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GUIDANCE MATERIAL
MECHANICAL
ENGINEERING
THERMODYNAMICS
Chapter
3 Thermodynamics
In the macroscopic approach, fluids are
Basic Concepts treated as continuous rather than made up of a
number of individual particles.
What is Thermodynamics? The macroscopic approach is not valid in
Thermodynamics is a science dealing with situations where very few molecules are
energy and its transformation. involved or where the behaviour of
It deals with equilibrium and feasibility of a individual molecules is sought.
process
It also deals with relations between heat and System:
work and the properties of a system. A system is a definite quantity of matter
bounded by some surface which separates it
Laws of Thermodynamics : from the rest of the world.
Zeroth law of thermodynamics: It deals with The boundary surface may be real or
thermal equilibrium and basis for temperature imaginary.
measurement. It also gives the concept of
isotherms. Surroundings:
The combination of matter and space external
First law of thermodynamics: It tells about the to the system constitutes the surroundings.
conversation of energy and introduces the A system can exchange energy in the form of
concept of internal energy. work and heat with its surroundings
Second law of thermodynamics: It dictates the
Isolated system:
limits of converting the internal energy into work
A system which is enclosed by a rigid and
and introduces the concept of entropy. It also tells
adiabatic boundary cannot exchange energy
whether a particular process is feasible or not.
either as heat or work with its
surroundings. Such a system is called an
Third law of thermodynamics: It provides a
isolated system.
datum for the measurement of entropy.
In this system neither the mass nor the energy
The laws of thermodynamics cannot be
crosses the boundaries of the system.
directly proved. They were deduced from
experimental results through logical
Closed system:-
reasoning.
The closed system is one, in which the
The validity of the laws of thermodynamics
boundaries are closed so that no substance
rests upon the fact that till date no
may enter or leave the system.
experimental evidence is available to disprove
In such a system, the mass of the substance
them.
within the system remains constant.
Different Approaches: A transfer of energy, may, however, take
There are two different approaches in the study of place at the boundaries.
thermodynamics. They are macroscopic and
microscopic.
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Spring catch A B
3
Second Law of Thermodynamics: QR
T=C
There are several statements of the second
law of thermodynamics. Any statement of the
second law denies the possibility of a V
spontaneous process reversing on its own. QS
1 2
(a) Kelvin-Plank Statement : T
It is impossible to construct a cyclically
operating device which produces no effect
other than the extraction of energy as heat WC WE
from a single thermal reservoir and performs
an equivalent amount of work.
A Perpetual Motion Machine of the second 4 3
QL
Kind (PMMSK) is a device which absorbs
energy as heat from a single thermal reservoir s
and delivers equivalent amount of work Fig : T-S diagram
continuously
(b) Clausius’ Statement : TH TL T
carnot 1 L
It is impossible to construct a cyclically TH TH
working device which produces no effect
other than the transfer of energy as heat from A Carnot engine is a hypothetical device and
a low temperature body to a high temperature is not practical to construct, since it consists
body. of reversible processes which proceed at a
Energy transfer as heat from a high
very slow rate without any temperature and
temperature body to a low temperature body pressure differences.
is a spontaneous process. Carnot engine serves as a yardstick to
The Clausius’ statement of the second law of
measure the performance of any other engine.
thermodynamics tells that this spontaneous
process cannot proceed in the reverse
direction.
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7 Thermodynamics
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9 Thermodynamics
At the dead state, the useful work potential same holds good for pressure drop due to friction
(exergy) of a system is zero. of a fluid flowing through an insulated pipe. If the
The available energy and unavailable energy first law is the law of conservation of energy, the
are shown in fig on a T-s diagram considering second law is called the law of degradation of
Carnot engine as an example. energy.
Q
1 2 Decrease of exergy principle:
T
The exergy of an isolated system during a
Available Energy
process always decreases or, in the limiting
T0 3 case of a reversible process, remains constant.
4 Exergy never increases and exergy is
Unavailable Energy
destroyed during an actual process.
S Since T0Sgen ≥0, it follows that for an isolated
Q = AE +UE system(2–1) ≤0.
Where Irreversibilties always cause increase in
T entropy.
Available energy (AE) 1 0 Q
T Increase in entropy leads to destruction of
energy.
T
Unavailable energy (UE) 0 Q Exergy destroyed is proportional to entropy
T generated.
Where, For actual processes, exergy destroyed is
Q = the quantity of energy received as heat always a positive quantity.
from a source at temperature T, by the Exergy destroyed represents the lost work
Carnot engine and potential and is also called the irreversibility
T0 = Temperature of sink or lost work
The degrees of freedom represent the number The critical point represents the highest
of intensive parameters that can be varied pressure and temperature at which the liquid
independently. and vapour phases coexist in equilibrium. At
Simple Compressible substance is a substance the critical point the liquid and vapour phases
which has only PdV work mode. According are indistinguishable. All thermodynamic
to state postulate, a simple compressible properties of liquid and vapour phases are
substance has only two variables which can identical at the critical point.
be varied independently. The temperature, pressure and volume at the
critical point are called critical temperature
Tc, critical pressure Pc and critical volume vc,
Dryness fraction:
A mixture of saturated liquid and saturated respectively.
vapour is described in terms of the quality x or p 2p
0 ; 2 0
dryness fraction which is defined as v Tcr v T cr
mass of vapour
x
Total mass of mixture The critical point properties of water are
mg mg Pcr =221.2 bar,
x
mf mg m
Tcr = 374.15C
where mf = mass of saturated liquid;
mg = mass of saturated vapour; vcr =0.00317m3/kg.
m = total mass of the mixture. Saturation Temperature : It is the
maximum temperature corresponding to a
Temperature – Volume diagram: given pressure at which a substance can exist
Critical point
in liquid form.
T Saturated pressure : It is the pressure
Pc = 221.2 bar
corresponding to a saturation temperature.
p=c From the temperature – volume diagram the
100 bar
following are defined.
p=c
Wet vapor state (‘c’) : It is a mixture of liquid The overall shape of the P-V diagram is
and vapor at the saturation temperature similar to the T- V diagram except that the
corresponding to a given pressure. constant temperature lines are drooping
downward
Dry saturated vapor state (‘d’) : When water is From the above P-V diagram as pressure
completely converted into steam is called dry and decreases at constant temperature, the specific
saturated steam and the saturation temperature volume of liquid increases marginally but the
corresponding to a given pressure. specific volume of vapour increases
considerably.
Super heated vapor state (‘e’):
When dry and saturated steam is further
Isothermal lines are horizontal line in vapour
heated, its temperature increases with dome
corresponding increase in its specific volume Isothermal lines are rectangular hyperbola in
and this steam is called superheated steam. superheated region.
The superheating is carried out at constant P-T diagram:
pressure. Fusion curve Critical
Superheated vapor temperature is above 221 bar point
saturation temperature at a given pressure.
At less than Tsat, when heat is supplied or
withdrawn temperature changes is called
sensible heat.
Pressure
water Vaporization
At Tsat, when heat is supplied or withdrawn ice curve
(solid)
the temperature doesn’t change till it becomes Water vapor (gas)
0.006 bar
completely liquid or vapour, is called as latent Sublimation Triple point
heat. curve
At T > Tsat, when the heat is supplied or 0.01 C 374C
withdrawn temperature changes is called as
superheated region. The P-T diagrams of pure substance is called
as a phase diagrams as it shows solid, liquid
P-V diagram: and vapour region of pure substance
simultaneously.
Critical point Each single phase of pure substance is
Gas phase Pc = 221.2 bar
PC Tc=374. 15C separated by saturation lines.
Vc = 0.00317 m3/kg The sublimation line separates solid and
tc
vapour regions.
The fusion lines separates solid and vapour
P
P= 1 MPa
Superheated vapour
Compressed liquid
melting point of ice decreases with increasing
pressure.
Only three substances (water, Antimony and
Bismuth have negative (–ve) slope for fusion Liquid +vapour
line whereas all remaining substances have v= c
453 K
positive ( +ve) slope.
Saturated vapour line
If any substance heated below its triple point v= c
pressure, solid becomes vapours and process 273.16 K
Schematic of a T-s diagram for water
is called sublimation.
If any substance is cooled below its triple The value of specific entropy at triple point is
point pressure, vapour becomes solid and zero.
process is called ablimation. The saturated liquid and saturated vapour line
If any substance is heated above its triple divides the diagrams into three regions i.e,
point pressure, solid becomes liquid and compressed liquid region at the left of the
liquid becomes vapour. saturated liquid line, superheated vapour
Isothermal compression less than triple point region right to the saturated vapour line and
temperature makes substance go from vapour the wet vapour region between the two lines.
to solid state. The two saturated lines are met at critical
point.
