On-Off (discrete) and Continuous control
Control systems dynamics
Pressure Measurement
 8
19
Terminology used in process automation
In process automation for ships, several key terminologies are used
to describe the various components and functions involved. Here are
some common terms:

Process Automation The use of technology, systems, and control

algorithms to automate and streamline various shipboard processes and
operations.

Ship Automation System (SAS) The overarching system responsible for

automating and controlling various shipboard processes. It typically
includes multiple subsystems.

Control System A subsystem of the ship automation system responsible

for monitoring and controlling specific ship processes, such as propulsion,
navigation, HVAC (Heating, Ventilation, and Air Conditioning), etc.
Terminology used in process automation 9
19

Sensors and Actuators Sensors are devices used to measure various

parameters (e.g., temperature, pressure, level) on the ship. Actuators, on
the other hand, are devices that act upon commands received from the
automation system (e.g., opening/closing valves, adjusting speed).

PLC (Programmable Logic Controller) A digital computer used in

process automation to control and monitor the ship's machinery and
systems. It is programmed to perform specific tasks based on input from
sensors.

SCADA (Supervisory Control and Data Acquisition) A system that

gathers real-time data from various sensors and equipment, displays it to
the operators, and provides the ability to control the ship's processes
remotely. SCADA system are used to control monitor physical processes.
Terminology used in process automation 19
10

Alarm and Monitoring System Part of the ship automation system that
monitors critical parameters and triggers alarms in case of deviations or
malfunctions.

Auto-Pilot An automated system that can control the ship's heading and
course to maintain a desired track without constant manual steering.

Dynamic Positioning System (DPS) An advanced automation system

that enables a ship to maintain its position and heading using a
combination of thrusters and sensors, often used in offshore operations
and precision maneuvers.

Condition-Based Maintenance (CBM) An automation approach that

uses sensors and data analysis to monitor equipment health, allowing for
predictive maintenance and reducing unplanned downtime.
Terminology used in process automation 11
19

Electronic Chart Display and Information System (ECDIS) An

automated navigation system that displays electronic navigational
charts and provides real-time ship positioning and route planning.

Voyage Data Recorder (VDR) A data recording system on ships that

stores essential navigation and communication information for
accident investigation and analysis.

Automatic Identification System (AIS) An automated tracking

system used on ships and by vessel traffic services to identify and
locate vessels via VHF radio transmissions.
Terminology used in process automation 19
12

Human-Machine Interface (HMI) The interface that allows ship crew

members to interact with the ship automation system. It provides real-
time data, alerts, and control options to the operators. HMI be applied to
any screen that allows a user to interact with a device.

Integrated Automation System (IAS) An advanced ship automation

system that integrates various control functions into a single cohesive
platform, offering centralized control and monitoring. Ex. Alarm &
monitoring system, extension alarm system, emergency shutdown.

These are just a few of the many terms used in process automation
for ships. The field of marine automation is continually evolving, and
new technologies and terminologies may emerge as technology
advances.
 13
Process Control Variables

Process control variables automation refers to the

use of automation systems to monitor and regulate
various parameters or variables in an industrial process. Some common process
The goal of process control automation is to ensure that control variables that can
the process operates within predefined limits, maintains
desired setpoints, and responds to changing conditions be automated:
automatically. 1. Temperature
2. Pressure
3. Flow Rate
4. Level
5. pH
6. Concentration
7. Speed
8. Position
9. Humidity
10. Oxygen Levels
 14
Types of Automation and Control
These are just some of the main types of automation and control
systems used in various industries to improve efficiency, productivity,
and safety. The choice of system depends on the specific requirements
and characteristics of the process or application being automated.

