Lesson Plan for NMC 23 Control Engineering Training

Reference
Contents Detail Time Total
Handout page
1st day
1 Opening 0900-0910 hrs 10 min’ 10(10)
Self introduction among trainees and instructors;
Name, rank, job experience (NYK, type of ships), etc.
Objectives
Explain the trainees about the objectives of this training course
based on the Reference No. NMC –23 P.1
Course schedule
Explain the trainees about the Course schedule of this training course
based on the Reference No. NMC –23
P.1
2 Standard signal
1) Pneumatic Signal 0910-0920 hrs 10 min’ 10(20)
Explain the output signal range of pneumatic controller
* Ask trainees the standard signal of the Pneumatic Signal.
* If they can’t answer, give them answer and explain why require the 100% signal and
the 0% P.5,6
* It's very imporatant to check the condition of pneumatic control system
Explain the reason for using range from 20kPa to 100kpa,
2) Current Signal 0920-0930 hrs 10 min’ 10(30)
Explain the standard Current signal range.
* Ask trainees the standard signal of the Current Signal.
* If they can’t answer, explain it. P.6,7
Explain the reason of not using the 0mA
* Ask them why the 0% signal is not 0mA. If they can’t answer, to be explained.
3) Voltage Signal 0930-0940 hrs 10 min’ 10(40)
Explain the standard Voltage signal range.
* Ask trainees about the standard signal for the Voltage Signal.
* If they can’t answer, to be explained. P.6,7
Explain the reason of not using the 0V
* Ask them why the 0% signal is not 0V. If they can’t answer, to be explained.
3 Control Theory
1) Feed back Control 0940-1005 hrs 25 min’ 25(65)
Explain the theory of feedback control
* Discuss various types of Sensors.
* Ask trainees what the Feed back Control is.
Explain and confirm what the Feed back Control is by referring the textbook and Figure P.8,9
* Point: When occur deviation between SP and PV, start/change the counter action/output
signal

Tea Break 1005 -1020 hrs 15 min’ 15(80)

2) Feed forward Control 1020-1045 hrs 25 min’ 25(105)
 Explain the theory of feed forward control
* Ask trainees what the Feed forward Control is.
Explain and confirm what the Feed forward Control is by referring the textbook and
Figure.
Point: Before change the PV, controller output signal change or start counter action P.9-11
Normally, high grade control system uses feedback control plus feed forward control, In
this type main control is feed forward and fine (minor) adjustment by feedback control.

3) Cascade control 1045-1115 hrs 30 min’ 30(135)

Explain the theory of cascade control
* Ask trainees what the Cascade control is.
Explain and confirm what the Cascade control is by referring the textbook and Figure.
Point: Upper side controller output signal uses as a set-point signal of lower side controller P.11,12
and It's high grade control system.

4) Split range control 1115-1145 hrs 30 min’ 30(165)

Explain the theory of split range control
* Ask trainees what the Split range control is.
Explain and confirm what the Split range control is by using the drawing 23 in Annex 2.
Point: Controller output signal operates two regulators within the different range of P. 13
signals.

4 Controller Operation
1) On/Off Control 1145-1200 hrs 15 min’ 15(180)
Explain the On/Off action
* Ask trainees following items;
What is the On/Off Control ?
What is the Neutral Zone ? P.14
Explain and confirm what the On/Off Control is by referring the textbook and Figure.
Explain the actual use: hydro fresh water tank level control and so on

Lunch break 1200- 1300 hrs

4 Controller Operation
2) Proportional Control 1300-1330 hrs 30 min’ 30(210)
Explain the proportional action
* Ask trainees following items;
What is the Proportional Control ?
What is the Offset ?
What is the Gain ?
What is the Proportional band ? P.15-17
How does the Gain affect the output signal under P control?
Explain and confirm what the Proportional Control is by referring the textbook and
Figure.
Point: any setting of proportional, 50% position is not changed

3) Integral Control 1330-1430 hrs 60 min’ 60(270)

 Explain the integral action
* Ask trainees following items;
What is the Integral Control ?
What is the Integral time ?
How does the Integral time affect the output signal under P+I control?
How does the gain affect the output signal under P+I control? P.18-20
Explain and confirm what the Integral Control is by referring the textbook and Figure
Point: Integral action dissolves the Offset and setting dial names RESET on the pneumatic
controller