Isothermal expansion less than triple point
temp makes substance go from solid to In the compressed liquid region, the constant
vapour state. pressure lines almost coincide with saturated
liquid lines.
Isothermal compression greater than triple In saturated liquid and vapour mixture region,
point temperature makes substance go from the constant temperature lines and constant
vapour to liquid state pressure lines are horizontal and parallel to
Isothermal expansion greater than triple point each other.
temperature makes substance go from liquid In superheated vapour region the constant
to vapour state. volume lines are steeper than constant
pressure lines.
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15 Thermodynamics
Beyond critical temp, it is called as The constant volume lines are steeper than
superheated gas. In this region molecular constant pressure lines.
separation is very high and ideal gas law is Mollier Diagram showing the constant
exhibited pressure, constant temperature and constant
Between dry saturated line and critical quality lines is shown in fig. The constant
temperature line it is called superheated pressure and constant temperature lines
vapour and in this region ideal gas law coincide in the two phase region.
behavior is approximated.
Tds = dh
dh Q
Slope = T
ds ds
On a Mollier diagram the slope is equal to the
absolute temperature
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Pressure
perfect gas and follows the relation P=C
T1 P=C
pV = mRT or p = RT T2
There is no change in the mass of the working T2 c
c b d
medium
All the processes that constitute the cycle are Volume S
reversible
Note:
Heat is assumed to be supplied from a The Ericsson cycle does not find practical
constant high temperature source and not application in piston engines but is approached by
from chemical reactions during the cycle. a gas turbine employing a large number of stages
Some heat is assumed to be rejected to a
with heat exchangers, insulators and reheaters.
constant low temperature sink during the
cycle.
Otto cycle:
It is assumed that there are no heat losses
from the system to the surroundings
The working medium has constant specific 3
heats throughout the cycle. P3
3
The physical constants viz., Cp, Cv, and M of
Pressure
Temperature
2 2
at standard atmospheric conditions. P2
P1 1 4
Stirling cycle: 1
It consists of two isothermal and two constant V1 =V4 V2 =V3 Entropy
volume processes. The heat rejection and addition Volume
take place at constant temperature. The p-V and
T-s diagrams for the Stirling cycle are shown Diesel Cycle:
below. It is clear that the amount of heat addition Diesel cycle consist of two reversible adiabatic,
and rejection during constant volume processes is one reversible isobar, and one reversible isochoric
same. process.
T1=T2 1 2
1
2 QS
Temperature
P1 3
3
Temperature
Pressure
P2 2 2
P4 T3=T4 4 4
Pressure
4
P3 3 QR 1
3 4 0 1
Volume Entropy
V1 =V4 V2 =V3 Entropy
Volume
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17 Thermodynamics
Dual Cycle :
The Dual cycle, also called a mixed cycle or
Pressure
Temperature
3
limited pressure cycle is a compromise between 3
V=c
Otto and Diesel cycles. QS
2 4
4 V=c
2
1 5
5 P=c
QS 1 QR
4 Volume Entropy
3
Temperature
4
3
Pressure
2 v 5 6 6’’ 6’ s
2
123 41 Otto cycle
QS 12 341 Diesel cycle
3
3 122341 – Dual cycle
1 1
QR From the above diagrams
(Peak pressure)Otto > (Peak pressure)Diesel
Volume Entropy
(Peak temp.)Otto > (Peak temp)Diesel
(Expansion ratio)Otto > (Expansion
ratio)Diesel
Atkinson cycle:
(Temp at beginning of heat rejection)Otto <
Atkinson cycle is an ideal cycle for Otto engine
(Temp at beginning of heat
exhausting to a gas turbine.
rejection)Diesel
(Heat rejected)Otto < (Heat rejected)Diesel
(Work)Otto > (Work)Diesel
(th )Otto (th )Diesel
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(b) For same compression ratio and heat (d) For same Maximum pressure and Heat
rejection: input
3
T T 3’ 3
P P P=C
3
V=c 2’ 3’ 3 2’
3’ 3’
2 2 S=C
2 V=C
4 P=c 4
4’ 4
4 2 4’
Isentropic process 1 1
v=c S=C
1 1 V=C
s
v
v 6’ 6 s
1-2-3-4- Otto cycle 5
1-2-3ʹ-4- Diesel cycle 12341 – Otto cycle
From the above diagrams 12341 – Diesel cycle
(Peak pressure)Otto > (Peak pressure)Diesel
(Peak temp)Otto > (Peak temp) Diesel
(Expansion ratio)Otto> (Expansion From the above diagrams
ratio)Diesel (compression ratio)Otto < (compression
(Work output) Otto >(Work output) Diesel ratio)Diesel
(Heat supply)Otto > (Heat supply) Diesel (Temp at the end of the compression)Otto <
(th)Otto > (th)Diesel (Temp at the end of the compression)Diesel
(Expansion ratio)Otto < (Expansion
(c) For same peak pressure, peak temperature ratio)Diesel
and heat rejection: (Work output)Otto < (Work output)Diesel
P=C 3 (Peak temp)Otto > (Peak temp)Diesel
2’ 3 2’ (th)Otto < (th)Dual < (th)Diesel
P
Isentropic process 2
v=c
4 T
2 4 Psychrometry
1 1 v=c
Isentropic process Psychrometry :
v s
It is study of air –water vapour mixture.
Atmospheric air is equal to sum of dry air and
1234 –Otto cycle water vapour.
1234 – Diesel cycle Dry air is nothing but air without water
From the above diagram vapour.
(Compression ratio) Otto< (Compression The air to be processed in air conditioning
ratio)Diesel systems is a mixture of dry air and water
(Temp at the end of compression)Otto < vapour. While the composition of dry air is
(Temp at th end of Compression)Diesel constant, the amount of water vapour present
(Work)Otto < (Work) Diesel in the air may vary from zero to a maximum
(Heat supplied)Otto < ( Heat supplied) Diesel depending upon the temperature and pressure
(th )Otto <( th) Diesel of the mixture (dry air + water vapour)
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19 Thermodynamics
DBT
WBT
DPT Dew Point Moisture air air
Content
Relative
Humidity
Volume
Tcoil
Dry –bulb Temperature
Fig. Constant property lines When air flowing in chamber, some of
on a psychrometric chart particles come in contact with coil and
temperature increase and some other receive
Various process on psychrometric chart: heat by convection and radiation. As a result
i. Sensible heating overall temperature of air coming out is less
ii. Sensible cooling than coil temperature this is called as bypass.
iii. Humidification Bypass signifies inefficiency.
iv. Dehumidification The bypass factor depends upon the following
v. Heating and Humidification factors.
vi. Heating and Dehumidification (a) The number of fins provided in a unit
vii. Cooling and Humidification length
viii. Cooling and Dehumidification (b) The number of rows in a coil in the
direction of flow
(i) Sensible Heating: (c) The velocity of flow of air
The process in which air is heated to higher If velocity of air in chamber is high then
temperature without change in specific bypass factor high because there is no time
humidity is called as sensible hating process. for heat pick up.
RH1 If velocity is less, there is sufficient time for
DBT-Increases heat pickup and bypass factor will be less.
RH2 WBT-Increases Note:
1 -constant
2 By pass factor of a cooling coil decreases
DPT-constant
RH-Decreases
with decrease in fin spacing and increase in
td1 td2 h-Increases number of rows.
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21 Thermodynamics
BPF T2 Tcoil
T1 Tcoil Air Air
T1 T2 < 100% = 100%
Contact Factor (CF)
T1 Tcoil
BPF + CF = 1
Applications of psychrometry:
T HVAC systems, animal, plant and human
Adiabatic saturation temp
comfort
1 Air-conditioning devices
Cooling towers
T2 Industrial processes requiring close control of
WBT 2
the vapor content in air
Tdp
3
Food science and engineering.
Animal housing
s Plant systems (Greenhouses, growth
Fig: T-s diagram for adiabatic saturation chambers, plant based bioregenerative life
process support systems etc.)
Evaporative coolers
Cooling Towers: Mold problems & health related issues (Dew
Refrigeration and air-conditioning plants, & Condensation!)
condensers in thermal power plants require Water harvesting in arid lands
large quantities of cooling water. Cooling
towers are extensively used to provide cold Rankine Cycle
water for these plants.
