DEVELOPMENT OF MARINE-ICT-ELECTRO-AUTOMATION ADVANCE TRAINER
by: 3/E Allan Roberto, Faculty College of Maritime Education.
INTRODUCTION
The maritime industry is rapidly evolving with advanced technologies, creating a pressing need for effective training resources. However, gaps in practical training can lead to inadequate preparedness for students entering the field. JBLFMU-MOLO, INC Introduction Implementation Result Learning Conclusion Contact
Addressing this issue, our project aims to enhance student learning by providing hands-on experience with modern equipment. By developing a process trainer that replicates actual onboard systems and integrating essential components such as sensors, valves, pumps, and control panels, we strive to bridge the gap between theory and practice in maritime education.
This initiative not only prepares students for real-world challenges but also equip them with the necessary skills to thrive in their future careers.
Key Benefits
Learning Outcomes
Auto 1- Basic Control Engineering
1. Explain the various types of process control.
2. Explain the construction and operation of the various pressure, level, flow and temperature measuring devices based on industrial standards
3. Measure the pressure using a manometer, pressure gauge and a pressure transmitter within +/- 10% of true value.
4. Measure the level in a column that is open and close to the atmosphere using a pressure transmitter within +/- 10% of true value.
5. Explain the construction and operation of the various pressure, level, flow and temperature measuring devices based on industrial standards.
6. Measure level in a bubbler system using a differential-pressure transmitter within +/- 10% of true value.
7. Measure flow using a rotameter or paddle meter and an orifice plate or venturi tube using a differential-pressure transmitter within +/- 10% of the true value.
8. Measure temperature using a Resistance Temperature Device (RTD) and a thermocouple within +/- 10% of the true value
9. Explain the construction and operation of various analytical measuring devices for liquid and gas properties based on industrial standards.
10. 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.
11. 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 industrial standards.
12. Explain the factors affecting the control of pressure using a PID controller.
13. Explain the characteristics of fluids that may affect PID control of a pressure measurement and control process.
14. Perform PID control of a pressure process for a given exercise based on the manufacturer's manual.
15. Explain the effects of fluid flow on PID control of a flow measurement and process control system.
16. Perform PID control for a level process for a given exercise based on manufacturer's manual
17. Explain the effects of hydrostatic characteristics in a closed and open tank level measurement and control system.
18. Perform PID control for a flow process fora given exercise based on the manufacturer's manual.
19. Explain the characteristics that affect PID control of a temperature measurement and control system.
20. Perform PID control for a temperature process for a given exercise based on the manufacturer's manual.
21. Perform cascade control for a level-flow process for a given exercise based on manufacturer's manual.
22. Calibrate various measuring instruments in process loop individually, based on industrial standards.
23. Perform manual open loop tuning (reaction rate) of a process loop using the Ziegler- Nichols method to achieve a stead state in the process.
24. Explain the purpose of the alarm and monitoring systems in support of the management of processes onboard ships
25. Explain the proper procedure for testing the performance of interlock systems based on manufacturer’s manual.
26. Calibrate the set point for a pressure and temperature switch used as a protective device to within +/- 5% of the true value.
Auto 2 - Marine Automation
1. Explain the operations of pneumatic and electro- pneumatic devices used in electro-pneumatic control circuits.
2. Explain the functions of the four main parts of a programmable logic controller (PLC).
3. Explain the step-by- step operation of a programmable logic controller (PLC).
4. Explain the different programming languages used for programming a PLC.
5. Explain the various applications of PLC onboard ships
6. Explain the operations of the different parts or module in a typical DCS on board
7. Explain the primary control features of a Supervisory Control and Data Acquisition in relation to control systems presently found on board ships. Explain the difference between single-element, 2- element, and 3-element boiler water level control system.
8. Explain the difference between a single-element, 2- element, and 3-element boiler water level control system.
9. Construct and operate a single-element level process control system using a level sensor/transmitter, a PID controller and a final control device.
10. Explain the operation of the boiler drum level and burner combustion control for boilers.
11. Develop a simple troubleshooting chart for the boiler drum level and combustion control system as per manufacturer’s manual.
12. Develop a simple troubleshooting chart for Main Engine Remote Control System as per manufacturer’s manual.
13. Explain the operation of Power and Energy Management System used on board ships.
14. Develop a simple troubleshooting chart for a given ship Power and Energy Management System as per manufacturer’s manual.
15. Adjust air to fuel ratio of the boiler combustion system to meet manufacturer’s nominal standard.
16. Adjust viscosity controller to match HFO characteristics as per recommended viscosity of propulsion plant manufacturer.
17. Explain how the Main Engine Jacket and Piston cooling water temperature are controlled with reference to manufacturer’s manual.
18. Adjust M.E. Fresh Water-Cooling system control system to return it to nominal operational parameters.
GALLERY
RESULTS OF THE PRACTICE
- Successful implementation of the training simulator.
- Positive student feedback and improved assessment scores.
- Significant cost savings of approximately 89% compared to purchasing a commercialized trainer which cost approximately 2.3 Million
- The price of our existing Process Trainer is approximately 1.2 Million. With our innovative Advanced Process Trainer developed for only Php 250,000, we achieved significant savings of approximately 79%.
LESSONS LEARNED
- Collaborative efforts among faculty and industry experts led to the effective design and implementation of the training simulator
- Continuous feedback from students helped refine training scenarios and enhance learning outcomes
- Significant cost savings of approximately 89% by developing an in-house trainer instead of purchasing a commercialized version.
- Challenges with funding led to delays in purchasing necessary equipment, impacting the project timeline
CONCLUSIONS
The development of the marine automation-electro-ICT-advance trainer has proven to be a significant advancement for students in maritime education. By providing hands-on experience with equipment and systems that closely resemble those found onboard vessels, students are better prepared to face real-world challenges in the industry. The initiative has not only fostered critical technical skills and problem-solving abilities but has also resulted in substantial cost savings of approximately 70% compared to purchasing a commercialized trainer. Overall, this project highlights the importance of practical training in enhancing student readiness and ensures that they are equipped with the necessary competencies to thrive in their future careers.
RECOMMENDATION
As the author of this project, I recommend that the other units within our system adopt similar technologies to enhance training quality and educational outcomes. Implementing advanced process trainers will provide students with essential hands-on experience, bridging the gap between theory and practice. Additionally, the significant cost savings from developing in-house solutions should motivate other units to explore innovative methods for improving their curricula. This approach will ultimately lead to a more skilled and competent group of seafarers ready to meet the demands of the maritime industry.