1. Fixed Automation 9. Feedback Control

2. Programmable Automation 10. Feedforward Control
3. Flexible Automation 11. Closed Loop Control
4. Integrated Automation
12. Open-loop Control
5. Process Control Automation
13. Distributes Control System (DCS)
6. Discrete Control Automation
14. Supervisory Control and Data
7. Sequential Control Automation
Acquisition (SCADA)
8. Motion Control Automation
AUTOMATION
• Fixed automation refers to the use of special purpose equipment to
automate a fixed sequence of processing or assembly operations. In
this example, the application is usually simple and will involve a
process or assembly that is dictated by programmed commands.
• Programmable automation is a form of automation for producing
products in batches. The products are made in batch quantities
ranging from several dozen to several thousand units at a time. For
each new batch, the production equipment must be reprogrammed
and changed over to accommodate the new product style.
• Flexible automation (FA) is a type of manufacturing automation which
exhibits some form of “flexibility”. Most commonly this flexibility is
the capability of making different products in a short time frame. This
“process flexibility” allows the production of different part types with
overlapping life-cycles
• For example, robot arms can be pre-programmed to conduct a variety
of tasks along a production line, such as drilling holes inserting rivets
or screws, sanding, spray-painting or welding.
• What is integrated automation?
• Benefits of Automation and Integration | Cyclr
• What is Integrated Automation? Integrated automation can be
defined as software workflows that operate independently and
constantly with minimal human input after parameters have been set.
 15
Open and Closed Loop System
Open-Loop Control In open-
loop control systems, the
control action is based solely
on predefined instructions,
without continuous feedback
from the process. There is no
adjustment based on actual
output, making them less
precise.
Closed-Loop Control
Closed-loop control systems
continuously monitor the
process variables, compare
them with the desired
setpoints, and adjust the
control variables to maintain
the desired conditions.
 16
On-Off (discrete) and Continuous control

On-Off (Discrete) Control:

• On-Off control is a simple and widely used control strategy where the control
action is binary: either the control is fully on or fully off.
• It operates in a discrete manner, with the control output toggling between two
states based on a predefined threshold or setpoint.
• When the process variable (PV) exceeds the setpoint, the control output is
switched on to actuate a device like a pump, heater, or valve to bring the PV
back to the desired range.
• Once the PV reaches the desired range or setpoint, the control output is
switched off until the PV again deviates from the setpoint.
• On-Off control is simple to implement, but it may cause frequent switching and
oscillation around the setpoint, especially when the PV approaches the setpoint.
• It is commonly used in applications where precise control is not required, and a
simple, robust solution is sufficient.
 17
On-Off (discrete) and Continuous control

Continuous Control
• Continuous control is a more sophisticated control strategy that continuously
adjusts the control output based on the feedback from the process variable.
• It operates in a continuous manner, allowing for fine-tuning of control actions to
maintain the process variable at or near the desired setpoint.
• Continuous control uses control algorithms to compute the required control
output based on the difference between the setpoint and the actual process
variable value.
• The control action is proportional to the error between the setpoint and the
process variable, and it is smoothly adjusted, allowing for precise control and
reduced oscillations around the setpoint.
 18
On-Off (discrete) and Continuous control

Continuous Control
• Proportional-Integral-Derivative (PID) control is a common type of continuous
control widely used in industrial automation and process control applications.
• Continuous control is more complex to implement than On-Off control, but it
offers better performance and stability, making it suitable for applications that
require precise and consistent control of process variables.
 19
Control System Dynamics

Control systems dynamics in automation refer to the behavior and response of a

control system to changes or disturbances in the process it is regulating.
Understanding the dynamics is essential for designing, tuning, and optimizing
control systems to achieve desired performance and stability.
Below are some key aspects related to control systems dynamics in automation:
1. Time Response 8. Damping Ratio
2. Stability 9. Frequency Response
10. Control System Design
3. Transient Response 11. Control System Tuning
4. Steady-State Response
5. Overshoot
6. Settling Time
7. Rise Time
 20
Pressure Measurement

Pressure sensors or transmitters are used to measure pressure levels in

various processes, and the data obtained from these sensors is used by control
systems to make decisions and take appropriate actions.

