Basic Mechanical Engineering Model I Key

Part - A
6) Coal and ash circuit , Air and flue gas circuit , Feed water and steam circuit , Cooling
water circuit
7) The water hammer is defined as the change in pressure rapidly above or below normal
pressure caused by sudden change in the rate of water flow through the pipe, according to
the demand of prime mover i.e. turbine
8) The fuel inside the reactor is metal called uranium. Uranium exists as an isotope in the
form of U235 splits into two fragments of approximately equal size. About 2.5 neutrons
are released and a large amount of energy (200 million electron volts, Mev) is produced.
The neutrons produced move at a very high velocity 1.5×107 m/s and fission other
nucleus of U235. Thus fission process and release of neutrons take place continuously
throughout the remaining material

9) Liquid and slurry pumps can lose prime and this will require the pump to be primed by
adding liquid to the pump and inlet pipes to get the pump started. Loss of "prime" is
usually due to ingestion of air into the pump. The clearances and displacement ratios in
pumps used for liquids and other more viscous fluids cannot displace the air due to its
lower density.

10) A centrifugal pump containing two or more impellers is called a multistage

centrifugal pump. The impellers may be mounted on the same shaft or on different shafts.

If we need higher pressure at the outlet we can connect impellers in series.

If we need a higher flow output we can connect impellers in parallel.

All energy added to the fluid comes from the power of the electric or other motor force
driving the impeller.

Part – B
13) a) STEAM POWER PLANT (THERMAL POWER PLANT)
 It is the plant where the chemical energy from the coal is converted into heat
energy of a steam to kinetic energy of a turbine and then converted into electrical
energy from the generator.

Energy transfer diagram

Working principle:
Power stations that burn coal or oil have three main parts – the boiler, the
turbine and the generator. The power station burns coal or oil to produce heat in its
boiler. The boiler is lined with pipes carrying water, which boils and turns to steam.
The steam is then passed through pipes to machines called turbines. Turbines have
huge wheels fitted with hundreds of steel fan like blades.

The steam rushes through the turbines at high speeds causing both the wheels and the
turbine shaft to spin. The spinning shaft turns the rotor of the electric generator
creating magnetic field, thereby producing electricity. In a large power station steam
passes through several wheels until almost all of its energy has been used up. The
used steam then cools in the cooling towers and changes back into water. This
changing process is called condensation. The water returns to the boiler and is heated
up again.

LAYOUT OF STEAM POWER PLANT

(i) Coal and ash circuit: In this circuit, the coal from the storage area called
stack is taken to the boiler by means of coal handling equipments such as belt
conveyors, bucket elevators etc. A thermal power plant of 400 MW capacity
requires 5000 to 6000 tonnes of coal per day. So highly reliable and efficient
devices should be used.

After the pulverized coal is burnt at 1500°C - 2000°C by combustion it gets

collected in the ash pit. It is removed from the ash pit by ash handling system
like belt conveyors, screw conveyors etc. In a power station producing 400
MW capacity of electricity 10 hectares area is required per year if ash is
dumped to a height of 6.5meters. So sufficient space should be provided for
ash storage.

(ii) Air and flue gas circuit: The air from the atmosphere gets heated in the air
preheater. The air receives its heat from the hot flue gas passing to the
chimney. The hot air enters the boiler and helps in combustion of fuel in the
boiler.
The flue gases after combustion in the boiler furnace pass around the boiler
tubes, heating the water present in the tubes. The fuel gases then pass through
a dust collector which removes any dust or solid particles. The filtered flue
gas passes through the economizer and preheater and is forced out through
the chimney by a draught fan.

(iii) Feed water and steam circuit: The superheated steam from the boiler enters
the steam turbine; the superheated steam temperature is about 600°C at a
pressure of 30 MPa. The steam expands in the turbine causing the turbine
blades to rotate. After doing mechanical work on the blades and loosing its
energy, the steam becomes wet and the pressure of steam becomes less.

The wet steam passes through a condenser where it is completely becomes

water. The condensed water that has a temperature of 30°C to 40°C is
collected in a tank called hot well. The water from the hot well is fed into the
boiler through economizer. The economizer preheats the water before
entering it. The economizer receives its heat from the flue gases leaving the
boiler. Preheating the feed water in the economizer increases the boiler
efficiency and helps quicker production of steam.

(iv) Cooling water circuit: In this circuit water is circulated around the
condenser to condense the steam coming out of the turbine. Cooling water
enters the condenser at 10°C to 15°C and leaves at 20°C to 25°C.

