Part 3 Truster Control

Kongsberg Functional Design Document (KFDD)
System Configuration Thruster Control
Strategic Hull 157
Project: 20114
Product: K-Thrust RCS, Application Software
Location:
Synopsis: This document describes the scope and functions of the
Kongsberg Thruster Control K-Thrust as delivered to the
specified vessel.
Functions within other systems are not described in this
document.
Document number: 1210515 Revision: C

Customer doc no: Document version: 3.0
Contract number: NOKBGG00392-14 Number of pages: 50
Rev. Date Reason for issue Made by Checked Approved
A 16/03/12 Issued for Approval MD MP VS

B 01/09/12 Updated after Comments MD MP VS
C 13/11/12 As Built MD
D
E
F
G
H
Kongsberg Maritime AS
www.kongsberg.com
Document history
Revision Description of Change
A First Issue
B Updated after comments from EMC
C As Built document update after CAT
References
No Doc No Description
[1] 308727/A Operator Manual Kongsberg K-Thrust RCS
[2] NA PSA and FMEA for K-Thrust RCS
[3] NA VDR Telegram Specification
[4] Layout drawing Thruster Levers forward
[5] Layout drawing Indicator Panel forward
[6] Layout drawing Thruster Levers aft
[7] Layout drawing Indicator Panel aft
[8] System Topology
[9] Alarm and Instrument List (IO List)
1210515 / C / Page 2 of 56
Copyright
The information contained in this document remains the sole property of Kongsberg
Maritime AS. No part of this document may be copied or reproduced in any form or by
any means, and the information contained within it is not to be communicated to a third
party, without the prior written consent of Kongsberg Maritime AS.
Disclaimer
Kongsberg Maritime AS endeavours to ensure that all information in this document is
correct and fairly stated, but does not accept liability for any errors or omissions.
1210515 / C / Page 3 of 56
Table of contents
1 Introduction ....................................................................................................... 7
1.1 Purpose ................................................................................................................ 7
1 K-Thrust thruster control system ..................................................................... 8

1.1 General Principles of the Remote Control System ................................................ 8
1.1.1 RCS Controller Software Platform .................................................................. 8
1.1.2 Maintenance Station ........................................................................................ 8
1.1.3 Communication links ...................................................................................... 9
1.1.4 Lever panel IO principle .................................................................................. 9
1.2 RCS Main Tasks .................................................................................................. 9
2 System Overview .............................................................................................. 10

2.1 RCS controllers.................................................................................................. 10
2.1.1 Location of RCS controller cabinets .............................................................. 10
2.1.2 System start/reset .......................................................................................... 11
2.2 Control positions................................................................................................ 12
2.3 Bridge panel ...................................................................................................... 12
2.3.1 Utility panel .................................................................................................. 13
2.3.1.1 Centralized dimmer and buzzer silence................................................. 14
2.3.2 Tunnel Thruster Lever Panel (Thruster 1) ...................................................... 15
2.3.3 Azimuth Lever Panel Retractable Thrusters (Thruster 2, 3 & 4) .................. 16
2.3.4 Azimuth Lever Panel Main Propulsion Thrusters (Thruster 5, 6 & 7).......... 18
2.4 Indicators ........................................................................................................... 19
3 RCS Functions ................................................................................................. 20

3.1 Project specific solutions.................................................................................... 20
3.2 Supported RCS system modes............................................................................ 22
3.3 Configuration details: Bumpless transfer of command control............................ 23
3.4 Other project specific configuration ................................................................... 23
3.5 Alarm indication ................................................................................................ 23
3.5.1 RCS lever panel ............................................................................................ 23
3.5.2 RCS Steering Gear Alarm system .................................................................. 24
3.6 C-Joy joystick system ........................................................................................ 25
3.7 Local Control ..................................................................................................... 27
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3.7.1 Local Control Panel ....................................................................................... 27

3.7.2 Command transfer to a local panel................................................................. 28
3.7.3 Local start and stop ....................................................................................... 28
3.7.4 Indication ...................................................................................................... 29
3.7.5 Interfaced to the LCP .................................................................................... 29
4 K-chief 700 ....................................................................................................... 31

4.1 Bow Tunnel Thruster Control ............................................................................ 33
4.1.1 Start Interlocks .............................................................................................. 33
4.1.2 Safety Stop .................................................................................................... 35
4.1.3 Start Sequence ............................................................................................... 35
4.1.4 Stop Sequence ............................................................................................... 37
4.1.5 Pitch Control ................................................................................................. 38
4.1.6 DP ready Signal ............................................................................................ 38
4.2 Bow Azimuth Thruster Control .......................................................................... 39
4.2.1 Start Interlock................................................................................................ 39
4.2.2 Safety Stop .................................................................................................... 41
4.2.3 Deploy Sequence ........................................................................................... 42
4.2.4 Retract Sequence ........................................................................................... 43
4.2.5 Start Sequence ............................................................................................... 44
4.2.6 Stop Sequence ............................................................................................... 45
4.2.7 Emergency Start Sequence ............................................................................ 46
4.2.8 RPM Control ................................................................................................. 47
4.2.9 Angle Control................................................................................................ 47
4.2.10 DP ready Signal ................................................................................... 48
4.3 Aft Azimuth Thruster Control ............................................................................ 49
4.3.1 Start Interlock................................................................................................ 49
4.3.2 Start Sequence ............................................................................................... 51
4.3.3 Stop Sequence ............................................................................................... 52
4.3.4 Emergency Start Sequence ............................................................................ 54
4.3.5 Safety Stop .................................................................................................... 55
4.3.6 Power/RPM Control ...................................................................................... 55
4.3.7 Rotation Control............................................................................................ 55
4.3.8 DP ready Signal ............................................................................................ 56
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Definitions / Abbreviations
AIM Advanced Integrated Multifunction system
DNET Dual Network
ECR Engine Control Room
FS Field Station (Cabinet with controller and/or RIO modules)
FU Follow Up
IAS Integrated Automation System
IO Input / Output
ISO Isolation (ISO amplifier)
KM Kongsberg Maritime
K-Chief Kongsberg Integrated Automation System
K-Pos Kongsberg Dynamic Positioning System
K-Thrust Kongsberg Thruster Control System
LCL Lever Communication Link
NA Not Applicable
NDU Net Distribution Unit
NFU None Follow Up
OS Operator Station
PCK Process Control Kernel
PMS Power Management System
RCS Remote Control System
RCU Remote Controller Unit
RI Resistor current (RI converter)
RIO Remote Input Output Unit
RBUS Synchronous IO Bus
SW Software
VDU Video Display Unit
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1 Introduction
1.1 Purpose
The Kongsberg Functional Design Document gives an overview of the K-Thrust system
as to be delivered to the Offshore Diving Support/Construction Vessel Strategic Hull
157.
The document is in three parts. This part covers the thruster control system functions
while the project specific systems are described in separate documents.
Figure 1 Kongsberg Functional Design Structure

