hydraulically operated skylight final report

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PROJECT REPORT

HYDRAULICALLY OPERATED SKYLIGHT

DEPARTMENT OF MARINE ENGINEERING

AMET UNIVERSITY

BE-8

2012



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.



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 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



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 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.



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



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



(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 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



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



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



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



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 DIAGRAM S:

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 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.



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

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.



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.



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.



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.



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



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.

hydraulically operated skylight final report

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