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AUGMENTATION OF TRAINING INFRASTRUCTURE
DIESEL ENGINE WING (DEW)
Bio-diesel is the alternative fuel which is produced from domestic, renewable resources. Bio-diesel contains no petroleum, but it can be extracted from both edible as well as non-edible oil. Biodiesel can be blended at any level with petroleum diesel to create a bio-diesel blend. It can be used in compression-ignition (diesel) engines with little or no modifications.
Biodiesel trials have been carried out at the establishment on marine DAs as well as MT vehicles. The trials have been carried out on following DAs/ MT vehicles for over a period of one year:
(i) MWM TBD12V : The Ruston & Hornsby make DA is rated for 200 kW. The diesel engine has 12 cylinders and operates at 1500 rpm. The Bore*Stroke of the engine is 120*130 mm and Compression Ratio is 16.5:1
(ii) KTA 1150 MG (300 kW): The Cummins make DA is rated for 300 kW. The diesel engine has 06 inline cylinder configuration and operates at 1500 rpm. The Bore*Stroke of the engine is 150*150 mm and Compression Ratio is 14:1
(iii) trucks: 02 four tonner trucks of Tata make
(iv) buses: 02 55 seater buses of Ashok Leyland make
The trials were conducted at different percentage of blending of biodiesel with conventional diesel. The final test results show that:
(i) biodiesel is a viable option in place of conventional diesel for Indian Navy's requirement,
(ii) NOx emissions rise at higher loads,
(iii) CO and UHCs emissions have reduced, and
(iv) marginal rise in fuel consumption |
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A 300kW 6V 396 TB-53 DA of ex INS Shakti was re-appropriated to INS Shivaji in Nov 07. A team from this establishment, comprising of U/T Officers and sailors, identified and removed all essential items like system pipes, valves, compensators, transformers, automatic voltage regulator, bus bars etc from ship. Shortfalls were made good with available in-house resources and indigenous designs. An exhaust silencer was designed and fabricated for the DA. Installation of the engine and integration of system pipes, electronic control panel, switchboard and Setting To Work (STW) have been completed as a staff-student project, and the DA is now live at INS Shivaji. |
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INHOUSE DEVELOPMENT OF PLC BASED CONTROLLER FOR GAS TURBINE GENERATOR
The advent of processor based controllers including PLCs has provided a low cost alternative for control system upgrades when faced with increasing maintenance costs and obsolescence issues of analog and hard relay logic control systems. The PLC is a software based system that provides the flexibility for increased functionality and algorithm development. PLCs have been proven to operate in extreme temperatures, in excess of 130°F (~55°C) and rugged environments. The Centre for Marine Engineering Technology at INS Shivaji has successfully developed a PLC based controller for the Gas Turbine Generator 1250E fitted on the SNF class of ships of the Indian Navy. This system will replace the existing control station and the operating panels viz the Local Control Panel (LCP) and the remote control Panel (RCP). The replacement controller is a Programmable Logic Controller (PLC) based system linked to a flat panel display and a supervisory control system. The controller includes logic for alarms, start/stop and automatic shutdown functions. Maximum use of Commercial-Off-The-Shelf (COTS) equipment was made subject to specific performance requirements. This included functional requirements for sequencing, governing, alarms, shutdowns, and auxiliary system control. Physical requirements were defined for all discrete and analog electrical interfaces between the generator set and the controller. Teaming was established with Ms Larsen and Toubro, Mumbai based upon the combination of low price and their experience in developing a data acquisition system for another ship. The choice of input/output signals was made after a thorough analysis of the operational characteristics of the Gas Turbine Generator. After realisation of the controller logic, the same was tested under simulated conditions for its proper operation before integration with the live machinery. On a comparative basis with the conventional Relay Logic Controller (RLC), the PLC based controller was able to achieve a 75% reduction in the number of relays and contacts used. The HMI pages that have been developed are a replica of the existing panels and hence offer smooth transition of the operator from a hardwired control panel to the PLC based soft panel. The PLC based controller so developed offered tremendous flexibility in evaluating the performance of various sub assemblies without the need to actually start the generator. The PLC based controller also posed advantages in the area of data logging and parameter trending which can be used to study the performance characteristics of a Gas Turbine Generator.