Cooling towers employ the principle of
evaporative cooling to cool warm water. Simple steam power plant (SSPS):
It is theoretically possible to obtain cold water A steam power plant consists of the following
from a cooling tower at the wet-bulb main components:
temperature of the air. 1. Boiler with its mountings and
Natural draft cooling towers and forced draft accessories
cooling towers are commonly employed in 2. Turbine
industry. 3. Condenser
In the cooling towers warm water is cooled by 4. Feed-water pump
evaporation and hence the relative humidity 5. Electric generator
of atmospheric air is important. It is necessary 6. Cooling tower
to add make-up water in the cooling towers. 7. Circulating water pump
Some amount of information regarding the 8. Chimney
performance of a cooling tower can be 9. Draught system
obtained from a knowledge of Psychrometry. 10. Feed-water treatment plant
Application of material and energy balance to
1 2
the cooling tower gives the desired Generator
information. Boiler Turbine
The steam generated in the boiler is passed It is denoted by SSC (Specific steam
through the turbine, where it expands to a consumption) is expressed as
lower pressure, thus power is generated. Mass of steam in kg / h
The steam leaving the turbine is passed SSC
Power output in kW
through the condenser, where it condenses to
water and creates a low pressure at the turbine m s (kg / h )
exit.
The cooling water is circulated in the m s (kg / s) Wnet (kJ / kg )
condenser. 3600kJ / kWh
The condensate is then re-circulated to the SSC
boiler with the help of the feed pump. Wnet (kJ / kg)
(v) Heat rate:
Performance parameters of vapour power It is the amount of heat required by a power
cycle: plant to produce 1 kWh of power.
(i) Thermal efficiency: Heat input in kJ/s 3600 s/h
The thermal efficiency of any power cycle is Heat rate
expressed as Net power output in kW
Network done in the cycle Wnet 3600
th H.R (kJ / kWh )
Heat sup plied in the cycle Q in th
h
from condensing vapour to low temperature 1
reservoir still remain externally irreversible. 1
P1
P1
4 P2 2
1 2
h 2
3
4 P2 s
h–s diagram for Rankine cycle
3
2 The steam leaving from boiler may be dry
and saturated, wet or superheated. The
s
corresponding T-s diagrams are 1-2-3-4-
1,1-2-3-4-1 or 1-2-3-4-1
h – s diagram for Carnot vapour cycle
1’’ T PS′
T
(+) 2′ PS
P1 1
1
2
4 (–) Pc
P2
3′ 3
3 2 2 2
s
T-s diagram for Rankine cycle s
T–s diagram
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4 3 3 P
PC
S Superheat
In super heating:
Turbine work (WT ) increases
Pump work(Wp) constant
Network done (Wnet) increases
Steam rate decreases s
Heat supplied increases
Dryness fraction (x) increases
Condenser load increases As condenser pressure increases:
Thermal efficiency (th) increases Turbine work (WT ) increases
Heat rate decreases Pump work (Wp) increases
Network done (Wnet) increases
Another advantage of using superheated is the Steam rate decreases
reduction of moisture in the lower stages of Heat supplied increases
the turbine. Though the heat rejection Dryness fraction (x) decreases
increases, the cycle work increases more in Condenser load decreases
proportion (due to the horn) as shown in the Thermal efficiency (th) increases
diagram. Heat rate decreases
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27 Thermodynamics
4
6 (P)RHP
4s 4
4 P2 4s
3 P3 2 2s 2 5
h-s diagram for reheat cycle s
s
(i) Piping Losses:
In reheat cycle:
(ii) Turbine Losses:
(iii) Pump Losses: Turbine work (WT ) increases
(iv) Condenser Losses: Pump work (Wp) constant
Network done (Wnet) increases
Methods for improving the efficiency of Steam rate decreases
Rankine cycle
Heat supplied increases
1. Reheat cycle
2. Regenerative cycle Dryness fraction (x) increases
Condenser load increases
1. Reheat cycle: Heat rate decreases
The reheat cycle is designed to take advantage
Work ratio increases
of higher boiler pressure by eliminating the
problem of excessive moisture content in the Thermal efficiency may increase, decrease
exhaust steam. In a reheat Rankine cycle, the or constant.
steam is expanded in a number of stages. If the reheat pressure is too high the quality
After each stage of expansion, the steam is at exhaust will be less.
reheated in the boiler. Then, it expands in the If the reheat pressure is too low the thermal
next stage of turbine and is finally exhausted efficiency is less.
to the condenser. Hence we have to make a compromise
T 1 3 between these two
PRHP
P1 0.2 to 0.25
Pint ial
(P)RHP Note: In a reheat cycle the maximum number of
2
reheats permitted is only two.
6 P2
5 4 4s
s
T-s diagram for reheat cycle
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S 2
Wc
Here heat of steam is recovered by the 4
condensate water as a result, condensate water p=c
4 1
1 Q2
gets heated and enters the boiler at higher v S
temperature. As a result the amount of heat
supplied in boiler decreases and thermal
Joule or Brayton cycle consists of four
efficiency increases.
processes as follows:
1-2: Reversible adiabatic compression
2-3: Constant pressure heat supply
3-4: Reversible adiabatic expansion
4-1: Constant pressure heat rejection
T2
1 1
th 1
1
rk
rk T1
th= f (rp,) or f (rk,)
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29 Thermodynamics
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P 5
7 3 3
C1 C2 T G 2 T 7
Fuel 4 6
2 3 4 5 2
4 5
8
CC 6
1
1 6
8 1
IC V S
2 p2 = 1000 kPa When a heat exchanger is employed, the
efficiency is higher with reheat than without.
compressor compressor Wc
I II
c intercooler
Intercooled cycle with heat exchange and
d
p1 = 100 kPa 1 Reheating:
Td = 300 K
T1 = 300 k
qR
Schematic
C1 C2 T1 T2 G
4 4 5
P 5 3
T 2 Fuel Fuel
4’
4 6 7 8
2 4 1 IC 5 9
3 CC1 CC2
2 6
6 3 1
10
v S 6
8
p 4 5 6
T 5
7
The Reheat and Heat exchange cycle: 3 2 4 9
7 8
Improvement in specific power output is achieved 2
in reheat cycle at the expense of the cycle 10
efficiency. This can be overcome by adding a 3
1 10 9
1
heat exchanger to the reheat cycle. The schematic V S
arrangement of reheat cycle with heat exchanger
is given in figure. The speed and output of the power turbine
can be controlled by controlling the fuel
supply in the combustion chamber, CC2.
C2 T1 T2 G If the two turbines T1 and T2 are on two
separate shafts, the systems as a whole will
Fuel Fuel
2 have higher efficiency at part loads and can
1 7 3 4 5 respond to change of load and speed quickly
6
C1 C2 and effectively.
In such arrangement the turbine T1, called
8 compressor, turbine and the compressor are
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on one shaft, and it can be run at the most Net refrigeration effect Q 2
suitable speed for the compressor, COPR
work input W
independent of the speed of the power
Q2
turbine T2.
(Q1 Q 2 )
Latent heat. Since the cooling in a Critical temperature and pressure. The
refrigeration cycle is produced by the critical temperature of a vapour is the
evaporation of liquid refrigerant, it is temperature above which the vapour cannot
desirable that the refrigerants should have be condensed irrespective of the pressure on
high latent heat. the system.
Thus for a refrigerant having high latent heat, It is desirable that the critical temperature of
the refrigerating effect per kg of refrigerant the refrigerant should be above the condenser
will be more and weight of refrigerant per ton temperature to facilitate easy condensation
of refrigeration will be less. The critical temperature and pressure of some
Evaporator and condenser pressures. The of the refrigerants are indicated below:
operating pressures in the evaporator and
Critical Critical
condenser should be positive but not very Refrigerant
temperature (C) pressure (bar)
high as it would result in high capital as well
NH3 138 112.0
as operating costs.
As discussed earlier, positive pressure in CO2 30.5 72.8
evaporator and condenser is desirable to avoid SO2 157.0 77.5
leakage of air or moisture in the system. Freon-11 197.5 43.2
The evaporator and condenser pressures for Freon-12 112.1 40.6
some of the refrigerants are indicated below: Freon-22 95.4 48.7
Refrigerant at 15C in Condenser (ii) Safe working properties:
Evaporator kgf/cm2 pressure at Flammability: It is desirable that the
pressure Condenser 29C refrigerants should be non-flammable and
pressure in kgf/cm2 non-explosive individually and when mixed
NH3 2.34 11.5 with lubricating oil or air.