How pressure measurement works in

automation:
1. Pressure Sensors: Gauge
Pressure Sensors, Absolute
Pressure Sensors, Differential
Pressure Sensors
2. Pressure Transmitters
3. Process Control and Automation
4. Control Actions
5. Alarms and Safety
 21

Types of Automation and Control Feedback, feed-

forward, ratio cascade split-range sequential control —
Types of Control Systems and Configuration — Level
Measurement
 22
Types of Automation and Control

Feedback In automation and control,

feedback control is one of the fundamental
types of control strategies used to regulate a
system's behavior based on the continuous
comparison between the desired setpoint
and the actual process variable. Feedback
control is also known as closed-loop control
because it involves a continuous feedback
loop to adjust the control actions.
 23
Types of Automation and Control

Feed-forward Feedforward control is another important type of control strategy

used in automation. Unlike feedback control that relies on continuously measuring
the process variable and adjusting the control actions based on the error signal,
feedforward control anticipates disturbances or changes in the system and
proactively adjusts the control inputs to counteract the effects of these
disturbances.
 24
Types of Automation and Control

Ratio cascade Ratio cascade control

is a specific control strategy used in
automation to maintain a specific ratio
between two process variables. It is a
type of multivariable control where one
controlled variable is used as a setpoint
for another controlled variable. The
primary purpose of ratio cascade
control is to maintain a certain
relationship between the two variables,
even when there are disturbances or
changes in the process.
example : changing cooling flow rate to
control flowrate to control condenser
pressure(vacuum) or changing steam
flow rate to control heat exchanger
outlet temperature.
 25
Types of Automation and Control

Split-range control is a specific type of control strategy used in automation to

control a single final control element (e.g., valve, damper, actuator) with two or
more separate and independent control signals. The primary purpose of split-
range control is to regulate a process variable by dividing the control output
between multiple manipulated variables. This approach allows the control system
to use different control strategies for different ranges of the process variable.
 26
Types of Automation and Control

Sequential control is a type of control strategy used in automation to manage

processes that involve a predefined sequence of steps or events. It is often
employed in manufacturing and industrial applications where a series of
operations must be executed in a specific order to achieve a desired outcome.
Sequential control ensures that each step is completed before moving on to the
next one, and it can include both time-based and event-based sequencing.
 27
Types of Control and Configuration

Control systems can be classified based on their functionality,

architecture, and control strategy. They are broadly categorized into the
following types:
1. Open-Loop Control System
2. Closed-Loop Control System (Feedback Control System)
3. Feedforward Control System
4. Cascade Control System
5. Ratio Control System
6. Adaptive Control System
7. Predictive Control System
Predictive control is a control algorithm based on a predictive model of
the process. The model is used to predict the future output based on
historical information about the process, as well as anticipated future
input. It emphasizes the function of the model, not the structure of the
model.
 28
Types of Control and Configuration

8. Distributed Control System (DCS)

9. Programmable Logic Controller (PLC)
10. Supervisory Control and Data Acquisition (SCADA)

These are some of the main types of control systems and

configurations used in various industries and applications. The
choice of control system depends on the specific requirements,
complexity, and goals of the process or automation task.
 29
Process Measuring Instruments

Process measuring 1. Pressure Transmitters

instruments play a crucial role in 2. Temperature Sensors and
automation by providing accurate Transmitters
and real-time data about various 3. Level Sensors
process variables. These
instruments are designed to 4. Flow Meters
measure specific parameters in 5. Analytical Instruments
industrial processes and transmit 6. Position Sensors
the measured data to control 7. Speed Sensors
systems for monitoring, analysis, 8. Load Cells
and control purposes. Here are 9. Gas Detectors
some common process 10. Humidity Sensors
measuring instruments used in 11. Vibration Sensors
automation:
 30
Level Measurement

Level measurement is a critical aspect of automation, especially in

industries that deal with liquids, solids, or slurries stored in tanks,
vessels, or silos. Accurate level measurement ensures proper process
control, inventory management, and safety. Various level measurement
techniques and instruments are used in automation to monitor and
control the level of substances in different industrial applications.