Part 1 Part 2 Part 3
General System K-Chief K-Thrust
Operator Interface Auxiliaries Thruster Control System
Alarm & Event system Ballast Thruster Auxiliaries
Command transfer PMS, Diesel Engines
Watch Call
Section 1 K-Thrust
This section describes the functionality of the K-Thrust system as implemented in the
K-Chief. The following control function provisions are:
General Principles
System Overview
K-Thrust Functions
Failsafe settings
Section 2 Propulsion
This section describes the functionality of the automation as implemented in the K-
Chief. The following control function provisions are:
Thruster deploy / retract sequencies
Thruster start / stop sequencies
1210515 / C / Page 7 of 56
1 K-Thrust thruster control system
1.1 General Principles of the Remote Control

System
Each propulsion unit, steering gear or thruster has its own separate remote control
system (RCS). A complete manual control system for a propulsion plant consists of a
number of parallel RCSs. Common functions for command transfer and control mode
selection at each control position synchronise the parallel systems.
In combination with other control systems, the RCS acts as the owner of the
propulsion/ thruster. It controls command access to the equipment and ensures that
transitions between control systems takes place in a safe manner. The RCS sees no
fundamental difference between a control system from KM and from other vendors,
although the integration with KM systems provides a more unified overall control
system.
As a consequence of individual RCS systems for each equipment unit, control systems
that require access to more than one unit are interfaced to the RCS systems of each of
the applicable units. KM DP control systems can do this via a LAN connection to the
RCS controllers, and in such cases the KM Independent Joystick control system must be
connected through traditional IO. Control systems from other vendors have to use serial
connections or traditional IO.
1.1.1 RCS Controller Software Platform

The RCS controller application is based on AIM. The runtime application for each
propulsion unit, steering gear or thruster is stored in the K-Chief operator stations.
1.1.2 Maintenance Station

When part of delivery, the Maintenance Station is used for configuration of the RCS
controllers via an Ethernet LAN and for system diagnostics. This station is not required
for regular operation or for viewing/ acknowledging operational alarms/ warnings.
The RCS controller has the AIM/PCK IO system, which allows transparent access to IO
signals in the RCS controller from any KM operator station connected to the same
LAN. E.g. a K-Pos or K-Chief operator station can be used for viewing IO in the RCS
controllers and for RCS system diagnostics.
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1.1.3 Communication links

The RCS controllers communicate with the Maintenance Station and other KM operator
stations and controllers via DNET local area network/ PCK. The communication
between the RCS lever panels and the RCS controller is a serial bus (SP bus), identical
to the communication link between the RCS controller and RIO units. In K-Thrust -
RCS context, this SP bus connection is referred to as the Lever Communication Link
(LCL).
1.1.4 Lever panel IO principle

The RCS controller considers the RCS lever panels as generic IO, supported by AIM/
PCK IO system. This implies that the R-bus is used as an IO bus and the panels are
considered as remote IO units with some panel-specific capabilities. With this principle,
the RCS control application is independent of the physical IO connection. The SW and
the configuration parameters that define the control capabilities are located in the RCS
controller.
1.2 RCS Main Tasks

The main functions available in the RCS controller can be summarized in the following:
Handle connected lever panels and respond to operator action

Handle command transfer between alternative control positions (panels)
Handle control system selection of the different control systems connected
(e.g. Manual Lever control, DP control system, Independent Joystick control
system, external Autopilot.)
Handle Synchronous Control between two propulsion units, steering gears
or thrusters.
Handle bumpless transfer between control positions and to Manual Lever
control from other control systems.
Execute start and stop sequences.
Execute servo loops (where applicable).
Execute load reduction (where applicable).
Run electric shaft logic (where applicable).
Handle field IO.
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2 System Overview
For a graphical overview of the delivered system, see [4, 5, 6 and 7].
2.1 RCS controllers

The basis of the K-Thrust system is that each thruster has its own dedicated RCS
controller. The RCS controller consists of one (two if redundant) Remote Control Unit
(RCU) and required number of Remote IO (RIO) units for handling field IO. The RCS
controllers are connected to each other via LAN.
2.1.1 Location of RCS controller cabinets
Cabinet ID Controller Location Remark

Type
FS31 RCU502 Thruster 1 Compartment Thruster 1
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Figure 2 System topology
2.1.2 System start/reset