CO2 23.7 71.2 Ammonia when mixed with air in
SO2 0.823 4.4 concentrations of 16 to 25% (ammonia) by
Freon-11 0.205 1.285 volume is explosive.
Freon-12 1.8 7.32 Some hydrocarbons such as propane, butane,
Freon-22 3.03 12.26 ethane, methane etc. are highly flammable.
However, widely used refrigerants are non
Coefficient of performance and power per ton. flammable
These two parameters are vital in selecting a Toxicity: Leakage of the refrigerant from the
refrigerant. The table below indicates the refrigeration system is inevitable. It is
value of these for some of the refrigerants. therefore desirable that it does not have any
adverse effect on the human beings. If the
Refrigerant Coefficient of refrigerant is toxic, it can cause serious injury
H.P/Ton
Performance resulting in death if its concentration in the air
NH3 4.76 0.989 is increased. Thus it is one of the most
CO2 2.56 1.84 important considerations in selecting a
SO2 4.73 0.995 refrigerant. Some refrigerants are in-toxic in
Freon-11 5.09 0.93 nature but become toxic when mixed with air.
Freon-12 4.70 1.00 Fluorocarbon group of refrigerants fall in this
Freon-22 4.66 1.01 category.
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37 Thermodynamics
Thermal conductivity: Thermal conductivity R114 (C2 Cl2 F4) – With rotary compressors.
also determines the heat transfer rate in R142 b – For Heat pump and high condensing
evaporator and condenser. Higher thermal temp. approximately
conductivity of refrigerant is desirable. R 502 – Large frozen food
Dielectric strength: The dielectric strength or F atom – Physiologically favorable.
electric resistance of the refrigerant is to be Cl atom – Depletion of O3 layer
considered while selecting refrigerant for H atom – Flammability.
hermetically sealed compressor where
refrigerant is in contact with the motor. The Designation of Refrigerants :
relative dielectric strength of refrigerant
(a) For saturated hydrocarbons
vapour is defined as the ratio of dielectric
R(m–1) (n+1) p
strength of N2.
Specific heat: As the specific heat of Refrigerant formula : CmHnFpClq
refrigerant in liquid and vapour state is
Condition : n + p + q = 2m + 2
different in order to get maximum
refrigerating effect it is desirable that liquid Where ,
refrigerant should have low specific heat to m = number of carbon atoms
increase the sub-cooling of liquid and vapour n = number of hydrogen atoms
refrigerant, high specific heat to decrease the p = number of fluorine atoms
super heating of liquid. The overall effect of q = number of chlorine atoms
this will be an increase in the refrigerating
effect.
Analysis Of Properties Of Refrigerant : (b) For Unsaturated hydrocarbon :
R1(m–1) (n+1) p
NH3– Used with Reciprocating compressors,
screw compressors, cold storages, Ice plants, Refrigerant formula: CmH2n
food refrigeration.
Condition: n + p + q = 2m
H2O--Used in water Lithium Bromide
absorption system and steam ejector system Refrigerant should be
only for A/C. Non Flammable
CO2–Used as solid CO2 or dry ice in NH3 + Air (16 – 25% by Volume) explosive
Transport refrigeration Propane, Butane, Ethane, Methane are
R11-(CCl3F)–Used with centrifugal flammable.
compressors in large capacity central A/C Non- Toxic
Plants. NH3 effects mucous membrane
R12 – (CCl2F2) – Used with reciprocating Non-Corrosive
compressors in small units, Domestic Chemically stable
refrigerators and water coolers. Leak Tendency is less for refrigerants of high
R22 – Used with reciprocating compressors density.
window A/C. Low temperature refrigeration NH3 detected by smell.
applications cold storages, Reciprocating NH3 in presence of sulphur candle gives
screw compressors. dense white fumes.
R113 (C2 Cl3 F3) – Centrifugal compressors for Freon group detected by prestolite torch.
A/C Light blue flame turns blue green.
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Viscosity should be less for better heat The only connections to the compressor
transfer rate. housing are suction and discharge fittings and
Thermal conductivity should be high for good terminals of the motor.
heat transfer rate. In some compressors the cylinder heads are
Dielectric strength is considered for removable type. Such units are called semi-
hermetically sealed compressors. hermetic or semi-sealed compressors.
The relative dielectric strength of refrigerant
vapour is defined as the ratio of dielectric (ii) Condensers:
strength of N2 vapour to dielectric strength of Condenser is a heat exchanger where heat
N2 transfer takes place between the super heated
Relative Dielectric strength refrigerant received from the compressor and
CO2 < R22 < SO2 < R11 < R12. the cooling medium of the condenser. The
Specific heat should be low to get maximum refrigerant is first cooled to saturation and
refrigerating effect. High specific heat then condensed to liquid state.
decreases superheating. Air and water can be used as the cooling
Flouro Carbons have high density and low media in a condenser either individually or
boiling point. Latent heat is not high. collectively. The condensing temperatures of
Isentropic work is small due to the condenser may vary from 160C to 200C
- low value of specific heat above the temperature of entering air, if air is
- Small volumes of suction vapour. used as the cooling medium. Similarly, it
varies from 4 to 120C above the entering
water temperature in case water is used as the
Refrigeration Equipment: cooling medium.
(i) Reciprocating Compressors: The quantity of air varies from 25 to 35 cubic
When the compressor is coupled to a motor meter/min/ton of capacity whereas quantity of
externally by extending its crank-shaft water varies from 5 to 20 litres/min/ton.
through the housing, it is called open type The recommended air and water velocities in
compressor. two types of condensers are between 250 to
To prevent refrigerant from leaking through 325 m/min and 120 to 175m/min respectively.
the compressor. To prevent refrigerant from
leaking through the housing where crank- The condensers are classified on the basis of
shaft is extended or to prevent air coming cooling medium used in them :
inside due to difference in pressure, a seal is 1. Air cooled condensers
provided in the housing around the crank- 2. Water cooled condensers
shaft. 3. Evaporative condensers
However the leakage problem is not fully
overcome. To avoid it, the motor and the 1. Air Cooled Condensers:
compressor are enclosed in the same housing. Air is used as the cooling medium in the air
Such compressors are called hermetically cooled condensers. Heat transfer takes place
sealed compressors. by air convection around the condenser
The insulation of the motor in such cases surface. The air may be circulated either by
should be of special type as it is continuously natural convection or by forced convection.
exposed to the oil and the refrigerant. In the natural convection air cooled
condensers, large condensing surface area is
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39 Thermodynamics
required as the circulated air quantity is less. These are suitable for applications above 100
These type of condensers are used in domestic tons capacity.
refrigerators, deep freezers and other small The condenser is named evaporative
capacity applications. condenser as it makes use of the principle of
In the case of forced convection condensers, evaporative cooling.
air is circulated by means of a fan or blower. The water evaporates when it comes in
These types of condensers are compact in contact with the refrigerant flowing in
design and are relatively more efficient. condensing coil.
High pressure Water is sprayed over the condensing coil
refrigerant vapour through which hot refrigerant vapour is
flowing.
A pump is utilized for this purpose. An
exhaust fan is fitted at the top of the
m
condenser and it sucks air from the side
opening.
Eliminators are provided in the condenser to
Receiver
prevent escaping of water particles with air.
Recalculated water
water is circulated through the condensers and Refrgerant
is disposed off. Liquid Out
However, in case of recirculated type Air
condensers, the same water is re-circulated Make up
water
after cooling it by some means.
Heater
Water cooled condensers are sub-divided into
the following: strainer
Sump
a) Shell and tube condensers Drain
b) Shell and coil condensers
c) Double pipe condensers Pump
Purge
Fig: Evaporative Condenser
3. Evaporative Condenser:
In this type of condensers, both air and water
are used as the cooling media. The air carries away the heat taken from the
These are used where there is scarcity of refrigerant by the water vapours. A make up
water, draining facilities are inadequate and water connection with float valve replenishes
the use of cooling tower is uneconomical. the loss in water due to evaporation.