4) Derivative Control 1430-1530 hrs 60 min’ 60(330)

Explain the derivative action
* Ask trainees following items;
What is the Derivative Control ?
What is the Derivative time ?
How does the Derivative time affect the output signal under P+D control?
How does the gain affect the output signal under P+D control? P.20-22
Explain and confirm what the Derivative Control is by referring the textbook and Figure.
Point: When setting increases output signal incresing is long, setting dial names RATE on
the pneumatic controller

Tea Break 1530-1545 hrs 15 min’ 15(345)

4 Controller Operation
5) PID Control 1545-1605 hrs 20 min’ 20(365)
Explain the function and action of the PID
* Ask trainees what the PID Control is.
Explain and confirm what the PID Control is by referring the textbook and Figure. P.23

5 PC Simulator Training 1605-1700hrs 55min'

Explain the Purpose and target why we use PC Simulator Training.
Explain meaning of display on the screen.
1) P control simulation 25 min’ 25(390)
Review P control action
* Ask trainees about the following items:
What is the Proportional Control ?
What is the Offset ?
What is the Gain ?
What is the Proportional band ?
PC Software
How does the Gain affect the output signal under P control?
Explain and confirm what the Proportional Control is by referring the textbook and
Figure.
Display the output signal difference between larger gain and smaller gain?
* Trainee changes the gain or PB and confirm that on the PC

2) PI control simulation 30 min’ 30(420)

 Review PI control action
* Ask trainees about the following items;
What is the Integral Control ?
How does the Integral time affect the output signal under P+I control?
How does the gain affect the output signal under P+I control?
Explain and confirm what the Integral Control is by referring the textbook and Figure. incl Tea
PC Software
Display the output signal difference between larger gain and smaller gain? Breaks
Display the output signal difference between larger integral time and smaller integral time?
* Trainee changes the parameter of P & I and confirm

2nd day
6 Pneumatic Controller and Equipments
1) Pneumatic Controller 0900-0930 hrs 30min’ 30(30)
Explain the pneumatic controller: Structure, elements, elements function and so on
* Ask trainees following items;
What is the Pneumatic Controller ?
　 How does the Pneumatic Controller work? (Purpose, Function, Structure, Working
principle, and etc.) P.24-25
Explain and confirm what the Pneumatic Nozzle Flapper system is by referring the
textbook and Figure.

2) Pneumatic Nozzle Flapper system 0930-0940 hrs 10 min’ 10（40）

Know the pronciple, structure, function of nozzle-flapper system
* Ask trainees about the following items;
What is the Pneumatic Nozzle Flapper system?
　 How does the Pneumatic Nozzle Flapper system work?
(Purpose, Function, Structure, Working principle, and etc.) P.26
Explain and confirm what the Pneumatic Nozzle Flapper system is by referring the
textbook and Figure.
Point: Linear range Fig1.2

3) Pilot Relay (Relay Valve) 0940-1000 hrs 20 min’ 20(60)

Explain the function and structure of pilot relay
* Ask trainees about the following items;
What is the Pilot Relay? (Purpose, Function, and etc.)
　 How does the Pilot Relay work?
(Purpose, Function, Structure, Working principle, and etc.) P.26,27
Explain and confirm what the Pilot Relay is by referring the textbook and Figure.
Point: Pilot relay is amplifying the pneumatic power (Air flow)

4) Air Regulator 1000-1015 hrs 15 min’ 15(75)

 Explain the function and structure of air regulator
* Ask trainees about the following items:
What is the Air Regulator?
How to control the pressure?
(Purpose, Function, Structure, Working principle, etc.) P.28
Explain and confirm what the Air Regulator is by referring the textbook and Figure.
Point: Setting point of controller air source

Tea Break 1015-1030 hrs 15 min’ 15(90)

5) Pneumatic Control Valve 1030-1050 hrs 20(110) 20(110)
Explain the stucture and action type of the control valve
* Ask trainees about the following items:
What is the Pneumatic Control Valve ?
　 How does the Pneumatic Control Valve work?
(Purpose, Function, Structure, Working principle, etc.) P.29
Explain and confirm what the Pneumatic Control Valve is by referring the textbook and
Figure.
Point: Direct/Reverse plug, Direct/Reverse diaphragm, 50% opening = 50% operation
signal