When RCS controllers are started or reset, the RCU needs to load application SW into
its memory. A flash memory located in each controller will serve the controller with
SW when powered up. This loading of SW from flash gives a quick startup and makes
the system during normal operation independent of any other components / stations in
the network to serve SW.
If the delivery consists of any KM operator stations, one or more of these stations will
be set up as SW servers for the RCS controllers. When an RCU is replaced, the new
RCU will at first boot up load SW from one of these servers. Deliveries without any OS
will have a Maintenance Station to serve files in these cases.
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The controllers will only read SW from an external station the first time its started.
When a controller starts up the first time it will, in addition to load files to run the
application, also load this SW into its flash memory. The next time its restarted or reset
the SW will be read from flash memory.
2.2 Control positions

The RCS system can be operable from different control positions.
This delivery has the following setup:
Position Controllable Functions Additional equipment

name / thrusters /
Location rudders
Bridge Fwd All Thrusters Start/Stop, Mode selection, Utility panel, Indicators
Synch control
Bridge Aft All Thrusters Start/Stop, Mode selection, Utility panel, Indicators
Synch control
2.3 Bridge panel

The lever and utility panels are the user interface devices for the RCS controller. Each
lever panel within a control position communicates the states and commands for one
thruster/ propulsion unit. The utility panel is common for all thruster / propulsion units.
Colours on status lamps and buttons are used to amplify the significance of the
button/lamp:
Green lamp: Normal state (e.g. function selected / status)
Red lamp: Abnormal state ( e.g. fault / alarm)
Orange lamp: State of caution ( e.g. power limit)
White button with black text: Double push button
Black button with white text: Single push button
Flashing status lamps indicates a condition that may require operator attention.
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2.3.1 Utility panel
Figure 3 Utility Panel
The utility panel is the user interface for functions common to more than one RCS
controller. The panels are installed in control positions with lever panels for more than
one thruster unit, and provide the following functions:
Command transfer between alternative bridge control positions
System mode selection
Buzzer silence
Lamp test
Light level dimmer
Utility panels are regarded as extensions to each lever panel. Lamps and buttons of the
utility panel are wired to each panel controller as shown in figure.
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Figure 4 - Internal signal wiring in an RCS control position (example configuration)
2.3.1.1 Centralized dimmer and buzzer silence

A panel dimmer potentiometer is part of the utility panel. Through the dimmer circuits
of the panel controller, this potentiometer can be used to dim the backlight of all lever
panels, levers and instruments within the control position.
All lever panels have their own dedicated buzzer to report audible when needed for that
specific thruster/rudder. However, the silence function is centralized with one button on
the utility panel silencing all buzzers within the control position.
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2.3.2 Tunnel Thruster Lever Panel (Thruster 1)
Figure 5 - Lever Panel Tunnel Thruster
Buttons with green status lamps:

START Start thruster
STOP Stop thruster
SYNCH CMD Synchronous command function
RESET Resets the sequences, sends reset pulse to starter
LOCK TO LEVER Lock command control to the manual lever.
Emergency stop button (red) with protective cover and status lamp:
EMERG. STOP - Emergency stop the thruster
Lamps:
SHUTDOWN (Red) Thruster tripped. Operator is required to shutdown the
thruster manually.
ALARM (Red) Thruster in abnormal state
RCS FAILURE (Red) Internal RCS failure detected (e.g. IO failure, power
failure)
EXTERNAL CONTROL (Blue) Thruster controlled by external system
THRUST COMMAND (Green) Thrust can now be controlled by this lever
READY TO START (Green) Thruster is ready to be started
Indicators connected:
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Pitch and Power
2.3.3 Azimuth Lever Panel Retractable Thrusters

(Thruster 2, 3 & 4)
Figure 6 Azimuth Lever Panel

STOP Stop thruster
DEPLOY Deploy function
RETRACT Retract function
RESET Resets the sequence, sends reset pulse to VFD
Lamps:
SHUTDOWN (Red) Thruster tripped
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RCS FAILURE (Red) Internal RCS failure detected (e.g. IO failure, power failure)
POWER LIMIT (Yellow)- Load reduction active on drive
AZIMUTH COMMAND (Green) Azimuth angle can now be controlled by this
lever
Thruster 2: Rpm, Azimuth, Power
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2.3.4 Azimuth Lever Panel Main Propulsion Thrusters

(Thruster 5, 6 & 7)
Figure 7 Azimuth Lever Panel

STOP Stop thruster
RESET Resets the sequence, sends reset pulse to VFD
POWER MODE Power Mode function
Lamps:
SHUTDOWN (Red) Thruster tripped
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RCS FAILURE (Red) Internal RCS failure detected (e.g. IO failure, power failure)
POWER LIMIT (Yellow) - Power reduction is requested.
AZIMUTH COMMAND (Green) Azimuth angle can now be controlled by this
lever
Thruster 5: Rpm, Azimuth, Power, independent from RCS
2.4 Indicators
Most of the indicators are connected to the RCS panel controllers and fed with feedback
information from the RCS controllers. However, there are some indicators which are
directly wired to the feedback potentiometers on the thrusters /steering gear.
The rudder angle panorama indicators are wired directly to the feedback potentiometers.
1210515 / C / Page 19 of 56
3 RCS Functions
3.1 Project specific solutions

All standard RCS functions are described in the Operator Manual [1]. However, there
might be functions that, because of special external equipment or special requests, have
been modified for the project. These solutions will be listed in the table below and
described in detail in chapters 4.2 ->.
Funtion: Standard CONFIGURATION FOR THIS VESSEL

function
reference:
Control system [1] chap 3.1 See chap. 3.2 for details included modes.
selection
Start and Stop [1] chap 3.2 See chapters: 4.1.4, 4.1.5, 4.2.4 4.2.7, 4.3.2, 4.3.3 for start,
functions stop, deploy and retract details.
Transferring [1] chap 3.3 No project specific solutions. Configured with TAKE/GIVE
command control button and not only TAKE due separate bridges.
Within bridge
Transferring [1] chap 3.3 NA

command control
Between ECR and
bridge
Bumpless transfer [1] chap 3.4 See chap. 4.3 for bumpless transfer configuration for this
of command control vessel.
Power mode [1] chap 3.5 No project specific solutions. Power mode button for operator
function selection of function is provided on thrusters 5, 6 and 7.
Cruise function [1] chap 3.6 No project specific solutions. No button for operator selection
of function is provided.
Synchronous [1] chap 3.7 No project specific solutions.
1210515 / C / Page 20 of 56
command function
Lock Lever [1] chap 3.8 No project specific solutions.