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Expansion Valves :
Adjusting screw
(a) Capillary tubes :
Capillary tube is the simplest form of the spring
expansion valve. It consists of a small bore Spring pressure
tube of fixed length and is installed between Bellows of
the condenser and the evaporator. diaphragm
The capillary offers high frictional resistance Needle and Evaporator pressure
owing to its length and small bore. It also seat out
restricts the flow of liquid refrigerant from
condenser to the evaporator. Due to these in
reasons, the pressure of liquid refrigerant strainer
Fig : constant pressure
decreases.
expansion valve
Capillary tube type expansion valve has the
limitation that once a particular bore and
length of capillary is selected for a particular It has the following limitations:
system, it cannot adjust to the variations in a) When the load falls, evaporator pressure is
discharge pressure, suction pressure and load. reduced, the valve moves to full open position
The requirement of an ideal refrigeration to bring evaporator pressure upto the pressure
system is that the compressor and the setting of the valve. This result in liquid
expansion valve must have such suction and Refrigerant flooding back the compressor,
discharge conditions that the compressor is thereby causing damage to it.
able to pump the same amount of refrigerant b) In case the load increases, the valve is closed
from the evaporator as the expansion valve is till the evaporator pressure is equal to the
feeding to the evaporator. pressure setting of the valve and thereby
Another disadvantage of the capillary tube is starving the evaporator.
that these are susceptible to clogging by On these accounts, its use is restricted to
foreign particles. small applications where constant load is
However their advantages have clear edge to encountered.
make them an ideal choice for all small
applications as they are simple in design, in (c)Thermostatic expansion valve:
expensive and have no moving parts. It is the most widely used expansion valve as
it is adaptable to any type of refrigeration
(b) Constant pressure expansion valve:
system. It has very feeler Bulbhigh efficiency
The constant pressure expansion valve
as well.
maintains a constant pressure at the inlet of
Though its name is thermostatic yet it is not
the evaporator. When the evaporator
actuated by the change in temperature of the
Diaphragm Adjustable screw pressure falls
evaporator. It is actuated by the superheat of
below the designed value, the valve opens
the refrigerant leaving the evaporator.
wider spring and partially closes when the
Its working is based on maintaining a constant
evaporator pressure increases.
degree of sufficient superheat at the
Its use is restricted to small systems. It has the
evaporator outlet. The evaporators remain
advantage that high suction pressures are not
filled with the refrigerant under all conditions
encountered since constant pressure is always
of load.
maintained at the inlet of the evaporator.
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41 Thermodynamics
The principle of the thermostatic expansion The evaporators are classified depending on
valve is shown in fig. It consists of pressure the type of construction, natural or draft
bellows/diaphragm, a needle and the seat, a convection used, operating conditions, type of
feeler bulb and the adjustable spring. refrigerant control and application.
Some of the most widely used evaporators are
described below:
Sensing Bulb
and capillary tube (a) Natural convection evaporators :
These are useful for the applications where
Diaphragm
low velocities are desired. Such as
refrigerators, cold storages, water coolers etc.
Natural convection current is set up because
spring of the temperature difference between the
Internal evaporator and the area/substance to be
Equalizer cooled. The refrigerant from the expansion
ports valve is fed through coils. Due to the
Pan Low pressure liquid
Valve and
refrigerant temperature difference air flows over the
seat ` High
coils. The surface area of the coils is
Valve pressure increased by providing fins, due to which
body liquid effective rate of heat transfer increases.
This type of evaporators has the advantage
Fig: Thermostatic expansion valve that they do not occupy any space and trouble
free. However their use is restricted to smaller
The feeler bulb is fixed on the suction line at applications owing to poor heat transfer rate.
the outlet of the evaporator to sense the
temperature changes of the refrigerant. (b) Flooded evaporators :
The pressure of the feeler bulb liquid acts on The flooded type evaporators are always full
one side of the bellows/diaphragm as it is of liquid refrigerant and a float valve
connected to it by state of equilibrium maintains the constant liquid level.
because of the two opposing pressures. A schematic diagram of flooded evaporator is
The valve setting gets disturbed, when the shown in fig.
change in the degree of superheat is Suction line
encountered, thereby it moves in the direction
Accumulator
depending on which side the pressure is Baffle
Flash Chamber
higher.
Normally thermostatic expansion valves are
Liquid Line
Evaporators:
An evaporator is a heat exchanger where
transfer of heat takes place between the
substance/area to be cooled and the
refrigerant. Fig: Flooded Evaporator
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The liquid refrigerant enters the evaporator This type of evaporator is used when it is to
Flash chamber or surface drum through a float be installed at a distance, its use should be
valve expansion valve into the flash chamber avoided owing to the following reasons:
or surge drum and flows Liquid ref. down to a) The amount of refrigerant charged in the
the tubes. system is more
Due to the heat transfer, the liquid refrigerant b) There are more chances of refrigerant
boils and a mixture of vapor and liquid leakage on account of greater length of
refrigerant re-merges in the flash liquid from refrigerant piping.
the vapour. c) The performance of the refrigeration
The vapour is drawn by the compressor and system is badly affected because with the
the liquid remains in the evaporator. increased suction line, the pressure drop is
more.
(c) Dry Expansion type Evaporator:
Dry expansion type evaporators are used with (d) Double pipe evaporator:
smaller capacity refrigeration plants. The It consists of two tubes. The fluid to be cooled
expansion valve feeds the liquid refrigerant to passes in the inner tube. The refrigerant
the evaporator. passes in the outer tube in the opposite
In an ideal evaporator, the rate of feeding of direction.
refrigerant in the evaporator should be such These evaporators provide better heat transfer
that by the time the refrigerant reaches at the rate and are extensively used in petroleum
end of the evaporator, it should be completely industry for cooling oil etc.
converted into vapour.
(e) Plate surface evaporators:
Liquid The coil of the evaporator is welded on one
refrigerant
side of the plate. In some cases, the coil is
from receiver Expansion valve placed between two plates. These are
generally used in refrigerators, deep freezers,
ice cream plants etc.
Liquid Evaporator
vapour Vapour Compression Refrigeration Cycle:
Feeler
mixture
bulb Heating effect (QL)
Suction line to
Superheated vapour Condenser 2
compressor 3
refrigerant
Fig: Dry expansion type Evaporator
Compressor
Throttle valve
The expansion valve feeds the liquid
refrigerant at a rate depending on the 1
refrigeration load. This type of evaporator has
the maximum efficiency when the system is 4
Evaporator
fully loaded.
Cooling effect (QE)
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43 Thermodynamics
Q1 S
P1 3 2
Fig :Dry and Wet compression processes
WC
Q2 s=c
With a reciprocating compressor, wet
P2 compression is not found suitable due to the
1
4 following reasons:
i) First, liquid refrigerant may be trapped in the
h head of the cylinder and may damage the
Fig: p– h diagram compressor valves and the cylinder itself.
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Even though the state of vapour at the end of Throttling versus isentropic expansion:
wet compression is theoretically dry-
Refrigerating machines are usually much
saturated, it is normal to expect some liquid
smaller devices compared to power plants.
droplets to remain suspended in the gas, as the
Thus the net work required by refrigeration
time taken by the compression process is
systems is quite small compared to the work
quite small compared to the time needed for
done in power-generating plants.
evaporation of droplets. For example, in a
Further, the positive work of the cycle,
modern high-speed compressor, say running
recovered during the isentropic expansion
at 2800 rpm, the time available in one
process, as shown by area 3-a-b-4’ in fig, is
revolution is only 0.021 second.
even smaller, as compared to the negative
ii) Secondly, liquid-refrigerant droplets may work of the cycle consumed during the
wash away the lubricating oil from the walls isentropic compression process, shown by
of the compressor cylinder, thus increasing area 1-2-a-b. This is evident from the
wear. expression for work, viz., –vdp. Thus for the
It is, therefore, desirable to have compression same pressure difference dp, the work
with vapour initially dry saturated at point 1 depends on the volume (v) of the working
as shown in fig. or even slightly superheated substance. In the expander, the refrigerant is
if a reciprocating compressor is used. Such in the liquid state, whereas, in the compressor,
compression is known as dry compression. it is in the gaseous state.
The state of the vapour at the end of The volume of the vapour is very large
compression will, therefore, have to be at 2, at compared to the volume of the liquid
pressure pk which is the saturation pressure of (vg>>vf). Hence, the positive work of
the refrigerant corresponding to the isentropic expansion is seldom large enough
condensing temperature Tk, instead of being at to justify the cost of an expander.
2”, which would be the state point if the On the other hand, the thermodynamic and
Carnot cycle were to be executed. It results in friction losses of an expander, if employed,
the discharge temperature T2 being higher may even exceed the gain in work. Moreover,
than the condensing temperature Tk.. there are practical difficulties in smoothly
Consequently, the refrigerant leaves the expanding a liquid of a highly wet vapour in
compressor superheated. The increased work an expander.
of the cycle due to the substitution of wet
compression by dry compression appears as P
the area 2-2–2, generally known as
superheat horn.