Plenty of water is required for condensing the steam in the condenser. The
water may be taken from sources such as river or lake.
13) b)
Parameter Centrifugal Pumps Reciprocating Pumps Rotary Pumps

Optimum Flow and Medium/High Capacity, Low Capacity, Low/Medium Capacity,

Pressure Applications
Low/Medium Pressure High Pressure Low/Medium Pressure
Maximum Flow Rate 100,000+ GPM 10,000+ GPM 10,000+ GPM
Low Flow Rate No Yes Yes
Capability
Maximum Pressure 6,000+ PSI 100,000+ PSI 4,000+ PSI
Requires Relief Valve No Yes Yes
Smooth or Pulsating Smooth Pulsating Smooth
Flow
Variable or Constant Variable Constant Constant
Flow
Self-priming No Yes Yes
Space Considerations Requires Less Space Requires More Space Requires Less Space
Costs Lower Initial Higher Initial Lower Initial

Lower Maintenance Higher Maintenance Lower Maintenance

Higher Power Lower Power Lower Power

Fluid Handling Suitable for a wide range Suitable for clean, clear, Requires clean, clear, non-
including clean, clear, non- non-abrasive fluids. abrasive fluid due to close
abrasive fluids to fluids with Specially-fitted pumps tolerances
abrasive, high-solid content. suitable for abrasive-slurry
service.

Not suitable for high

viscosity fluids Suitable for high viscosity Optimum performance
fluids with high viscosity fluids

Higher tolerance for

Lower tolerance for entrained gases
entrained gases Higher tolerance for
entrained gases

Selecting between Centrifugal or Positive Displacement Pumps

Selecting between a Centrifugal Pump or a Positive Displacement Pump is not always

straight forward.

Flow Rate and Pressure Head

The two types of pumps behave very differently regarding pressure head and flow rate:
 • The Centrifugal Pump has varying flow depending on the system pressure or head
• The Positive Displacement Pump has more or less a constant flow regardless of
the system pressure or head. Positive Displacement pumps generally gives more
pressure than Centrifugal Pump's.

Capacity and Viscosity

Another major difference between the pump types is the effect of viscosity on the
capacity:

• In the Centrifugal Pump the flow is reduced when the viscosity is increased
• In the Positive Displacement Pump the flow is increased when viscosity is
increased

Liquids with high viscosity fills the clearances of a Positive Displacement Pump causing
a higher volumetric efficiency and a Positive Displacement Pump is better suited for high
viscosity applications. A Centrifugal Pump becomes very inefficient at even modest
viscosity.

Mechanical Efficiency

The pumps behaves different considering mechanical efficiency as well.

• Changing the system pressure or head has little or no effect on the flow rate in the
Positive Displacement Pump
• Changing the system pressure or head has a dramatic effect on the flow rate in the
Centrifugal Pump

Net Positive Suction Head - NPSH

Another consideration is the Net Positive Suction Head NPSH.

• In a Centrifugal Pump, NPSH varies as a function of flow determined by pressure

• In a Positive Displacement Pump, NPSH varies as a function of flow determined
by speed. Reducing the speed of the Positive Displacement Pump pump, reduces
the NPSH

14) a) DIESEL POWER PLANT

It is the plant in which the heat energy from the diesel engine in converted into electrical
energy from the electric generator.
Lay out

This is a fossil fuel plant since diesel is a fossil fuel. Diesel engine power plants are
installed where supply of coal and water is not available in sufficient quantity.
(i) Diesel Engine: A diesel engine is required for a diesel power plant. A diesel
engine is a compression ignition engine.
A diesel engine may be four stroke or two stroke cycle engine. The two stroke
cycle engine is more favoured for diesel power plants. Air is admitted into the
cylinder of the engine and is compressed; fuel (diesel) is injected into the
cylinder through fuel injectors. Due to the high temperature and pressure
obtained during compression, it ignites. The fuel burns and the burnt gases
expand to do work on the moving part inside the cylinder called piston. This
movement of the piston rotates a flywheel. The engine is directly coupled to
the electric generator. The gases after expansion inside the cylinder are
exhausted into the atmosphere and passes through a silencer in order to reduce
the noise.
The fuel for the diesel engine is drawn through a filter from the all day tank.
The air required for the diesel engine is drawn through the air filter from the
atmosphere.