function
Deploy function [1] chap 3.9 No project specific solutions.
Retract function [1] chap 3.10 No project specific solutions.
Combinator [1] chap 3.10 Not applicable.

function
Separate function [1] chap 3.11 Not applicable.
RPM High function [1] chap 3.12 Not applicable.
RPM Low function [1] chap 3.13 Not applicable.
DP Control [1] chap 3.14 No project specific solutions.

functions DP
Manual button
DP Control [1] chap 3.14 No project specific solutions.

functions DP
Enable button
Steering wheel [1] chap 3.15 Not applicable.

function
Electrical shaft [1] chap 3.16 Not applicable.
1210515 / C / Page 21 of 56
3.2 Supported RCS system modes

The RCS supports the following modes.
MANUAL : In this mode the control is on manual levers. When mode is enabled the
manual status lamp is lit. Thrust control is on lever when Thrust Command
status lamp is steadily lit and azimuth control when Azimuth Command
lamp is steadily lit. In case of one of these status lamps flashing, bumpless
function is active and command must be picked up to achieve control on
lever.
DP : The RCS controllers are set up to read all thruster force and direction
commands from the DP control system. Other command privileges remain
within the RCS, except start/stop of thruster/propulsion which can be shared
with the DP control system. DP system contains own autopilot function.
INDEP. : The RCS controllers are set up to read all thrusters rpm and direction
JOYSTICK commands from the Independent Joystick system. Other command privileges
remain within the RCS. Joystick system contains own autopilot function.
AUTO PILOT : NA
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3.3 Configuration details: Bumpless transfer of

command control
The bumpless function can be activated for different cases of transferring command.
The table below shows this vessels configuration of the bumpless function.
Bumpless function: Active: Remark:
Transfer of command control between control YES

positions on bridge
Transfer of command control from DP, Joystick YES

or Autopilot to Manual lever control
Changing group master when the Synchronous YES These two are covered by the
command function is enabled same parameter in SW. Both are
either active or disabled.
Disabling the Synchronous command function YES
Changing from DP Enable to DP Manual control NO
3.4 Other project specific configuration

The failsafe setting returns the Azimuth and Rpm set points to zero in JS and DP mode.
While the set points freezes Manual Mode.
3.5 Alarm indication

3.5.1 RCS lever panel
There are three lamps on each RCS lever panel used for alarms and failures in the
system.
SHUTDOWN lamp
ALARM lamp
RCS FAILURE lamp
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Shutdown lamp - The Shutdown lamp is used for thruster tripped conditions. The
lamp will be flashing when the thruster has tripped, and otherwise will stay dark. The
lamp condition is controlled by an external signal given from the thruster, and a reset of
the alarm must be done on the thruster.
Together with visual indication there will be a buzzer giving audible indication. This
buzzer is set of by the RCS controller when a Shutdown condition is given by the
thruster. The silence button on the Utility panel must be used to silence the buzzer.
Alarm lamp - Alarms that are generated from the thrusters will be displayed by light in
the Alarm lamp on each lever. The Alarm lamp will flash when unacknowledged. If
there are no active alarms in the system, the lamp will be dark. The lamp condition is
controlled by an external signal given from the thruster, and a reset of the alarm must be
done on the thruster.
Together with visual indication there will be a buzzer giving audible indication. This
buzzer is set of by the RCS controller when an Alarm condition is given by the thruster.
The silence button on the Utility panel must be used to silence the buzzer.
RCS Failure lamp The RCS Failure lamp is used for visual indication of an
abnormal state in the RCS system. This will be given together with an audible
indication, which must be silenced from the Silence button on the utility panel.
The RCS Failure lamp will flash as long as there are unacknowledged alarms in the
system, and be steady lit if all alarms are acknowledged but system still is in abnormal
state. To find out which system failure that has been detected, the operator must use the
message view on a KM operator station (if available) or the Maintenance Station.
3.5.2 RCS Steering Gear Alarm system

The RCS Steering Gear Alarm system consists of a 15 screen with an integrated
computer which provides required visual alarms for steering gear on bridge. Alarms and
essential information is received at the alarm unit through LAN from the dedicated RCS
controllers for steering gear (or main azimuth).
Figure 8 shows information displayed on screen.
1210515 / C / Page 24 of 56
Figure 8 Steering Gear Display
3.6 C-Joy joystick system

A separate independent joystick system is connected directly to the thruster control
system. Everything is separated from the DP control network. The RPM and azimuth
command will be connected directly to the thrusters control cabinets which is connected
to the VFD and ACU systems.
1210515 / C / Page 25 of 56
Figure 9 - Standard Independent Joystick configuration
Note! Strategic H157 have two cJoy Operator Terminals (one on each bridge) and
one cJoy Wing Terminal.
1210515 / C / Page 26 of 56
3.7 Local Control

3.7.1 Local Control Panel
The aft azimuth thrusters can be controlled locally from the Local control panel (LCP).
Local control panels are located in the thruster controller cabinet door. The functions of
the panel are the same as for the lever panels, with the following exceptions:
The lever is replaced by increase/ decrease and clockwise/ counter clockwise
command buttons
Local/ Remote command changeover switch
This panel works as a pseudo NFU panel, as the increase/ decrease and clockwise/
counter clockwise switches will not act directly on the equipment but increment/
decrement the commands going into the thruster servo control loop.
1210515 / C / Page 27 of 56
Figure 10 - Thruster Local Control panel layout
Note: The Emergency Stop signals are hardwired directly to the thruster main circuit
breaker control circuit in the converter and open immediately the main circuit breaker.
3.7.2 Command transfer to a local panel