6) Valve Positioner 1050-1110 hrs 20(130) 20(130)

Know the function, structure, etc. of the valve positioner
* Ask trainees following items;
What is the valve positioner Valve ?
　 Why necessary the valve positioner?
(Purpose, Function, Structure, Working principle, and etc.) P.30-32
Explain and confirm what the Pneumatic Control Valve is by referring the textbook and
Figure.
Point: Sourse air pressure is not only 140kPa, make a quick response and make a high
power

7) Pressure　switch 1110-1120 hrs 10(140) 10(140)

Explain the function, structure, etc. of the pressure switch
* Ask trainees about the following items:
What is the Pressure　switch ?
　 How does the Pressure　switch work?
How is the Pressure　switch's working pressure set?
(Purpose, Function, Structure, Working principle, etc.) P.33-35
Point: Differential setting, which point is ON or OFF, how to set, etc.

7 Differential Pressure Transmitter 1120-1200hrs 40 min' 40(180)

1) Differential pressure cell 10min'
 Explain the function, structure, dumping valve, etc. of the differentical transmitter
* Ask trainees about the following items:
What elements are used in the system?
What is the Differential pressure cell?
　 How does the Differential pressure cell work?
(Purpose, Function, Structure, Working principle, etc.) P.36
Explain and confirm what the Differential pressure cell is by referring the textbook and
Figure.
Point: Cell is a diaphragm type and very weak. Requires carefull operation

2) Suppressed Zero Range & Elevated Zero Range 5 min’

Explain the suppression and elevation of the differential pressure transmitter
* Ask trainees about the following items:
What are the “Suppressed Zero Range & Elevated Zero Range”?
How do the “Suppressed Zero Range & Elevated Zero Range” work? P.37
(Purpose, Function, Working principle, etc.)
Explain and confirm what the “Suppressed Zero Range & Elevated Zero Range” are by
referring the　textbook and Figure.
3) Open tank and Closed tank 20min’
Explain how to use the differential pressure transmitter
* Ask trainees about the following items:
What does the Differential Pressure Transmitter suffer from the condition of “Open
tank and Closed tank” ?
P.38, 39
Explain and confirm what the condition of “Open tank and Closed tank” are by referring
the　textbook and Figure
Point: Close tank = wet leg and dry leg, wet leg uses base level condenser

4) Damping valve 5 min'

Explain the damping valve for differential pressure transmitter
* Ask trainees about the following items:
Do you know the damping adjustment?
Why require the damping valve? Picture 1.8
Explain and confirm the operation of damping valve.
Point: Most of the differential pressure transmitter has a damping valve and it requires
necessary adjustment.

Lunch break 1200-1300 hrs

8 Optimum control 1300-1320 hrs 20min' 20(200)
1) Ziegler Nichols Method 10 min’ 10(190)
Explain the optimum control adjustment: TUNING
* Ask trainees about the following items:
What is the theory of “Nicholas Ziegler Method ”? P. 40
Explain and confirm what the “Nicholas Ziegler Method” is, by referring the　textbook
and Figure.
2) Ultimate Sensitivity Method 5 min’ 5(195)
 Explain the optimum control adjustment: TUNING
* Ask trainees about the following items:
What is the theory of “Ultimate Sensitivity Method ”? P.41
Explain and confirm what the “Ultimate Sensitivity Method” is, by referring the　textbook
and Figure.
3) Reaction-Curve Method 5 min’ 5(200)
Explain the optimum control adjustment: TUNING
Ask trainees about the following items:
What is the theory of “Reaction-Curve Method ”? P.42-43
Explain and confirm what the “Reaction-Curve Method ”is, by referring the　textbook
and Figure.
9 AMCO Simulator training
To make three groups for simulator training
To explain the simulator system
To explain the simulator training items to each group 1320-1330 hrs 10 min’ 10(210)
To prepare the next day training: preview
1) Differential Pressure Transmitter 1330-1700 hrs 210min' 210(420)
Explain method for following calibration procedure to trainees. incl Tea
Make each trainee practice these methods and familiarize. break
a) Blow off and Air purging methods
b) Zero/Span Adjustment
c) Suppression/ Elevation mehods