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DIESELISATION OF SMW BOILER
The Y-160 boiler was commissioned in 1977 at the Seam Machinery Wing as FFO fired boiler with a 06 burner arrangement. The case for dieselisation was initiated in 2001 in order to make it at per with the boilers onboard the Leander, Godavari and Brahamputra class of ships. The modification was required to be undertaken to enable realistic hands on training on the boiler to ensure personnel are confident to take on watch keeping duties onboard ships without taking recourse to further training.
The work was undertaken from 27 May 07 to 28 Jul 07 with joint effort by ship's staff and ND(MB). The modified Y-160 boiler was inaugurated in the presence of Rear Admiral KC Sekhar, VSM, ASD(MB) on 09 Aug 07 for re-initiating training of officers and sailors on steam machinery. |
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INDUSTRIAL TRAINING WING (ITW)
A Pneumatic Power Hammer of 150 Kgs has been installed and commissioned at Fabrication Shop to impart practical training and demonstration to the trainees. |
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INSTRUMENTATION & CONTROLS WING (ICW)
Design and development of Level Control Trainer . A level control trainer incorporating a PID Controller has been designed and developed as a staff-student project. It comprises of a Graduated Level Tank, Level Sensor (Capacitive Level Transducer), Electronic PID Controller (Microprocessor Based), Pneumatic Control Valve, I/P Converter, Sump Tank and a motor driven Pump. The output (measure value) from the level transducer and set point (desired value) is compared to generate error signal. A PID Controller acts on error signal and produces control signal. Control signal (4-20mA) is converted into Pneumatic signal (3-15 psi) in I/P (Current to Pressure) converter. The pneumatic signal controls the opening/closing of pneumatic control valve to produce the desired level.
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EPCT SCHOOL
Ship specific training for all classes of ships is conducted at INS Shivaji during the PCT courses. There has been a continuous endeavour to install live and static equipment at this establishment for improving the quality and effectiveness of training. Installation of equipment is being undertaken as staff-student projects which have resulted in augmentation of training aids and also enormous savings to the exchequer.
Installation of training facility for CPP system had been a long felt requirement to impart in-depth knowledge and training on the complex CPP system. The opportunity presented by decommissioning of two Indian Naval Ships was availed for removal of CPP system of SNM class of ships for creation of a live CPP training facility at the establishment. The installation of live CPP system was completed in Apr 08.
Burya Simulator : Burya Simulator for 1135.6 Main Propulsion Control System developed by the OEM, M/S CAE India Private Limited (CIL), Bangalore was installed at EPCT School and commissioned on 27 Nov 09 by Cmde DM Deshpande, VSM. The simulator is capable of full function real time simulation for practical training on main propulsion control system.
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CADETS' TRAINING
SILVER JUBILEE OF NAVAL ENGINEERING COURFSE.
The 10+2 (Tech) entry for the cadets, known as the Naval Engineering Course (NEC) at INS Shivaji celebrated its Silver Jubilee from 20 to 21 Nov 09. The Naval Engineering Course which had a modest beginning at INS Shivaji in 1984 has over the last 24 years provided yeoman service to the Navy by training officers who now number over a thousand.
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BASIC PARA COURSE. 10 NEC cadets successfully completed the basic para course at PTS Agra and were awarded the para wings. |
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NEC CADETS AT HEXA GO NALS 2010
The cadets of the Naval Engineering Course did their alma mater and the Service proud by winning the prestigious Cross Country event of the Hexagonal Sports Meet 2010 at National Defence Academy, Khadakwasla. The Hexagonal meet is conducted every year at NDA and IMA alternately and all pre-commissioning training academies of the services viz. NDA, IMA, NEC, INA, AFA and OTA participate in it. The sports events of football, hockey, basketball, volleyball, squash and tennis are conducted in alternate years. The Cross Country, introduced in 2003, remains the only event which is conducted every year and it aptly summarizes the physical and mental build-up of the cadets of each PCT academy.
The cadets of NEC won the event for the first time to secure the gold medal in the event. This was also the first time that any academy, other than NDA and IMA has won the Cross Country event. ACC H Choudhary and SCA(L) AK Jha led from the front and finished individual third and fourth. They were followed by Cdt V Tomer and Cdt Bejoy Das who finished sixth and seventh finishing with an overall total of 21 points. It is not the first time that the cadets of NEC have brought laurels to their organisation but they have time and again re-asserted their supremacy as a small and potent force to compete with.
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