Command transfer to a local panel is by taking the command at the panel. This is
possible independent of the current RCS mode.
3.7.3 Local start and stop

It will be possible to start and stop the thruster from the local panel when command is
taken at the panel. The start/stop signal will trig the same sequence as when start/stop is
pressed on the bridge lever panels.
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3.7.4 Indication
When a thruster/propulsion unit is taken in local control, an External Ctrl status lamp
on the corresponding RCS lever panel(s) will be lit.
3.7.5 Interfaced to the LCP
FD Tag Description Remarks

Ready to Start Green Light
Running Green Light
Failure Red Light, Common Failure

Speed Feed back 0-100 % speed indication. The
indication will switch to speed set point
indication when a speed decrease or
increase command is active.
Azimuth Feedback 0-360 deg angle indication. The
indication will switch to azimuth set
point indication when azimuth CW or
CCW command is active.
1210515 / C / Page 29 of 56
FD Tag Description Remarks

Remote Control Mode Switch, with flip over cover
Start Push Button

Stop Push Button
Emergency Stop Push Button with cover, Hardwired
directly to thruster feeder breaker.
Speed Increase Will ramp the speed setpoint to 100
Command
Speed Decrease Will ramp the speed setpoint to 0
Command
Azimuth CW Command Will ramp the azimuth angle set point
CW
Azimuth CCW Will ramp the azimuth angle set point
Command CCW
1210515 / C / Page 30 of 56
4 K-chief 700
The ship is equipped with:
Main Azimuth thrusters: 3 x 2200 kW Rolls Royce Aquamaster FP
Fwd Azimuth thrusters: 3 x 1500 kW Rolls Royce Aquamaster UL 205 FP
Fwd Tunnel thruster: 1 x 1350 kW Rolls Royce Ulstein TT 2400
All thrusters are controlled via frequency converters. The thruster control system
consists of the following main units:
K-Pos OS Dynamic Positioning Operator Station
DPC-22 Dynamic Positioning Controller - Redundant
DPC-12 Dynamic Positioning Controller Fire Backup
K-Chief OS Vessel Control Operator Stations
RCU Remote Control Units
cJoy Joystick Operator Terminal
cJoy Joystick Controller
Redundant data network
1210515 / C / Page 31 of 56
P ower
K -Thrust K -Pos Process P ower Lim it S ignal
S tation
Network A
Network B
B us bar
Caterpillar
Rolls-Royce
Control
Cabinet
Luboil
Sys tem
M ain E -
M otor
T hruster
P roces s
Station
M otor
Tem perature
F requency
Controller
S teering
F eedbac k
S teering
Hydraulic
S teering
Starter B ox
No.1
S teering
Starter B ox
No.2
Figure 11 The Thruster Control System.
The start/stop functions are performed from the TC system or from the local control
places. A start command will in sequence close the main contactor, excitation of
converter, enable the frequency converter and accelerate the drive to the reference
value.
A stop command will disable the inverter (RPM = 0 command) and switch off the
converter by opening the main contactor.
Thrusters that were running will be reconnected after a blackout on the main
switchboard. Commands to the converters will be set to zero.
1210515 / C / Page 32 of 56
4.1 Bow Tunnel Thruster Control

The one Rolls Royce TT 2400 tunnel thruster in the bow is pitch controlled with fixed
rpm. The control system consists of the following main tasks:
Pitch setting
Alarm monitoring
Fail safe consideration
Command transfer
4.1.1 Start Interlocks

Signal that will cause start interlock. There are 3 groups of interlocks:
Control Set:
FD Tag Signal Range Setp Type Delay Remarks
Tc1PitchCtr Lever Order -100% -10%< AI Start is interlocked if

not zero 100% condition not OK
<10%
404.01.UA.04 Emergency DI Start is interlocked

Stop Active when active
405.01.MC.01 Hydraulic DI Start is interlocked

Pump Ready when not active
(remote or
running)
722.01.MC.01 Cooling DI Start is interlocked

Pump Ready when not active
(remote or
running)
404.01.MC.01 Starter DI Start is interlocked

Remote when not active
404.01.YS.01 Starter DI Start is interlocked

Ready when not active
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If one of the above conditions is not fulfilled, system will not allow to start thruster.
Operator is required to do necessary actions (Check status of Lever/pumps/Emergency
Stops etc.).
Software Interlock:
404.01.MC.01 Starter Error DI Start is interlocked if

signal active
404.01.MC.01 Internal DI Start is interlocked

Shutdown when active
Active
722.01.MC.01 CW Pump Error DI Start is interlocked

when active
Tc1Blackout Blackout DI Start is interlocked

when active
404.01.YS.01 Ready to Start DI Start is interlocked

when signal not
received
Tc1Seqadm Sequence DI Start is interlocked

Timeout when active

Pump Error when active
If one of the above conditions is not fulfilled, system will not allow to start thruster.
Operator is required to do necessary actions (reset alarms).
Hardware interlock:
404.01.MC.01 Starter Tripped DI Start is interlocked if

signal not is received
404.01.UA.03 Transformer DI Start is interlocked

temp high when active
1210515 / C / Page 34 of 56
404.01.UA.01 Starter internal DI Start is interlocked

failure when active
405.01.MC.01 Hydr Pump DI Start is interlocked

Tripped when active
722.01.MC.01 Cooling Water DI Start is interlocked

Pump Tripped when active
405.01.UA.03 Hydr Pump DI Start is interlocked

Overload when active
If one of the above conditions is not fulfilled system will not allow to start thruster.
Operator is required to do necessary actions in the field. Check Pumps / Starter.
Analogue signal that is out of range (sensor error) will not cause interlock of thruster,
except for feedback error.
4.1.2 Safety Stop

