PROJECT REPORT

HYDRAULICALLY OPERATED SKYLIGHT

DEPARTMENT OF MARINE ENGINEERING AMET UNIVERSITY BE-8 2012

BONAFIDE CERTIFICATE
This is to certify that this project workHYDRAULICALLY OPERATED SKYLIGHT is a product of the ingenious efforts by a group of EIGHT cadets under BE-MARINE ENGINEERING (2011-12) {BE-8} of AMET UNIVERSITY. The names of the cadets whose cumulative thoughts were put for the successful completion of this project are:
S.NO 1. 2. 3. 4. 5. 6. 7. 8. NAME MANOJ.B MOHANKUMAR.M MOHD MOHAIDEEN.M.S NAGARAJAN.M NIRANJAN.M PARTHIBAN.K PRABAKARAN.E PRADEEP.B ROLL NO 701 B 709 B 711 B 713 B 723 B 725 B 727 B 732 B

The content of our project HYDRAULICALLY OPERATED SKYLIGHT is not a replication of any other project or report previously made in any manner.

Date: Place:

C/E A.VENUGOPAL

C/E K.R. CHIDAMBARAM

DEAN

PROJECT GUIDE

INTERNAL EXAMINER

EXTERNAL EXAMINER

ACKNOWLEDGEMENT
OUR SINCERE THANKS TO, We would like to take this opportunity to thank our respected DEAN Mr. A.VENUGOPAL for giving us this wonderful opportunity to setup a working model for our own ship-in-campus and to bring out the fineness in our practical and technical skills.

We would also gladly like to thankC/E Mr.K.R.CHIDAMBARAM sir who stood along with us all day in SHIP-IN-CAMPUS and helping us a lot and made us to feel that we too can finish a SUCCESSFUL PROJECT. We would like to thank C/E Mr.D.IMMANUEL THIYAGARAJANfor giving us approval to carry out this venture. We like to thankC/E MR.K.R.CHIDAMBARAM,C/EMR.A.VISWESWARAN, C/E Mr.SURESH PATTABHIRAMANfor guiding us through the course of our degree. We would also like to thank Mr.JOHN PEREIRA, Mr.ACHIMUTHU, Mr.RAMAMOORTHY,Mr.ANANTHKUMAR,Mr.JEYAKUMAR, Mr.BALAJI, Mr.ESWARAN for providing us finer points of work during our day to day practical classes. We would also like to thank our AMET CIVIL AND ELECTRICAL STAFFS AND OTHER PROJECT MATES who helped us finish our project successfully.

Finally we thank the almighty for showering his blessings upon us..

CONTENTS
INTRODUCTION AIM LOCATION

 DIMENSION FABRICATED ITEMS

PURCHASED ITEMS

PROJECT ESTIMATION COST RULES & REGULATIONS CONCERNING SKYLIGHT INITIAL CONDITION OF OUR PROJECT PLAN OF ACTION

BRIEF EXPLANATION ABOUT THE PROJECT

FABRICATION CIRCUIT DIAGRAM PROPERTIES OF HYDRAULIC OIL USED MAINTENANCE

OPERATING SEQUENCE OF THE SKYLIGHT

DIFFICULTIES FACED DURING THE PROJECT CONCLUSION

INTRODUCTION

The skylight was used in old ships for the illumination and the ventilation of the engine room along with providing an opening for lowering and removing heavy items with the ship or the shore crane.

However in modern ships the sky light is normally bolted shut and only opened for lowering goods and spares into the engine room.

The location of the sky light should be such that it can lower the spares near the cylinder head platform from where it can be transferred easily to the overhead crane. In case it is not possible it should have guide rails near the opening so that once the items have been lowered into the engine room it can be easily shifted by chain blocks and physical labour is saved.

The opening should be free of pipelines and obstructions, so that the spares can be easily lowered and lifted without much maneuvering.

Sometimes the restricted opening causes the crane hook to catch on to some obstructions or pipelines and the spares can fall endangering life and property.