3 Pk Wet compression
Wet compression in some cases is indeed a 2
desirable, and also practicable with the use of Isentropic
a continuous flow machine like a centrifugal
or a screw compressor with no valves in place Isenthalpic
of a reciprocating compressor. b
4 4 Po 1
v
Fig: Comparison of Isentropic and Isenthalpic
process on P–v diagram
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45 Thermodynamics
The effect of sub cooling of the liquid from Providing a flash in a refrigerating circuit:
t3 to t3’ is shown in figure. It will be seen that
The flash chamber is provided between the
sub cooling reduces flashing of the liquid
throttle valve and evaporator and separates
during expansion and increases the
liquid refrigerant and vapour refrigerant and
refrigerating effect. Consequently, the piston
ensures only liquid refrigerant to enter the
displacement and horsepower per ton of
evaporator.
refrigeration are reduced for all refrigerants.
In this system as only liquid refrigerant enters
The percent gain is less pronounced in the
the evaporator, the size of the evaporator can
case of ammonia because of its larger latent
be reduced.
heat of vaporization as compared to liquid
specific heat. Condenser
t3
p t3
Throttle valve
Compressor
3 3 tk 2
Flash chamber
to
Evaporator
4 4 1
Q0
Providing a flash chamber in a refrigerating
unit has no effect on net refrigerating effect
h (NRE), power consumption (Wc), and
Fig: Effect of liquid subcooling
coefficient of performance (COP).
Normally, cooling water first passes through
the subcooler and then through the condenser. Providing accumulator in a refrigerating
Thus, the coolest water comes in contact with circuit:
the liquid being subcooled. But this results in Accumulator is provided between throttle
a warmer water entering the condenser and valve and evaporator; the accumulator
hence a higher condensing temperature and separates vapour refrigerant and liquid
pressure. Thus, the advantage of sub-cooling refrigerant before evaporation as well as after
is offset by the increased work of evaporation and ensures only dry vapour to
compression. enter the system.
This can be avoided by installing parallel
Condenser
cooling water inlets to the subcooler and
condenser. In that case, however, the degree
Throttling valve
of sub-cooling will be small and the added
cost of the subcooler and pump work may not Compressor
be worthwhile. It may be more desirable to
use the cooling water effectively in the
condenser itself to keep the condensing Accumulator
temperature of the cooling water inlet as
minimum as possible. Evaporator
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Providing an accumulator has no effect on net When difference between condenser pressure
refrigerating effect (NRE), power and evaporator pressure is very high, we go
consumption (Wc), and coefficient of for cascaded system.
performance (COP).
Due to cascading:
Providing an expansion cylinder in a i. NRE increases
refrigerating circuit instead of a throttle valve : ii. Wc decreases
Compressor connects low pressure side to iii. COP increases
high pressure side where as expander iv. compressor discharge temperature
connects high pressure side to low pressure decreases, dryness fraction decreases
side. v. pressure ratio(rp) decreases
In a refrigeration circuit expansion starts on vi. volumetric efficiency( vol ) increases
the saturated liquid line. Due to fluid friction
and eddy currents whatever gain in work is Bell Coleman cycle or Reversed Joule cycle:
there it is lost in friction. As a result the net
gain in work is less. T
2
Condenser HP-side P
3 2
3 1
3 2
Expansion 4
4 1
cylinder Compressor
v s
Condenser
2
3 1
Liquid–vapour
Regenerative
Heat Exchanger
3
1
Evaporator
4
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IC Engines
IC Engines EC Engines
Open Cycle Wankel Gasoline Diesel Steam Stirling Steam Closed Cycle
Gas Turbine Engine Engine Engine Engine Engine Turbine Gas Turbine
5. Stroke length: The distance traveled by the 1. High temperature reduces the strength of the
piston from one dead centre to the other dead piston and cylinder liner.
center position (DCP) is called the stroke 2. Overheating may lead to burning of
length. This is always equal to twice the crank lubricants, thus there may be possibility of
throw or crank radius. i.e., L = 2r lubrication failure and metal to metal contact,
Where, L = stroke length, r = crank radius. thus more heat generation due to friction.
3. The overheating may cause uneven expansion
6. Compression ratio: It is the ratio of the total of the piston and cylinder that may lead to
volume of the cylinder to the clearance piston seizure.
volume, Referring to above figure, 4. The overheated cylinder or piston may lead to
Vs Vc pre-ignition of charge in SI engines.
the compression ratio =
Vc 5. As temperature of the cylinder increases, the
Where, Vs = the swept volume, volumetric efficiency decreases, and hence
Vc = the clearance volume the power output of the engine is reduced.
For petrol engines, compression ratio varies
from 5 : 1 to 7 : 1 and for diesel engines Effects of Engine Undercooling :
varies from 14 : 1 to 22 : 1 The cooling system in an internal combustion
engine should provide adequate cooling but not
ENGINE-COOLING SYSTEM excessive cooling. However, the excessive
cooling is not as harmful as overheating. But
Necessity of cooling : undercooling is undesirable due to the following
The temperature of gases inside the engine reasons.
cylinder, due to combustion reaches a quite high 1. At low temperature, starting of the engine
value (more than 25000C) during a cycle. If an becomes difficult.
engine is allowed to run without external cooling, 2. At low temperature, there is poor vaporization
the cylinder walls, cylinder liner, and piston will of fuel, the combustion is not proper and the
tend to attain the average temperature of the hot engine runs erratically.
gases to which they are exposed, which may be of 3. At low temperature, the viscosity of
the order of 1000 to 15000C. If the cylinder wall lubricating oil increases, it offers more
temperature exceeds 2650C, the lubricating oil frictional resistance and thus the output of the
starts losing its viscosity, starts evaporating, thus engine decreases.
tending towards lubrication failure. Also, the high 4. Undercooling of the engine may change the
temperature may cause excessive stresses in some valve clearance and settings.
parts, making them useless for further operations. 5. Overcooling may reduce engine life due to
Therefore, the internal combustion engines are corrosion and carbon deposits.
provided with cooling arrangement, which keeps In general, undercooling affects the economy and
the engine temperature well within the safe life of the engine.
working temperature limits. There are two basic types of cooling systems used
in reciprocating engines to absorb and dissipate
Effects of engine Overheating: the heat from hot cylinders.
The following are the harmful effects of engine 1. Air-cooling system, and
overheating: 2. Liquid-cooling system.
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Where, R is the characteristic gas constant. Enrichment beyond the chemically correct ratio
Cp = a1 + k1T + k2T2 will lead to incomplete combustion and loss in
Cv = b1 + k1T + k2T2 thermal efficiency. Therefore, it will appear that
thermal efficiency will increase as the mixture is
The value of decreases with increase in made leaner. However, beyond a certain leaning ,
temperature due to variation of specific heats.
the combustion becomes erratic with loss of
During the compression stroke, the final
efficiency. Thus the maximum efficiency is
temperature and pressure would be lower if
within the lean zone very near the stoichiometric
constant values of specific heat are used. This is
ratio. This gives rise to combustion loop. This
shown in the below figure.
shown in below figure.
2. Fuel-Air Ratio :
(i) Efficiency: As the mixture is made lean (less
fuel) the temperature rise due to combustion
will be lowered as a result of reduced energy
input per unit mass of mixture. This will Fig 4: Effect of mixture strength on thermal
result in lower specific heat. Further, it will (iii) Maximum temperature: At a given
lower the losses due to dissociation and compression ratio the temperature is slightly
variation in specific heat. The efficiency is rich, ie., around 6% or so (F/A = 0.072 or A/F
therefore, higher and in fact, approaches the = 14 : 1) as shown in figure6. At chemically
air-cycle efficiency as the fuel-air ratio is correct ratio there is still some oxygen present
reduced as shown in (fig. 4). because of chemical equilibrium effects a rich
mixture will cause more fuel to combine with
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55 Thermodynamics
oxygen at that point thereby raising the (v) Exhaust Temperature : The exhaust gas
temperature. However, at richer mixtures temperature, T4 is maximum at the chemically
increased formation of CO counters this correct mixture as shown in figure7. At this
effect. point the fuel and oxygen are completely used
up, as the effect of the chemical equilibrium is
not significant. At lean mixtures, because of
less fuel, T3 is less and hence T4 is less. At
rich mixtures less sensible energy is
developed and hence T4 is less. However, the
behaviour of T4 with compression ratio is
different from that of T3 as shown in figure 7.