The starter cabinet handles all shutdowns.
4.1.3 Start Sequence

The Start sequence is available from the location in command. The Start Lamp will
flash while the sequence is active. Failure of each step will cause and indication with
error message on sequence control module. Condition not fulfilled in the step will be
shown.
Step Description Next step if not OK
1 Reset Starter / SW modules
2 Set Auto and Start CW Pump (Check Running Feedback)
Set Auto and Start Hydr. Pump (Check Running

3
Feedback)
4 Check Hydr. Oil Pressure (Low or High Press. Alarm)
5 Set Zero Pitch (Start Interlock in Starter)
6 Check Zero Pitch
1210515 / C / Page 35 of 56
7 Heavy Consumer Power Request
8 Start Thruster Motor
9 Check Main Breaker (Check if closed)
10 Check Running Feedback
11 Sequence Finished
1210515 / C / Page 36 of 56
4.1.4 Stop Sequence

The Stop sequence is available from the location in command. The Stop Lamp will
flash while the sequence is active. Failure of each step will cause and indication with
shown.
1 Reset Starter / SW Modules
2 Set Zero Pitch
3 Check Zero Pitch
4 Stop Thruster Motor
5 Check Running Feedback from Thruster
6 5 min delay
7 Stop Servo Pump (Check Running Feedback)
8 5 min delay
9 Stop Cooling Pump (No Running Feedback)
1210515 / C / Page 37 of 56
4.1.5 Pitch Control

Tunnel Thruster Pitch Setting:
The speed setting is performed either from the DP or TC units if thruster is ready for
remote operation. The speed command is routed via the network to the K-Chief process
station located near the thruster.
The pitch is controllable from +100% to -100%.
FD Tag: Signal: Range: Type: Remarks:
Pitch command +/-100% 4-20mA
Power feedback 0-1350 kW 4-20mA Max: 1350 kW
4.1.6 DP ready Signal

Signal required to get ready for DP.
FD Tag Signal Range Type Remarks
Ready2 (Ready +Running) DI
In order to be able to select the thruster into DP control the signal DP Ready must be
received. In case the DP Ready is lost during DP operation the actual thruster will be
automatically deselected from the DP control.
1210515 / C / Page 38 of 56
4.2 Bow Azimuth Thruster Control

The three Rolls Royce Aquamaster UL 205 FP retractable azimuth thrusters is speed
controlled with fixed pitch position. The control system consists of the following main
tasks:
Enabling of frequency control
Speed setting
Azimuth setting
Deploy / Retract sequence
Alarm monitoring
Failsafe consideration
Command transfer
4.2.1 Start Interlock

Signal that will cause start interlock.
Control Set:
Tc1SpeedCtr Lever Order 0 -100% <10% AI Start is interlocked if

not zero condition not fulfilled.
404.02.YS.08 MSB Stop DI Start is interlocked if

Command signal is received.
404.02.UA.01 Emergency Start is interlocked if

Stop Activated signal is received.
405.02.MC.01 Hydraulic DI Start is interlocked if

Pump Ready condition not fulfilled.
(remote or
running)
722.01.MC.01 Cooling Pump DI Start is interlocked if

Ready (remote condition not fulfilled.
or running)
Tc2ExtCtr Local Control DI Start is interlocked if

Selected signal is received.
1210515 / C / Page 39 of 56
404.01.MC.01 VFD Remote DI Start is interlocked if

signal is not received.
Stops etc.).
Software Interlock:
404.02.MC.01 VFD Error DI Start is interlocked if

signal active

Active
722.01.MC.01 CW Pump DI Start is interlocked

Error when active

when active

Timeout when active

HW Interlock:
404.02.YS.01 VFD Ready for DI Start is interlocked if

Use signal not is received.
1210515 / C / Page 40 of 56
722.01.MC.02 CW Pump DI Start is interlocked if

Tripped signal is received.
405.01.UA.03 Hydraulic DI Start is interlocked if

Pump signal is received.
405.01.UA.04
Overload or
Phase fault

Pump Trip signal is received.
404.01.MC.01 VFD Common DI Start is interlocked if

Trip signal is received.
404.01.YS.16 VFD External DI Start is interlocked if

Conditions not signal is received.
OK
404.02.YS.04 Thruster DI Start is interlocked if

Deployed and signal is not received.
Shaft Engaged
405.02.UA.01 ACU Failure DI Start is interlocked if

signal is received.
404.02.YS.12 RR Startup DI Start is interlocked if

Allowed signal is not received.
404.02.YS.13 Rolls Royce DI Start is interlocked if

Clutched in signal is received.
4.2.2 Safety Stop

The frequency converter handles all shutdowns.
1210515 / C / Page 41 of 56
4.2.3 Deploy Sequence

The Deploy sequence is available from the location in command. The Deploy Lamp
will flash while the sequence is active. Failure of each step will cause and indication
with error message on sequence control module. Condition not fulfilled in the step will
be shown.
The Deploy Lamp will flash while the sequence is active.
1 Ships Speed OK? (<3 Knots)
2 Check if Lift / Lowering Pump Remote
3 Thruster in Liftable Direction?
3 Start Lowering (Check Running Feedback)
No Stop Lifting/Lowering Command (Termination of

4
sequence)
5 Unit Down and Shaft Engaged?
6 Sequence Finished
1210515 / C / Page 42 of 56
4.2.4 Retract Sequence

The Retract sequence is available from the location in command. The sequence can be
activated when the drive is stopped. Failure of each step will cause and indication with
shown.
The Retract Lamp will flash while the sequence is active.
1 Ships Speed OK? (<3 Knots)
2 Thruster Not Running?
3 Hydraulic Steering Pump Remote?
4 Lifting Pump Remote?