Common level measurement methods in automation

1. Ultrasonic Level Sensors- ex. method use to inspect the metal
thickness of ships hull.
2. Radar Level Transmitters - microwaves are transmitted by the
antenna system of the radar sensor. high frequency signal. used in
boiler technologies as fuel level or fluid level indicators.
3. Guided Wave Radar Level Sensors- guided by probe. the wavw
energy remains high which allows measurment even in harsh
conditions.
4. Capacitance Level Sensors - a proved, as well as cost
effective solution for level measurement and point level detection
in liquids and bulk solids. It has electrode that changes when the
height ot the medeium changes and causes its capacitance, the
ratio of its electrical charge to change.
5. Differential Pressure Level Transmitters - measure the
difference between two pressures used to determine if a pipeline
has any clog or contaminates as particles flow through orfices
and filters.
 31
Level Measurement

6. Float Level Sensors - featuring a magnetic float that rises and

falls as liquid level levels changes.
7. Hydrostatic Level Tranmitters - measuring device used read an
input vlaue from measuring device to a corresponding scaled
linear output signal.
8. Conductivity Level Sensors- conductivity level switch is sensor
with an electrical contact output at a specified liquid level.
applications in reservoirs, sumps, closed vessels, open tanks.
9. Nuclear Level Gauges - use radioactive sources to identify the
thickness, density or make up of a wide variety of materials or
surfaces.
• uranium - it is silvery - grey metal, used to power commercial reactors
that produces electricity and to produce isotopes used for medical,
industrial, and defense purposes around the world.
• where uranium mostly found - kazakhstan, Canada, Australia
 32
Flow Measurement

Flow measurement is
an essential aspect of
automation in industries
where the accurate
monitoring and control of
fluid flow rates are critical
for process optimization,
efficiency, and product
quality. Flow measurement
automation involves the
use of various flow meters
and instruments to
measure and control the
flow of liquids or gases in
industrial processes.
 33

Flow Measurement

Common Flow measurement techniques and instrument used

in automation:
1. Differential Pressure Flow Meters
2. Magnetic Flow Meters (Electromagnetic Flow Meters)
3. Ultrasonic Flow Meters
4. Coriolis Flow Meters
5. Vortex Shedding Flow Meters
6. Positive Displacement Flow Meters
 34
Flow Measurement

Common Flow measurement techniques and instrument used in

automation:
7. Turbine Flow Meters
8. Thermal Mass Flow Meters
9. Vortex Flow Meters
 35
Temperature Measurement

Accurate and reliable temperature

measurement is essential in various
industries, including manufacturing,
chemical processing, food and
beverage, HVAC (Heating, Ventilation,
and Air Conditioning), and many
others.
 36
Temperature Measurement

Common temperature measurement techniques and instruments

used in automation:
1. Thermocouples
2. Resistance Temperature Detectors (RTDs)
3. Thermistors
4. Infrared (IR) Temperature Sensors
5. Bimetallic Temperature sensors
6. Thermowells
7. Temperature Transmitters
 37
Temperature Measurement

Common temperature measurement techniques and instruments

used in automation:

8. Temperature Controllers
9. Temperature Data Loggers
 38
Analytical Measurement

Analytical measurement automation involves the use of

sophisticated instruments and sensors to analyze and measure
various chemical and physical properties of substances in industrial
processes. These measurements are crucial for ensuring product
quality, process optimization, regulatory compliance, and safety.
 39
Analytical Measurement - measure the analyte’s chemical or physical properties. ex. boiler water

Types of Analytical Measurement Instruments:

1.pH Sensors - able to measure the amount of alkalinity and

acidity in water. consist of glass electrode that is immersed in
the solution and the ph is determined based on the voltage
difference between the electrode and reference electrode.
2.Conductivity Sensors- measure the conductivity of water, pure
or drinking water, sewage water ot the concentration of ion in
water.
3.Dissolved Oxygen Sensors - measure the amount of oxygen
that is in disolved water, by unit volume. ex waste water
treatment. (electrode method)
4.Gas Analyzers - determine the concentration of a known gas in
an atmosphere that contains various gases. The purpose is to
monitor the process and emissions in the atmosphere.
5.Liquid Chromatography (LC) - use to confirm the identity of a drug and
provide results and also monitor of the progress of the thersphy, and
Gas Chromatography (GC) use to analyze volatile liquid or gas mixture.
volatile is substance easily evaporated.
6.Mass Spectrometers - to identify a substance or given information
about the structure of a compound
7.Spectrophotometers- measure the amount of protons absorbed after
is passes through a sample solutions.
8.Turbidity Sensors - to identify the clarity and particle contents in a
solution, like water. an infrared diode irradiates infrared light which
detect the turbidty of water.
9.Total Organic Carbon (TOC) Analyzers
10.Particle Size Analyzers
 40
Proportional-Integral-Derivative Control Mode