(ii) Starting system: diesel engine used in diesel power plants is not self starting.
The engine is started from cold condition with the help of an air compressor.

(iii) Fuel supply system: Fuel from the storage tank is pumped through a filter
into a smaller tank called all day tank. This tank supplies the daily
requirements of the diesel engine. The all day tank is placed high so that the
fuel flows to the engine under gravity and sufficient pressure.

(iv) Air intake system: The air required for the combustion of fuel inside the
diesel engine cylinder is drawn through the air filter. The purpose of the filter
is to remove dust from the incoming air. The dry filter used may be made of
felt, wood or cloth. In wet filter, oil bath is used; in this the air passes over a
bath of oil where the dust particles get coated on the oil.

(v) Exhaust system: The exhaust gases coming out of the engine is very noisy. In
order to reduce the noise a silencer (muffler) is used..

(vi) Cooling system: The temperature of the burning fuel inside the engine
cylinder is in the order of 1500°C to 2000°C. In order to lower this
temperature water is circulated around the engine. The water envelops (water
jacket) the engine, the heat from the cylinder, piston, combustion chamber etc,
is carried by the circulating water. The hot water leaving the jacket is passed
through the heat exchanger. The heat from the heat exchanger is carried away
by the water circulated through the heat exchanger and is cooled in the
cooling tower.

(vii) Lubricating system: This circuit includes lubricating oil tank, oil pump and
oil cooler. The purpose of the lubrication system is to reduce the wear of the
 engine moving parts. Part of the cylinder such as piston, shafts, and valves
must be lubricated. Lubrication also helps to cool the engine.
In the lubrication system the oil is pumped from the lubricating oil tank
through the oil cooler where the oil is cooled by the cold water entering the
engine. The hot oil after cooling the moving parts return to the lubricating oil
tank.

14)b)

The positive-displacement principle is well illustrated in the reciprocating-type pump, the

most elementary positive-displacement pump,. As the piston extends, the partial vacuum
created in the pump chamber draws liquid from the reservoir through the inlet check
valve into the chamber. The partial vacuum helps seat firmly the outlet check valve. The
volume of liquid drawn into the chamber is known because of the geometry of the pump
case, in this example, a cylinder.

As the piston retracts, the inlet check valve reseats, closing the valve, and the force of the
piston unseats the outlet check valve, forcing liquid out of the pump and into the system.
The same amount of liquid is forced out of the pump during each reciprocating cycle.
All positive-displacement pumps deliver the same volume of liquid each cycle
(regardless of whether they are reciprocating or rotating). It is a physical characteristic of
the pump and does not depend on driving speed. However, the faster a pump is driven,
the more total volume of liquid it will deliver.

15) a)

Hydraulic Turbines

Hydraulic Turbines have a row of blades fitted to the rotating shaft or a rotating plate.
Flowing liquid, mostly water, when pass through the Hydraulic Turbine it strikes the
blades of the turbine and makes the shaft rotate. While flowing through the Hydraulic
Turbine the velocity and pressure of the liquid reduce, these result in the development of
torque and rotation of the turbine shaft. There are different forms of Hydraulic Turbines
in use depending on the operational requirements. For every specific use a particular type
of Hydraulic Turbine provides the optimum output.

Classification of Hydraulic Turbines: Based on

pressure change

One more important criterion for classification of Hydraulic Turbines is whether the
pressure of liquid changes or not while it flows through the rotor of the Hydraulic
Turbines. Based on the pressure change Hydraulic Turbines can be classified as of two
types.

1. Impulse Turbine: The pressure of liquid does not change while flowing through
the rotor of the machine. In Impulse Turbines pressure change occur only in the
nozzles of the machine. One such example of impulse turbine is Pelton Wheel.
2. Reaction Turbine: The pressure of liquid changes while it flows through the
rotor of the machine. The change in fluid velocity and reduction in its pressure
causes a reaction on the turbine blades; this is where from the name Reaction
Turbine may have been derived. Francis and Kaplan Turbines fall in the category
of Reaction Turbines.

Hydraulic Turbines are being used from very ancient times to harness the energy stored
in flowing streams, rivers and lakes. The oldest and the simplest form of a Hydraulic
Turbine was the Waterwheel used for grinding grains. Different types of Hydraulic
Turbines were developed with the increasing need for power. Three major types are
Pelton Wheel, Francis and Kaplan Turbine.