If Thruster in liftable
5 Thruster not in Liftable Direction? Direction jump to 10.
6 Thruster Down?
7 Set Auto and Start Hydraulic Steering Pump
8 Set Liftable Direction (Azimuth 0 command)
9 Thruster in Liftable Direction?
10 Wait 5 sec.
11 Stop Hydraulic Steering Pump
12 Retract Command.
8 Lift Pump Running?
9 Unit Lifted and Locked?
1210515 / C / Page 43 of 56

The Start sequence is available from the location in command. The sequence can be
shown.
The Start Lamp will flash while the sequence is active.
1 Thruster Down and Engaged?
5 Breaker Ready?
6 VFD Ready for Use?
7 Start CW Pump (Check Running Feedback)
8 Start Hydr. Pump (Check Running Feedback)
9 Check Hydr. Oil Pressure
10 Start VFD Command

12 (if Starting feedb. Not
11 Starting Feedback? received)
12 Running Feedback?
1210515 / C / Page 44 of 56
4.2.6 Stop Sequence

The Stop sequence is available from the location in command. The sequence can be
shown.
The Stop Lamp will flash while the sequence is active.
1 Set Liftable Direction

3 i(f not in Liftable
2 Check Liftable Direction Direction)
3 Stop Command to Thruster

5 (if Stopping feedback
4 Stopping Feedback? not received)
5 Not Running Feedback?
6 Wait 5 sec
7 Stop Command to Hydraulic Pump
8 Hydraulic Pump not Running?
1210515 / C / Page 45 of 56
4.2.7 Emergency Start Sequence

The Emergency Start sequence is available from the thrusters mimic. The sequence
can be activated when the drive is stopped. Failure of each step will cause and
indication with error message on sequence control module. Condition not fulfilled in the
step will be shown.
The Start Lamp will flash fast while the sequence is active.
1 Activate alarm Thruster Emergency Start
2 Thruster Down and Engaged?
3 Reset Drive command
5 (if pump not started)

5 Wait 2 sec
6 Start Hydr. Pump (Check Running Feedback) 7 (if pump not started)
7 Wait 4 sec
8 Start VFD Command

11 Sequence finished
1210515 / C / Page 46 of 56
4.2.8 RPM Control

Azimuth Thruster Speed Setting:
The speed setting is performed either from the DP or TC if thruster is ready for remote
operation. The speed command is routed via the network to the K-Chief process station
located near the thruster.
The rpm rotational direction is controllable from 0% to +100% rotation. The feedback
signals from the converter are speed and power.
Rpm command 0-100% 4-20mA
Rpm feedback 0-1800 rpm 4-20mA Max: 1800 rpm
4.2.9 Angle Control

The angle setpoint is controllable from -180 to +180 angle. The feedbacks for the
angle are the two signals sinus and cosine that is installed on the Rolls Royce
Aquamaster.
Angle command 180 4-20mA
Angle feedback Sinus 1 4-20mA Signal from Resistor Potmeter converted

to 4-20mA
Angle feedback 1 4-20mA Signal from Resistor Potmeter converted

Cosine to 4-20mA
1210515 / C / Page 47 of 56

Signal required to get a ready for DP.
FD Tag Signal: Range Type Remarks
Converter Running DI
Aquamaster Ready DI
UL unit down DI
In order to be able to select the thruster into DP control the DP Ready signal must be
1210515 / C / Page 48 of 56
4.3 Aft Azimuth Thruster Control

The three Rolls Royce Aquamaster Azimuth Thrusters are speed controlled with fixed
pitch position. The control system consists of the following main tasks:
Enabling of frequency control
Speed setting
Azimuth setting
Alarm monitoring
Fail safe consideration
Command transfer
4.3.1 Start Interlock

Signal that will cause start interlock.
Control Set:
Tc5SpeedCtr Lever Order 0 -100% <10% AI Start is interlocked if

not zero condition not fulfilled.
404.05.YS.08 MSB Stop DI Start is interlocked if

(404.06.YS.08 Command signal is received.
and
404.06.YS.09
for Thruster 6)
404.05.UA.04 Emergency Start is interlocked if

Stop Activated signal is received.

Pump Ready condition not fulfilled.
(remote or
running)
722.01.MC.05 Cooling Pump DI Start is interlocked if

Ready (remote condition not fulfilled.
or running)
1210515 / C / Page 49 of 56
Tc5ExtCtr Local Control DI Start is interlocked if

Selected signal is received.
404.05.MC.01 VFD Remote DI Start is interlocked if

signal is not received.
Stops etc.).
Software Interlock:
404.02.MC.01 VFD Error DI Start is interlocked if

signal active

Active
722.01.MC.01 CW Pump DI Start is interlocked

Error when active

when active

Timeout when active

1210515 / C / Page 50 of 56
HW Interlock:
404.02.YS.01 VFD Ready for DI Start is interlocked if

Use signal not is received.
722.01.MC.02 CW Pump DI Start is interlocked if

Tripped signal is received.
405.01.UA.03 Hydraulic DI Start is interlocked if

Pump signal is received.
405.01.UA.04
Overload or
Phase fault

Pump Trip signal is received.
404.01.MC.01 VFD Common DI Start is interlocked if

Trip signal is received.
404.01.YS.16 VFD External DI Start is interlocked if

Conditions not signal is received.
OK
405.02.UA.01 ACU Failure DI Start is interlocked if

signal is received.