Proportional-Integral-Derivative (PID) control mode is a widely

used control strategy in automation and process control systems. It is
a type of feedback control that adjusts the control output based on
the error signal, which is the difference between the desired setpoint
and the actual process variable. The PID control mode uses three
components - Proportional (P), Integral (I), and Derivative (D) - to
calculate the control output and maintain the process variable close
to the setpoint.
 41
Proportional-Integral-Derivative Control Mode
Proportional-Integral-Derivative (PID) control mode is a widely
used control strategy in automation and process control systems. It is
a type of feedback control that adjusts the control output based on
the error signal, which is the difference between the desired setpoint
and the actual process variable. The PID control mode uses three
components - Proportional (P), Integral (I), and Derivative (D) - to
calculate the control output and maintain the process variable close
to the setpoint.
 42
Proportional-Integral-Derivative Control Mode

Proportional (P) Control

Integral (I) Control
Derivative (D) Control

The PID control mode combines these three components to compute

the total control output, which is then applied to the final control
element (e.g., valve, motor) to regulate the process variable. The
control action continuously adjusts the process to minimize the error
and maintain the process variable close to the setpoint.
 43
Final Control Elements

Final control elements are essential components in automation

systems used to regulate and control industrial processes. These
elements are responsible for converting the control output from the
control system (such as a PID controller) into an action that directly
influences the process variable. The final control element is the last
link in the control loop, ensuring that the desired setpoint is achieved
and maintained.
 19
44
Final Control Elements

Types of Final Control Elements in Automation:

1. Control Valves
2. Variable Speed Drives (VSDs)
3. Dampers
4. Heaters and Coolers
5. Actuators
6. Pumps
7. Solenoid Valves
8. Throttling Devices
9. Clutches and Brakes
• What is a variable speed drive?
• Variable speed drives (VSDs)

• A VSD controls the speed and torque of an AC motor by converting

fixed frequency and voltage input to a variable frequency and voltage
output. System performance can be greatly improved by controlling
speed to precisely match the load.
• What are the examples of variable speed drive?
• AC Motor Drives

• AC variable frequency drives are used in many applications such as

swimming pool pumps, air compressors, conveyor belts, lathes, mills,
food processing production lines, waste water treatment pumps,
HVAC fans and blowers, and many more applications in the industrial
manufacturing world.
 45
Control Loop Signal Processing
Control loop signal processing in automation refers to the
manipulation and analysis of signals within a control loop to achieve
accurate and stable control of a process variable. The control loop
signal processing involves various operations and techniques applied
to the control signals and process measurements to ensure smooth
and precise control.
 46
Control Loop Signal Processing
Common aspects of control loop signal processing
in automation
1. Signal Filtering
2. Signal Conditioning
3. Signal Averaging
4. Signal Linearization
5. Sampling
6. Dead Time Compensation
7. Data Interpolation
8. Signal Smoothing
9. Adaptive Signal Processig
10. Signal Fault Detection and Diagnosis
 47

Re-cap

• IMO Levels of Automation Guidelines

• Terminology used in process automation, Process Control
Variables, Types of Automation and Control Open and Closed
Loop System On-Off (discrete) and Continuous control
Control systems dynamics Pressure Measurement
• Types of Automation and Control Feedback, feed-forward,
ratio cascade split-range sequential control — Types of
Control Systems and Configuration — Level Measurement
• Process Measuring Instruments
• Level Measurement
 48

Re-cap

• Flow Measurement
• Temperature Measurement
• Analytical Measurement
• Proportional-Integral-Derivative Control Mode
• Final Control Elements
• Control Loop Signal Processing