Design of Pelton Wheel Turbine

The Pelton Turbine has a circular disk mounted on the rotating shaft or rotor. This
circular disk has cup shaped blades, called as buckets, placed at equal spacing around its
circumference. Nozzles are arranged around the wheel such that the water jet emerging
from a nozzle is tangential to the circumference of the wheel of Pelton Turbine.
According to the available water head (pressure of water) and the operating requirements
the shape and number of nozzles placed around the Pelton Wheel can vary.

Working Principle of Pelton Turbine

The high speed water jets emerging form the nozzles strike the buckets at splitters, placed
at the middle of a bucket, from where jets are divided into two equal streams. These
stream flow along the inner curve of the bucket and leave it in the direction opposite to
that of incoming jet. The high speed water jets running the Pelton Wheel Turbine are
obtained by expanding the high pressure water through nozzles to the atmospheric
pressure. The high pressure water can be obtained from any water body situated at some
height or streams of water flowing down the hills.

The change in momentum (direction as well as speed) of water stream produces an

impulse on the blades of the wheel of Pelton Turbine. This impulse generates the torque
and rotation in the shaft of Pelton Turbine. To obtain the optimum output from the Pelton
Turbine the impulse received by the blades should be maximum. For that, change in
momentum of the water stream should be maximum possible. That is obtained when the
water stream is deflected in the direction opposite to which it strikes the buckets and with
the same speed relative to the buckets.

Pelton Turbine Hydroelectric Setup

A typical setup of a system generating electricity by using Pelton Turbine will have a
water reservoir situated at a height from the Pelton Wheel. The water from the reservoir
flows through a pressure channel to the penstock head and then through the penstock or
the supply pipeline to the nozzles, from where the water comes out as high speed jets
striking the blades of the Pelton Turbine. The penstock head is fitted with a surge tank
which absorbs and dissipates sudden fluctuations in pressure.

For a constant water flow rate from the nozzles the speed of turbine changes with
changing loads on it. For quality hydroelectricity generation the turbine should rotate at a
constant speed. To keep the speed constant despite the changing loads on the turbine
water flow rate through the nozzles is changed. To control the gradual changes in load
servo controlled spear valves are used in the jets to change the flow rate. And for sudden
reduction in load the jets are deflected using deflector plates so that some of the water
from the jets do not strike the blades. This prevents over speeding of the turbine.

Francis Turbine is the first hydraulic turbine with radial inflow. It was designed by
American scientist James Francis. Francis Turbine is a reaction turbine. Reaction
Turbines have some primary features which differentiate them from Impulse Turbines.
The major part of pressure drop occurs in the turbine itself, unlike the impulse turbine
where complete pressure drop takes place up to the entry point and the turbine passage is
completely filled by the water flow during the operation.

Design of Francis Turbine

Francis Turbine has a circular plate fixed to the rotating shaft perpendicular to its surface
and passing through its center. This circular plate has curved channels on it; the plate
with channels is collectively called as runner. The runner is encircled by a ring of
stationary channels called as guide vanes. Guide vanes are housed in a spiral casing
called as volute. The exit of the Francis turbine is at the center of the runner plate. There
is a draft tube attached to the central exit of the runner. The design parameters such as,
radius of the runner, curvature of channel, angle of vanes and the size of the turbine as
whole depend on the available head and type of application altogether.

Working of Francis Turbine

Francis Turbines are generally installed with their axis vertical. Water with high head
(pressure) enters the turbine through the spiral casing surrounding the guide vanes. The
water looses a part of its pressure in the volute (spiral casing) to maintain its speed. Then
water passes through guide vanes where it is directed to strike the blades on the runner at
optimum angles. As the water flows through the runner its pressure and angular
momentum reduces. This reduction imparts reaction on the runner and power is
transferred to the turbine shaft.

If the turbine is operating at the design conditions the water leaves the runner in axial
direction. Water exits the turbine through the draft tube, which acts as a diffuser and
reduces the exit velocity of the flow to recover maximum energy from the flowing water.
Power Generation using Francis Turbine

For power generation using Francis Turbine the turbine is supplied with high pressure
water which enters the turbine with radial inflow and leaves the turbine axially through
the draft tube. The energy from water flow is transferred to the shaft of the turbine in
form of torque and rotation. The turbine shaft is coupled with dynamos or alternators for
power generation. For quality power generation speed of turbine should be maintained
constant despite the changing loads. To maintain the runner speed constant even in
reduced load condition the water flow rate is reduced by changing the guide vanes angle.