The Start sequence is available from the location in command. The sequence can be
shown.
The Start Lamp will flash while the sequence is active.
1210515 / C / Page 51 of 56
4 Breaker Ready (at least one breaker for Thruster 6)?
5 VFD Ready for Use?
7 Start Hydr. Pump (Check Running Feedback)
8 Check Hydr. Oil Pressure
9 Start VFD Command

4.3.3 Stop Sequence

The Stop sequence is available from the location in command. The sequence can be
shown.
The Stop Lamp will flash while the sequence is active.
1 Stop Command to Thruster

3 (if Stopping feedback
2 Stopping Feedback? not received)
3 Not Running Feedback?
4 Wait 5 min
5 Stop Command to Hydraulic Pump
6 Running Feedback?
1210515 / C / Page 52 of 56
7 Wait 5 min
8 Stop Command to Cooling Water Pump
9 Running Feedback?
1210515 / C / Page 53 of 56
4.3.4 Emergency Start Sequence

The Emergency Start sequence is available from the thrusters mimic. The sequence
can be activated when the drive is stopped. Failure of each step will cause and
indication with error message on sequence control module. Condition not fulfilled in the
step will be shown.
The Start Lamp will flash fast while the sequence is active.
1 Activate alarm Thruster Emergency Start
2 Reset Drive command
4 (if pump not started)

4 Wait 2 sec
5 Start Hydr. Pump (Check Running Feedback) 6 (if pump not started)
6 Wait 4 sec
7 Start VFD Command

9 Running Feedback?
10 Sequence finished
1210515 / C / Page 54 of 56
4.3.5 Safety Stop

The frequency converter handles all shutdowns.
4.3.6 Power/RPM Control

The converter reference has to modes, rpm mode or power mode. The mode for the
converter is selected on the K-Chief operation station and will be set equal for all
thrusters.
Azimuth Thruster Speed Setting:

The speed setting is performed either from the DP or TC if thruster is ready for remote
operation. The speed command is routed via the network to the K-Chief process station
located near the thruster.
The rpm is controllable from 0% to +100%. The feedback signals from the converter are
speed and power.
Rpm command 0-100 % 4-20mA
Rpm feedback 0-2051 rpm 4-20mA Max: 2051 rpm
4.3.7 Rotation Control

The angle set point is controllable from -180 to +180 angle. The feedbacks for the
angle are the two signals sinus and cosine that is installed on the Rolls Royce
Aquamaster.
Angle command 180 4-20mA
Angle feedback Sine 1 4-20mA Signal from Resistor Potmeter

converted to 4-20mA
Angle feedback 1 4-20mA Signal from Resistor Potmeter

Cosine converted to 4-20mA
1210515 / C / Page 55 of 56

Signal required to get ready for DP.
Converter Running DI
Aquamaster Ready DI
Regulation mode selection DI Rpm Mode is selected
In order to be able to select the thruster into DP control the DP Ready signal must be
1210515 / C / Page 56 of 56

Part 3 Truster Control

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Part 3 Truster Control

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Kongsberg Functional Design Document (KFDD)

System Configuration Thruster Control

Strategic Hull 157

Document number: 1210515 Revision: C

A 16/03/12 Issued for Approval MD MP VS

Revision Description of Change

B Updated after comments from EMC

C As Built document update after CAT

[1] 308727/A Operator Manual Kongsberg K-Thrust RCS

[2] NA PSA and FMEA for K-Thrust RCS

[3] NA VDR Telegram Specification

[4] Layout drawing Thruster Levers forward

[5] Layout drawing Indicator Panel forward

[6] Layout drawing Thruster Levers aft

[7] Layout drawing Indicator Panel aft

[8] System Topology

[9] Alarm and Instrument List (IO List)

1 K-Thrust thruster control system ..................................................................... 8

2 System Overview .............................................................................................. 10

3 RCS Functions ................................................................................................. 20

3.7.1 Local Control Panel ....................................................................................... 27

4 K-chief 700 ....................................................................................................... 31

Figure 1 Kongsberg Functional Design Structure

1 K-Thrust thruster control system

1.1 General Principles of the Remote Control

1.1.1 RCS Controller Software Platform

1.1.2 Maintenance Station

1.1.3 Communication links

1.1.4 Lever panel IO principle

1.2 RCS Main Tasks

Handle connected lever panels and respond to operator action

2.1 RCS controllers

2.1.1 Location of RCS controller cabinets

Cabinet ID Controller Location Remark

FS31 RCU502 Thruster 1 Compartment Thruster 1

FS32 RCU502 Thruster 2 Compartment Thruster 2

FS33 RCU502 Thruster 3 Compartment Thruster 3

FS34 RCU502 Thruster 4 Compartment Thruster 4

FS35 RCU502 Thruster 5 Compartment Thruster 5

FS36 RCU502 Thruster 6 Compartment Thruster 6

FS37 RCU502 Thruster 7 Compartment Thruster 7

Figure 2 System topology

2.1.2 System start/reset

2.2 Control positions

Position Controllable Functions Additional equipment

2.3 Bridge panel

2.3.1 Utility panel

Figure 3 Utility Panel

Figure 4 - Internal signal wiring in an RCS control position (example configuration)

2.3.1.1 Centralized dimmer and buzzer silence

2.3.2 Tunnel Thruster Lever Panel (Thruster 1)

Figure 5 - Lever Panel Tunnel Thruster

Buttons with green status lamps:

Pitch and Power

2.3.3 Azimuth Lever Panel Retractable Thrusters

Figure 6 Azimuth Lever Panel

Buttons with green status lamps:

2.3.4 Azimuth Lever Panel Main Propulsion Thrusters

Figure 7 Azimuth Lever Panel

Buttons with green status lamps:

3.1 Project specific solutions

Funtion: Standard CONFIGURATION FOR THIS VESSEL

Transferring [1] chap 3.3 NA

Synchronous [1] chap 3.7 No project specific solutions.