Unlike T3, the exhaust gas temperature, T4 is
lower at high compression ratios, because the
increased expansion causes the gas to do more
work on the piston leaving less heat to be
rejected at the end of the stroke. The same
Fig 5: Effect of F/A ratio on Power effect is present in the case of air-cycle
analysis also.
(iv) Maximum Pressure: The pressure of a gas
in a given space depends upon its temperature
and the number of molecules. The curve of p3,
therefore follows T3, but because of he
increasing number of molecules p3 does not
start to decrease until the mixture is some
what richer than that for maximum T3 (at F/A
= 0.083 or A/F 12 : 1), i.e., about 20 per cent
rich (shown in fig 6).
Fig 7: Effect of F/A ratio on exhaust gas temperature
of higher compression ratios and thus the the ignition lag increases, the amount of fuel
engine thermal efficiency and the power accumulated in the combustion chamber
output can be greatly increased. increases and when combustion actually takes
place, abnormal amount of energy is suddenly
(vii) Gum Deposits: Reactive hydrocarbons and released causing an excessive rate of pressure
impurities in the fuel have a tendency to rise which results in an audible knock. Hence,
oxidize upon storage and form liquid and solid a good CI engine fuel should have a short
gummy substances. The gasoline containing ignition lag and will ignite more readily.
hydrocarbons of the paraffin, naphthenes and Furthermore, ignition lag affects the starting,
aromatic families forms little gum content will warm up, and leads to the production of
cause operating difficulties such as sticking exhaust smoke in CI engines. The present day
valves and piston rings carbon deposits in the measure in the cetane rating, the best fuel in
engine, gum deposits in the manifold, general, will have a cetane rating sufficiently
clogging of carburetor jets and enlarging of high to avoid objectionable knock.
the valve stems, cylinders and pistons. The
amount of gum increases with increased (ii) Volatility: the fuel should be sufficiently
concentrations of oxygen, with rise in volatile in the operating range of temperature
temperature, with exposure to sunlight and to produce good mixing and combustion.
also on contact with metals. Gasoline Figure below is a representative distillation
specifications therefore limit both the gum curve of a typical diesel fuel.
content of the fuel and its tendency to form
gum during storage.
prerequisite to ensure good mixing and Because of this non-linear variation, a new scale
therefore complete combustion. was derived which expresses the approximate
relative engine performance and the units of this
(v) Viscosity: CI engine fuels should be able to scale are known as the Performance Numbers,
flow through the fuel system and the strainers PN. Octane numbers, ON above 100 can be
under the lowest operating temperatures to computed by
which the engine is subjected to.
ON(>100)
(vi) Corrosion and Wear: The fuel should not 28.28A
cause corrosion and wear of the engine = 100
1 0.736A 1 0736A 0.035216A 2
components before or after combustion.
These requirements are directly related to the Where, A is TEL in ml/gal of fuel,
presence of sulphur, ash and residue in the Or from the performance number, PN
fuel. PN 100
Octane Number 100
3
Rating of SI Engine Fuels:
According to a standard practice, the antiknock Rating of CI Engine Fuels:
value of an SI engine fuel is determined by In compression-ignition engines, the knock
comparing its antiknock property with a mixture resistance depends on chemical characteristics as
of two reference fuels, iso-octane (C8H18) and well as on the operating and design conditions of
normal heptane (C7H16). Iso-octane chemically the engine. Therefore, the knock rating of a
being a very good antiknock fuel, is arbitrarily diesel fuel is found by comparing the fuel under
assigned a rating of 100 octane number. Normal prescribed conditions of operation in a special
heptane (C7H16), on the other hand, has very poor engine with primary reference fuels. The
antiknock qualities and is given a rating of 0 reference fuels are normal cetane, C16H34, which
octane number. is arbitrarily assigned a cetane number of 100 and
Octane Number: The Octane number of fuel is alpha methyl naphthalene, C11H10, with an
defined as the percentage by volume, of iso- assigned cetane number of 0.
octane in a mixture of iso-Octane and normal Cetane Number: Cetane number of fuel is
heptane, which exactly matches the knocking defined as the percentage by volume of normal
intensity of the fuel in a standard engine under a cetane in a mixture of normal cetane and -
set of standard operating conditions. methyl naphthalene which has the same ignition
The addition of certain compounds (e.g. tetraethyl characteristics (ignition delay) as the test fuel
lead) to iso octane produces fuels of greater when combustion is carried out in a standard
antiknock quality (above 100 octane number).The engine under specified operating conditions.
antiknock effectiveness of tetraethyl lead, for the Since ignition delay is the primary factor in
same quantity of lead added, decreases as the controlling the initial auto ignition in the CI
total content of lead in the fuel increases. engine, it is reasonable to conclude that knock
Furthermore, each octane number at the higher should be directly related to the ignition delay of
range of the octane scale will produce greater the fuel. Knock resistance property of diesel oil
antiknock effect compared to the same unit at the can be improved by adding small quantities of
lower end of the scale. For instance, octane compounds like amyl nitrate, ethyl nitrate or
number increases from 32 to 33 octane number. ether.
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59 Thermodynamics
bsfc (kg/kW h)
complete combustion for a particular fuel. Power output
Complete combustion means all carbon in the
fuel is converted to CO2 and all hydrogen to H2O.
A mixture which contains less air than the bsfc
stoichiometric requirement is called a rich
mixture (example, A/F ratio of 12:1, 10:1 etc.). Best economy
A mixture which contains more air than the 8 10 12 14 16 18 20 22
Stoichiometric requirement is called a lean A/F ratio (kg of air/kg of fuel)
mixture (example, A/F ratio of 17:1, 20:1 etc.)
There is however, a limited range of A/F ratios in Carburetor
a homogeneous mixture, only within which
combustion in an SI engine will occur. Outside Compensating Devices:
this range, the ratio is either too rich or too lean to A mixture of constant air-fuel ratio is always
sustain flame propagation. This range of useful required for wide range of speed of an engine for
A/F ratio runs from approximately 9:1 (rich) to economic operation. This required condition
19:1 (lean) as indicated in the figure cannot be fulfilled with a single jet carburetor as
it gives richer mixture with increasing speed. A
Excess fuel Excess air number for devices are used to fulfil the above
Too rich
requirement. The increased richness of the
Combustible Too lean
to burn range to burn
mixture with increasing speed can be reduced
either by supplying more quantity of air
9 15 19 (proportionately increased) or reducing the
Fig: Air - fuel ratio
quantity of fuel supplied (proportionately
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60 ISRO_Interview Guidance - 2020
Valve
spring
Float Extra air
Float chamber
From atmosphere
Fig: Auxiliary valve Carburetor
Fig: Compensating jet device
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61 Thermodynamics
With the increase in air flow rate, there is the main jet and the air bleed jet will be filled
decrease of fuel level in the compensating well, with fuel. When the engine starts, initially the
with the result that fuel supply through the fuel starts coming through the main as well as the
compensating jet decreases. The compensating jet air bleed jet (A). As the engine picks up, only air
thus progressively makes the mixture leaner as starts coming through the air bleed and mixes
the main jet progressively makes the mixture with fuel at B making a air-fuel emulsion. Thus
richer. The sum of the two tends to keep the fuel- the fluid stream which has become an emulsion
air mixture more or less constant as shown in of air and liquid has negligible viscosity and
below Fig. The main jet curve and the surface tension. Thus the flow rate of fuel is
compensating jet curve are more or less augmented and more fuel is sucked at low
reciprocals of each other. suctions. By proper design of hole size at B
compatible with the entry hole at A, it is possible
to maintain a fairly uniform mixture ratio for the
entire power range of the operation of an engine.
If the fuel flow nozzle of the air-bleed system is
placed in the centre of the venturi, both the air-
bleed nozzle and the venturi, are subjectd to same
engine suction resulting approximately same fuel-
air mixture for the entire power range of
operation.
Fig: Effect of Compensating jet device on F/A ratio
(d) Automatic Choke:
It is necessary to provide a very rich mixture
(c) Air bleed jet: during starting of the engine in cold weather.
This is accomplished by providing starting jet
and a valve in the air-passage on the air
stream side of the venturi. This valve is
known as choke valve.