AIM
To construct a skylight and operate it hydraulically with the following features: 1. Open/close by hydraulic pump(motor driven) 2. Open/close by hand pump 3. Emergency shut-off

4. Accidental stop

LOCATION
The skylight is constructed adjacent to the engine room blower funnel, on the weather deck of SHIP-IN-CAMPUS.

DIMENSION
LENGTH OF THE DOOR BREADTH OF THE DOOR THICKNESS OF THE DOOR STROKE OF THE RAM ANGLE OF OPENING : 2m : 1.15m : 0.003m : 0.42m : 80 DEGREE

FABRICATED ITEMS
DOOR

FRAMES

STIFFENERS

PURCHASED ITEMS
HYDRAULIC POWERPACK

(Motor, Pump, Relief valve, Filter, 4/3 way solenoid operated & spring centered directional control valve, Reservoir)

RAM & CYLINDER HYDRAULIC HOSES CONTROL PANEL (Limit switches, Relays, Push button, LED etc.,) HAND PUMP 4/3 WAY HAND OPERATED D.C VALVE WITH DETENT HYDRAULIC OIL RUBBER SEAL
NOTE:All hydraulic components were purchased from A.M. KHALEEL HYDRAULICS
No.6,7,8, Nehru Market, SydenhamsRoad,Choolai, Chennai-600 003. Ph:32472118 Cell:9884012327, 9884081786

PROJECT ESTIMATION COST

FORTY THREE THOUSAND RUPEES(approx)

RULES & REGULATIONS CONCERNING SKYLIGHT

MARITIME RULES
Part 40E: Design, Construction and Equipment Sailing Ships
Watertight and weathertight Integrity

40E.20 Openings on the deck

(8) Skylights must be of weathertight construction and located on, or as near as practicable to, the centreline of the ship. (10) A skylight that is capable of being opened must have efficient means of weathertight closure approved by a surveyor. (11) A skylight that serves as a means of escape must be capable of being opened from both sides.

HULL CONSTRUCTION REGULATIONS (C.R.C., c. 1431)

167. Every skylight in a machinery space of CategoryA or cargo pump room shall be made of steel and be capable of being easily closed from outside the space or room that it serves. SOR/78-605, s. 3; SOR/83-521, s. 4. 169. No window or port light shall be fitted in a skylight that is fitted in a machinery space of Category A or cargo pump room. SOR/78-605, s. 3; SOR/83-521, s. 4.

SOLAS: ChapterII-2: REGULATION9

Section 5 Regulation 9. Containment of fire

5 Protection of openings in machinery spaces boundaries 5.2 Protection of openings in machinery space boundaries 5.2.1 The number of skylights, doors, ventilators, openings in funnels to permit exhaust ventilation and other openings to machinery spaces shall be reduced to a minimum consistent with the needs of ventilation and the proper and safe working of the ship. 5.2.2 Skylights shall be of steel and shall not contain glass panels. 5.2.3 Means of control shall be provided for closing power-operated doors or actuating release mechanisms on doors other than poweroperated watertight doors. The controls shall be located outside the space concerned, where they will not be cut off in the event of fire in the space it serves 5.2.4 In passenger ships, the means of control required in paragraph 5.2.3 shall be situated at one control position or grouped in as few positions as possible, to the satisfaction of the Administration. Such positions shall have safe access from the open deck. 5.2.6 Windows shall not be fitted in machinery space boundaries. However, this does not preclude the use of glass in control rooms within the machinery spaces.

Guidance 9 G57 Machinery space boundaries - protection of openings

G57.1 Skylights G57.1.1 Windows and sidescuttles should not be fitted in skylights serving machinery spaces of Category A or cargo pump rooms in compliance with paragraphs 5.2.2 and 2.4.2.6 respectively. The steel skylights should be of substantial construction and capable of preventing the passage of flame and smoke as far as is reasonably practicable.

