Training Manual
K-Pos Systems
Introduction
The range of K-Pos DP systems provides functions which fulfil the requirements for the
International Maritime Organisation (IMO) and all major classification societies, in
combination with an independant joystick control system. The K-Pos DP system is type-
approved by Det Norske Veritas (DNV) and American Bureau of Shipping (ABS).
The Heading Control System (HCS) (Autopilot) has a mark of conformity (wheelmark) in
accordance with the Marine Equipment Directive (MED) (EU Council Directive 96/98/EC on
marine equipment) of the European Union.
• The stand-alone systems interface with other systems, such as power plant and
thrusters, via conventional signal cables and serial lines.
• The integrated systems communicate with other KONGSBERG systems such as
K-Chief (MarineAutomation) andK-Thrust (Thruster Control) via a dual ethernet
LAN.
The design gives the K-Pos concept a high degree of flexibility and extensive possibilities for
upgrading. In addition, the K-Pos concept has a number of options in order to adapt to various
demands and safety requirements.
The K-Pos systems are based on a small number of flexible hardware units which form the
building modules of the different system types. The same modules are also used as the
building blocks for integrated systems.
The following table shows the basic systems within the K-Pos DP family.
System
DP-11 Stand-alone single DP control system
DP-12 Integrated single DP control system
DP-21 Stand-alone dual-redundant DP control system
DP-22 Integrated dual-redundant DP control system
DP-31 Stand-alone triple-redundant DP control system
DP-32 Integrated triple-redundant DP control system
The flexibility of the K-Pos concept means that systems designed for a particular class
notation can be easily upgraded to fulfil the requirements of a higher class, as shown in the
table below. The table shows the basic system types and the corresponding IMO Equipment
Class. The remarks indicate the first stage of the upgrading possibilities. The flexibility of the
K-Pos concept allows a simple upgrade path.
The IMO Equipment Classes are defined in the IMO MSC/Circ.645 Guidelines For Vessels
With Dynamic Positioning Systems.
Hardware concept
DPC-2
RCU RCU To
To
NET 501 Red.Net 501 NET Field
Field PSU 1
A PSU 3 A B B
B
3
RSER
RSER
RSER
RMP
RSER
RMP
RMP
RMP
RMP
RMP
RMP
RMP
A
1
Legend:
RBUS A
RBUS B
U41-47 U71-77 NET A
RMP
RMP
RMP
RMP
RMP
RMP
RMP
RMP
RMP
RMP
RMP
RMP
RMP
RMP
NET B
SERIAL
(OPTION) (OPTION)
Section-A Section-B
RSER200 Serial
communication module
Redundant power
Controller Cabinets
Network
The network used is an industrial Local Area Network (LAN) compatible with the Ethernet
IEEE 802.3 standard. The network is organised as a star-shaped structure with a switch at its
centre. Designing networks with switches gives the opportunity to segment the network traffic
in integrated systems. Dual- and triple-redundant stand-alone K-Pos systems, and all
integrated K-Pos systems, use a dual-redundant network comprising two separate but identical
networks (A and B). In integrated K-Pos systems, switches are installed in wall-mounted
cabinets known as Network Distribution Units (NDU). Several interconnected NDUs may be
used, depending on the scope of the system.
Dual Redundancy
The most common redundancy concept for dynamic positioning systems is the use of
redundant sensors (two or more) and a dual computer system. The dual system, often referred
to as “online” and ”hot standby”, significantly increases the total availability and reliability of
a system compared to a single system. The following list specifies the main advantages of
redundancy:
• No single-point failure
The system is designed to avoid total system failure if single failure occurs.
• Failure detection
The system will detect a failure, allowing corrective actions to be taken.
• Fault isolation
If one system component fails, the other components will not be affected.
• Switchover to hot standby
If the online computer in a dual-redundant system fails, a successful switchover to
the hot-standby computer takes place automatically.
The system provides redundancy in accordance with Class 2 requirements. The two controller
computers are separate and operate independently of each other. The operator may choose
which computer is to be online, while the other computer acts as the hot standby.
The two computers operate in parallel, each receiving the same input from the operator,
sensors, reference systems and thrusters, and each performing the same calculations.
However, only the online computer can control the thruster system. A switchover is activated
either automatically, if a failure is detected in the online computer, or manually by the
operator. Automatic switching is allowed only once. The operator must explicitly enable any
further automatic switching.
Both control computers are continuously checked for both hardware and software failures. If a
failure is detected, a warning or alarm is given.