3rd day
9 AMCO Simulator Training
1) Differential Pressure Transmitter 0900-1015 hrs 75min' 75(75)
* Continue
Tea Break 1015-1030 hrs 15min' 15(90)
2) Controller 1030-1200 hrs 90min' 90(180)
Explain method for following calibration procedure to trainees.
Make each trainee practice these methods and familiarize.
a) Zero/Span Adjustment
b) Balancing adjustment
Lunch Break 1200-1300 hrs
3) Valve Positioner 1300-1500 hrs 120min' 120(300)
Explain method for following calibration procedure to trainees.
Make each trainee practice these methods and familiarize.
a) Valve Positioner Zero & Span Adjustment

Tea Break 1500-1515 hrs 15min' 15(315)

4) Pressure switch 1515-1615 hrs 60min' 60(375)
Explain method for following calibration procedure to trainees.
Make each trainee practice these methods and familiarize
a) Pressure switch Setting procedure

5) Demonstration of Balanced condition of the control system 1615-1700 hrs 45min' 45(420)
 6) Debriefing on simulator exercises incl. Tea
Breaks
4th Day
10 Maintenance 0900-1000 hrs 60min'
1) Check point of pneumatic control equipment 20min' 20(20)
Explain the checking points and trouble points of pneumatic controller
* Ask trainees about the experience of troubles regarding pneumatic control equipment.
Share the trouble cases with each other.
Explain and confirm the Causes of troubles (Blockage of pneumatic line, Crater by
contaminated oil dust, Aging degradation and Eccentric abrasion), Principal location of P.45-49
failure, and Countermeasures by referring the textbook and Figure.

2) Check point of other equipments 40min' 40(60)

Explain the checking points and trouble points of pneumatic equipments
* Ask trainees about their experience of trouble regarding other equipments;
Control valve
VALVE positioner
Differential transmitter
Share the trouble cases with each other. P 50-59
Explain and confirm the Cause of trouble (Blockage of pneumatic line, Crater by
contaminated oil dust, Aging degradation and Eccentric abrasion), Principal location of
failure and Countermeasures by referring the textbook and Figure.

Tea Break 1000-1015 hrs 15 min’ 15(75)

11 Actual Control system: Case Study
1) Aux' Boiler Level Control System Part1 1015-1030 hrs 15min' 15(90)
<Two differential transmitter type level control system>
Explain the outline of control system
Explain the outline of safety
Review procedure for transmitter drain blowing Refer Instructor's guide notes
Discuss & explain the one transmitter trouble response
Discuss & explain the procedure

2) Aux' Boiler Level Control System Part2 1030-1045 hrs 15min' 15(105)
<Differential transmitter & rod type>
Explain the outline of control system
Explain the outline of safety Refer Instructor's guide notes
Trouble study

12 Electric Control System 1045-1200 hrs

1) Outline of Electric Control System 60 min’ 60(165)
 Explain the outline of electric control system, important point
Point:
1) Source voltage is important
2) DC source circuit: diode bridge & smooth circuit (capacitor)
3) Weak point is connecter P 60-65
4) When system trouble, check the three part (input part, output part and semiconductor)
Explain and confirm what the Electric Control System is by referring the textbook and
Figure.

2) Signal converter 15 min’ 15(180)

Explain the signal converter: Pneumatic signal - Current signal, Pneumatic signal - Voltage
signal
Lunch break 1200-1300 hrs
13 Troubleshooting exercises on Simulator
1300-1500 hrs 120min' 120(300)

Tea Break 1500-1515 hrs 15 min’ 15(315)

14 Discussion on Case studies
1515-1600 hrs 45min' 45(360)
15 Assessment and Final Q & A 1600-1645 hrs 45min' 45(405)
Answer the trainee's questions and clear any doubts

16 Closing 1645-1700 hrs 15 min’ 15(420)

Collect submission paper or assignment regarding training course if necessary. incl Tea
Give them advice how important the control engineering to manage machineries.

Breaks