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PROJECT REPORT
HYDRAULICALLY OPERATED SKYLIGHT
DEPARTMENT OF MARINE ENGINEERING
AMET UNIVERSITY
BE-8
2012
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BONAFIDE CERTIFICATE
This is to certify that this project work-
“HYDRAULICALLY 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 NAME ROLL NO
1. MANOJ.B 701 B
2. MOHANKUMAR.M 709 B
3. MOHD MOHAIDEEN.M.S 711 B
4. NAGARAJAN.M 713 B
5. NIRANJAN.M 723 B6. PARTHIBAN.K 725 B
7. PRABAKARAN.E 727 B
8. PRADEEP.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.
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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.
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We would also gladly like to thank C/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 THIYAGARAJAN for giving us
approval to carry out this venture.
We like to thank C/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
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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
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The skylight was used in old ships for theillumination and the ventilation of the engineroom along with providing an opening for lowering and removing heavy items with theship 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 engineroom.
The location of the sky light should be such
that it can lower the spares near the cylinder head platform from where it can betransferred easily to the overhead crane.
In case it is not possible it should have
guide rails near the opening so that oncethe items have been lowered into the engineroom it can be easily shifted by chain blocksand physical labour is saved.
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The opening should be free of pipelines and
obstructions, so that the spares can beeasily lowered and lifted without muchmaneuvering.
Sometimes the restricted opening causes
the crane hook to catch on to someobstructions or pipelines and the spares canfall endangering life and property.
AIM
To construct a skylight and operate it hydraulically with thefollowing features:
1. Open/close by hydraulic pump(motor driven)
2. Open/close by hand pump
3. Emergency shut-off
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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 : 2m
BREADTH OF THE DOOR : 1.15m
THICKNESS OF THE DOOR : 0.003m
STROKE OF THE RAM : 0.42m
ANGLE OF OPENING : 80 DEGREE
FABRICATED ITEMS
DOOR
FRAMES
STIFFENERS
PURCHASED ITEMS
HYDRAULIC POWERPACK
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(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
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MARITIME RULESPart 40E: Design, Construction and Equipment– Sailing ShipsWatertight 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 fromoutside 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
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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-operateddoors or actuating release mechanisms on doors other than power-
operated 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
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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 steelskylights 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
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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 tothe 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
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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
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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.
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CIRCUIT DIAGRAM S:
Electrical circuit
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Fitting the electrical components to the control box.
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Hydraulic circuit
We constructed the following hydraulic circuit which fulfilled all the
conditions that were told to us.
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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 thecircuit 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.
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Placing the frame & door on the platform.
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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.
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Blowing through the hoses with compressed air.
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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.
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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.
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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.
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Fixing rubber seal on the skylight door.
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PROPERTIES OF HYDRAULIC OIL USED
Excellent wear protection, thereby ensuring longer
equipment life.
Outstanding protection against oxidation.
Possesses excellent water separation characteristics.
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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
2. Switch ON the motor. (the oil flows from tank to tank since
the DCV is in centre position)
3. Press the OPEN button to open the door till the RED light
glows.
4. RED light indication implies that the door is fully open and
the system is hydraulically locked. (the limit switch de-
activates 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.
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2. GREEN light indication implies that the door is fully shut
and the system is hydraulically locked. (the limit switch de-
activates 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. Operate the hand pump by hand till the RED light glows.
3. RED light indication implies that the door is fully open.
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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.
3. GREEN light indication implies that the door is fully shut.
FAIL SAFE ARRANGEMENT
The system incorporates a 4/3 way solenoid operated and
spring centered direction control valve which helps in fail-
safe 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.
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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-in-
campus . 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 weren’t matching. Later we connected the ram to
the door with the door slightly in open condition.
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Although our electrical connections were given correctly, we didn’t
get the desired operations. Only later we found that we had installed
N/C switch for EMERGENCY STOP instead of N/O switch.
We couldn’t 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 alsolearnt 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
the“HYDRAULICALLY OPERATED
SKYLIGHT” project to the best of our abilities andsuccessfully on time. It will be useful for
demonstrating purposes, bringing any large
components inside the first floor from the open
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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.