INITIAL CONDITION OF OUR PROJECT

Initially the area was covered by just asbestos sheets which leaked severely during heavy rains. This gave us the idea to take up something which was a necessity to the SHIP-IN-CAMPUS and our batch came out with the HYDRAULICALLY OPERATED SKYLIGHT project unanimously.

Preparing the platform for placing the skylight door.

PLAN OF ACTION

 We will fabricate a door for the skylight along with a frame covering the entire platform which was supporting the asbestos sheets, as well as to support the door at the centre. We will fix the frame along with door on the platform with cement.

We will fix rams on both the sides of the door. We will fix an electric motor with hydraulic pump which has a solenoid-operated DCV for normal operation and a hand-operated hydraulic pump with a hand-operated DCV for operating during abnormal power failures &BLACKOUTs. We will lay the hydraulic connections and prime the system with hydraulic oil and test the hand pump for proper operation of the rams and the DCV. We will lay the electrical connections and check for proper operations of the electric motor, rams, control panel and the solenoids. We will carry out complete cycle of operations in our project till the system is working satisfactorily and will rectify mistakes, if any. Finally we will prepare our finished work for the FINAL REVIEW of our project.

BRIEF EXPLANATION ABOUT THE PROJECT

As our project was based on hydraulics, it was necessary for us to construct a working hydraulic circuit for operating the skylight door as stated in our project approval form. (same is mentioned in our AIM above)The electrical circuit employed for our project is shown below.

Soldering work carried out for control panel connection.

CIRCUIT DIAGRAMS:

Electrical circuit

Fitting the electrical components to the control box.

Hydraulic circuit
We constructed the following hydraulic circuit which fulfilled all the conditions that were told to us.

Before going into the operation of the circuit it becomes necessary to have the knowledge of the components used in the circuit. We can discuss about each of the components used in the circuit one by one, some of which were fabricated and others purchased.

FABRICATION
FABRICATING THE SKYLIGHT DOOR & THE FRAME

The dimensions of the platform were taken (3.43*2.10m) and the door was ordered for fabrication such that it approximately covers 1/3rd area at its centre. (2*1.15m)

The door was made up of MS sheets of thickness 3mm. Stiffeners were used to give additional strength to the door.

The door was welded with latching arrangements to connect it with the ram & cylinder units.

Placing the frame & door on the platform.

HYDRAULIC SYSTEM CONNECTION AND TESTING

Hydraulic power pack, ram & cylinder units , hydraulic hand pump, direction control valve ,high pressure hoses ,T-joints, 2 way adaptors , seals and hydraulic oil were purchased. Fix 2 hoses on each of the ram & cylinder units, one on top and another below it. Connect the both hoses from the top of the ram & cylinder units by a T-joint and connect another hose on the third side of the T-joint. Similarly connect the other 2 hoses from the ram & cylinder units. Now connect 2 T-joints in each of these hoses from the other T-joints.

Connect the parallel side of the T-joints to the powerpack and the third side to hand pump connection with the help of hoses.

Blowing through the hoses with compressed air.

FIXING HYDRAULIC RAM TO THE DOOR

The top of the ram & cylinder units were fixed to the skylight door with the help of bolts & nuts. With the ram & cylinder units at 45 to the platform, mark & drill holes on either side. Insert foundation bolts on either side and cement them such that it can accommodate the base of the ram & cylinder units which can be locked by nuts.

FIXING THE LIMIT SWITCHES

Bring the door to fully open position and fix the limit switch such that it activates green light.

Bring the door to fully shut position and fix another limit switch such that it activates red light.

Fixing limit switch on to the frame.

FIXING THE RUBBER SEAL

Measure the clearance between the door & the frame with the help of VERNIER CALIPER.

Purchase the rubber seal and cut the rubber seal into the required size.

Fix the rubber seal on the frame.

Maintain 45 connection at the ends to ensure proper sealing at the corners.

Fixing rubber seal on the skylight door.