The three DP control computers perform the same positioning tasks. Each individual
computer uses the same data from each of the sensors and position-reference systems to
calculate the command signals to the thrusters/propellers.
The concept of majority voting is used to detect and isolate faults in the sensors and in the K-
Pos system itself. Once the voting has taken place, the failed (incorrect) computer will, if
possible, correct itself automatically, based on the values of the other computers. If the failed
computer cannot correct itself, the operator is informed and the faulty computer should be
replaced. Meanwhile, the two other computers continue working and perform dual-
redundancy procedures in the same way as a dual system. The system will automatically
reconfigure itself to a triple-redundant system as soon as the failed computer is replaced.
All three control computers perform voting, but only one of the control computers (the
“master” computer) communicates with the operator stations and outputs serial-line
information. The operator can explicitly select the computer that is to be the master.
If the present “master” computer should fail, another computer will immediately take over the
“master” responsibility.
The main advantages of triple redundancy are:
• Voting of sensor input signals
The voting is performed between tightly synchronised computers to:
- Detect sensor errors such as compass drift and sensor breakdown.
- Ensure that all three computers use the same data as a basis for
calculation of command signals.
• Software Implemented Fault Tolerance (SIFT)
The Triple Modular Redundancy (TMR) detects an error in the processing
elements and corrects the error by employing voting algorithms. The system
represents a Software Implemented Fault Tolerance (SIFT) concept.
• Voting on command (output) signals
- DP-31: The thruster commands from the three control computers are
compared by the “master” computer and the median command is
selected to be the final output.
- DP-32: The voting of the thruster commands is performed in the
thruster control field station.
• No single-point failure
The system is designed to avoid total system failure if single failure occurs.
• Failure detection
The system will detect a failure, allowing corrective action to be taken.
• Fault isolation
If one system component fails, the other components will not be affected.
• No standby unit, all computers are “hot”
If one DP control computer fails in a triple-redundancy system, the two other
computers continue working and perform dual-redundancy procedures in the same
way as a dual system. Should a second computer failure take place, there is an
automatic switchover to the remaining computer.
• Hot repair
It is possible to replace a computer while the other computers continue the
operation.
K-Pos DP-31 Standard System
Operator Stations
Additional DP operator stations can be connected to the data network. Each operator station
operates independently. Command of the vessel can easily be transferred between the operator
stations.
Operator Terminals
Operator terminals (cJoy DP-OT) can be connected to the data network. Each terminal
operates independently. Command of the vessel can easily be transferred between the operator
stations and operator terminals.
Wing Terminals
Wing terminals (cWing) can be connected to one of the operator stations/terminals. Command
of the vessel can easily be transferred between the operator stations, operator terminals and
wing terminals.
Controller redundancy
The K-Pos DPC-1 controllers can be upgraded to DPC-2 (dual redundancy) by adding:
• a controller computer (RCU)
• I/O Bus (RHUB)
• preconfigured mounting plate (with fuse, power, filter, patch box for LAN,
cableducts etc.)
It would also need software update and, if needed, adding units to the IO system to get proper
segregation.
The K-Pos DPC-2 controllers can be upgraded to DPC-3 (triple redundancy) by simply
adding a third control computer (RCU).
Screen Capture Printer
A screen capture printer can be connected to the data network. This gives the operator the
possibility to print the current display picture.
Data Logging System
Extensive data logging functions are available for the K-Pos systems as a separate History
Station with recording and reviewing facilities.
IMO Equipment Class 2
The K-Pos DP-11 and DP-12 systems can be upgraded to IMO Equipment Class 2 (redundant
system) by adding one or more operator stations, upgrading the DP controller to DPC-2 (or
DPC-3) and add necessary reference systems and sensors.
IMO Equipment Class 3
The K-Pos DP-21/22 and DP-31/32 systems can be upgraded to the requirements of IMO
Equipment Class 3 by installing an DP-11/12 system in a separate compartment and
connecting it to the data network as a backup system. At least one of each sensor type and one
position-reference system must be connected to the backup system.
Integrated redundant DP control system (K-Pos DP2) with Independant Joystick system
(cJoy) and levers for each thruster (K-Thrust). This setup would fulfill IMO DP class 2
requirements for DP control system if the number of sensors and position reference systems
where correct.
Examle of integrated vessel control system consisting of K-Pos DP, cJoy, K-Thrust, K-Bridge
and K-Chief