PROPERTIES OF HYDRAULIC OIL USED

Excellent wear protection, thereby ensuring longer equipment life.

Outstanding protection against oxidation. Possesses excellent water separation characteristics.

Superior deaeration properties. Very good chemical stability leading to longer oil service life.

Meets: DIN 51524 Part 1,BIS 10522-1983 & BIS 3098-1983 Specifications.

OPERATING PROCEDURE OF THE SKYLIGHT

BY MOTOR
WHILE OPENING
1.

Close the Circuit Breaker the DCV is in centre position)

2. Switch ON the motor. (the oil flows from tank to tank since Press the OPEN button to open the door till the RED light glows.
4.

3.

RED light indication implies that the door is fully open and the system is hydraulically locked. (the limit switch deactivates the solenoid and brings the DCV to centre position)

WHILE CLOSING
1.

Press the CLOSE button to close the door till the GREEN light glows.

2.

GREEN light indication implies that the door is fully shut and the system is hydraulically locked. (the limit switch deactivates the solenoid and brings the DCV to centre position)

3. Switch OFF the motor.

4.

Open the Circuit Breaker.

NOTE:
In case of emergency, release the emergency CLOSE button at any time to

shut the door. In case the power fails, the DCV comes to the centre position which implies the system is hydraulically locked and the door remains in the same position as and when the power failed.
Either wait for the power to restore and continue with the operation or use

the hand pump, which is in open deck near the skylight platform, to open/close the door.

BY HAND PUMP
WHILE OPENING 1. Bring the handle of the DCV to FWD position to open the door.
2. 3.

Operate the hand pump by hand till the RED light glows. RED light indication implies that the door is fully open.

WHILE CLOSING 1. Bring the handle of the DCV to REV position to close the door.
2.

Operate the hand pump by hand till the GREEN light glows. GREEN light indication implies that the door is fully shut.

3.

FAIL SAFE ARRANGEMENT The system incorporates a 4/3 way solenoid operated and spring centered direction control valve which helps in failsafe operation of the skylight door during power failures & blackouts.

MAINTENANCE(monthly)
Check hydraulic oil level in the powerpack reservoir and the hand p/p reservoir and replenish them accordingly.

Check all lines and joints for any leakage.

 Check water tightness of the door once in a week.

DIFFICULTIES FACED DURING THEPROJECT

Most of the problems faced during the project was based on the cost factor. For example, we found purchasing the material for the door and the frames was very costly which was managed by incorporating stiffeners which reduced the thickness of the door considerably.

We found it extremely difficult to lift the whole fabricated items which weighed 150kg and was very large(3.30*2.10m) for just the eight of us to carry them all the way to the open deck of the ship-incampus . We managed to carry it only with the help of other project mates. Although we made drill for fixing base of the ram to the cemented bolt on the wall by proper calculations and markings, while connecting they werent matching. Later we connected the ram to the door with the door slightly in open condition.

Although our electrical connections were given correctly, we didnt get the desired operations. Only later we found that we had installed N/C switch for EMERGENCY STOP instead of N/O switch.

We couldnt get matching 2-way adapters for the hand operated DCV since its ports had BSP threads. Then we had to make metric threads over the same and buy matching adapters for the same.

CONCLUSION
This project was a great opportunity for us to gain knowledge and prove our technical and practical skills. We have also learnt how to complete a project step by step, and say to keep that in working condition, more importantly how to work as a team. We had put our fullest efforts to complete theHYDRAULICALLY OPERATED SKYLIGHTproject to the best of our abilities and successfully on time. It will be useful for demonstrating purposes, bringing any large components inside the first floor from the open

deck and will also prevent rain water entering the first floor in SHIP-IN-CAMPUS. Once again we wish to thank one and all from our heart for helping us in making our project successful within time. This idea, review whatsoever we got not only helped us to finish our project, but also gave us a great confidence to face the tough tasks that may come up in our career at sea.