The choke valve is kept almost closed during
starting in cold weather. This creates the high
vacuum around the fuel jet and causes extra
flow of fuel through the jet and enrich the
mixture.
the pressure difference causing the fuel flow mono-oxide emission. The enrichment E, due
is zero and therefore there will be no fuel to density variations closely follows the
flow. By adjusting the control valve, any relationship
desired pressure difference can be maintained 0 PT
causing the flow of desired fuel rate. E 1 0
P T0
Where subscript ‘0’ refers to the calibration
conditions.
Control valve To engine
Small vent
V
line Firing Order :
Every engine cylinder must fire once in every
cycle. This requires that for a four-stroke four-
cylinder engine the ignition system must fire for
2 2 every 180 degrees of crank rotation. For a six-
cylinder engine the time available is only 120
degrees of crank rotation.
Float chamber
The order in which various cylinders of a
multicylinder engine fire is called the firing order.
Large vent line
1 1 The number of possibilities of firing order
From atmosphere depends upon the number of cylinders and throws
Fig: Pressure reduction method of compensation
of the crankshaft. It is desirable to have the power
impulses equally spaced and from the point of
ALTITUDE COMPENSATION view of balancing this has led to certain
conventional arrangements of crankshaft throws.
An inherent characteristic of the conventional Further, there are three factors which must be
float type carburetor is to meter air and fuel considered before deciding the optimum firing
by volume and not by weight which is the order of an engine. These are :
basis of calculating combustible air-fuel ratio. 1) Engine vibration
The weight of one cubic metre of air 2) Engine cooling
decreases as altitude increases. Most 3) Development of back pressure.
automobile carburettors are calibrated at
altitudes near sea level and similarly The firing order for some multicylinder engines
production carburettors are flow tested and are given below.
adjusted in a controlled environment.
When the atmospheric conditions are different Number of cylinders Firing order
from those at which the carburettor was 2-cylinder engine 1, 2
calibrated, density of air changes. If the 3-cylinder engine 1, 3, 2
vehicle is driven at an altitude lower than the 4-cylinder engine 1, 3, 4, 2 or
calibration altitude a lean mixture is obtained 1, 2, 4, 3
which results in poor driveability. 6-cylinder engine 1, 5, 3, 6, 2, 4 or
1, 4, 2, 6, 3, 5
At altitudes higher than the calibration
8-cylinder engine 1, 6, 2, 5, 8, 3, 7, 4
altitude a rich mixture is supplied which
Or 1, 8, 7, 3, 6, 5, 4, 2
causes increases in hydrocarbon and carbon
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63 Thermodynamics
Fig: Valve timing diagram for 2-stroke The intake valve starts to open 10 before TDC. It
Diesel engine may be noted from Fig. that for a low speed
engine, the intake valve closes 10 after BDC,
The valve timing values for a two stroke Petrol
and for a high speed engine, 60 after BDC.
engine is as follows
TPO before 35 BDC At low engine speeds, the charge is moving into
the cylinder relatively slowly, and its inertia is
TPC after 35 BDC
relatively low.
EPO before 45 BDC
EPC after 45 BDC If the intake valve were to remain open much
Spark ignition before 20 TDC beyond BDC, the up-moving piston on the
compression stroke would tend to force some of
The valve timing values for a two stroke Diesel the charge, already in the cylinder back into the
engine is as follows intake manifold, with consequent reduction in
volumetric efficiency.
TPO before 45 BDC
TPC after 45 BDC
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64 ISRO_Interview Guidance - 2020
Hence, the intake valve is closed relatively early Valve Timing Diagram of Four-Stroke Diesel
after BDC for a slow speed engine. High speed Engines
engines, however, bring the charge in through the The valve timing values for a four stroke CI
intake manifold at greater speeds, and the charge engine is as follows
has greater inertia. As the piston moves up on the IVO up to 30 before TDC
compression stroke, there is a “ram” effect IVC up to 50 after BDC
produced by the incoming mixture which tends to EVO up to 45 before BDC
pack more charge into the cylinder. EVC up to 15 before TDC
For either a low speed or a high speed engine
operating in its range of speeds, there is some
point at which the charge per cylinder per cycle
becomes a maximum, for a particular valve
setting.
If the revolutions of the low speed engine are
increased beyond this point, the intake valve in
effect close too soon, and he charge per cylinder
per cycle is reduced.
If the revolutions of the high speed engine are
increased beyond this maximum, the flow may be
chocked due to fluid friction. These losses can
become greater than the benefit of the ram, and
the charge per cylinder per cycle falls off.
The timings of the exhaust valve also affects the
Fig: Valve timing diagram high speed 4-stroke Diesel engine
volumetric efficiency. The exhaust valve usually
opens before the piston reaches BDC on the
expansion stroke. This reduces the work done by
the expanding gases during the power stroke, but
decreases the work necessary to expel the burned
products during the exhaust stroke, and results in
an overall gain in output.
During the exhaust stroke, the piston forces the
burned gases output at high velocity. If the
closing of the exhaust valve is delayed beyond
TDC, the inertia of the exhaust gases tends to
scavenge the cylinder better by carrying out a
greater mass of the gas left in the clearance
volume, and results increased volumetric
efficiency. Consequently, the exhaust valve is
often set close a few degree after TDC on the
Fig: Valve timing diagram low and medium speed
exhaust stroke, as indicated in Fig. 4-stroke Diesel engine
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65 Thermodynamics
CEMS is vital to ascertain the performance will more and also speed of vehicle vice
of the boiler e.g excess O2 emission infers versa.
that you are supplying excess air which
would cool your boiler. In order to heat this 26. How many types of engine?
excess air you will be supplying extra fuel. Ans: 2 types, i.e internal and external combustion
Thus decreasing the efficiency of boiler. engine.
Similarly the qty of CO would mean less air
and thus incomplete combustion in the 27. Why shaft eccentricity is not monitored in
boiler. SOX and NOX are measured for gas turbines?
environmental reasons. Ans: Eccentricity is usually measure in steam
Hope this bird's eye description of CEMS turbines as the turbine shaft is much longer
satisfies your query. than gas turbine and the chances of
displacement of shaft from its central
21. What is meant by excess air? rotational axis very low that's why it is not
Ans: It is the extra amount of air which is require considered in case of gas turbine.
for the combustion of fuel in an engine
because mixture of air and fuel is not 28. Define boiler parts, types and working.
homogenous. Ans: Boilers are usually installed to produce
steam which ultimately is used in Power
22. Why is steam-water separation equipment Plants, and for other processing units. There
so important in good boiler operation? are different type of Boilers based on the
Ans: To get final steam temperature as per applications. Some of them are listed below.
Design. If water is present in the steam, 1. Atmospheric Fluidised Bed Combustion
super heating of steam will suffer. Boiler
2. Pulverized Fluidised Bed Combustion
23. Major purposes of the steam drum? Boiler
Ans: Steam drum separates steam and water. 3. Circulating Fluidised Bed Combustion
Boiler
24. The Length of the Divergent Cone is about 4. Travelling Grate Boiler
3 to 4 times than that of the Convergent 5. Waste Heat Recovery Boiler.
Cone why?
Ans: In the divergent cone fluid expands with The General Parts include as mentioned
high pressure and high velocity this causes below.
the damage of the pipe line. To compensate 1. Steam Drum (Heart of the Boiler where
this divergent cone is always 3 to 4 times steam and water is segregated)
the convergent cone. 2. Furnace (Water Wall) is a closed system
where combustion takes place
25. What is the effect of changing in C.C of the 3. Economiser (Nothing But Pipes of size
engine? 50 NB (varies depending on the size of
Ans: In I. C engine C.C is actually cubic capacity the boiler) to preheat water by the flue
of engine that is required for producing gas produced during the combustion
power of engine. So when C.C of engine 4. Evaporator, Superheater coils,
will more then its power producing capacity 5. Air Preheater
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68 ISRO_Interview Guidance - 2020
6. Bunker and Fuel Feeding Systems Ans: Generally the steam turbine is shown in
7. Dosing Systems, Sample Coolers horizontal V-shape position which indicate
8. ID, FD, PA & SA Fans that the blades will be smaller for high
9. Bed Ash Coolers pressure side and slight big for medium
10. Valves, Fittings etc. pressure and bigger for low pressure this to
Normally Boiler capacity is mentioned in compensate the expanded volume of a
tph (tonnes per hour) i.e. how much steam is steam in a turbine
produced in an hour. Normally to produce so small size blade = high pressure
an electricity of 1 MW, 4 to 5 tonnes of medium size blade = medium pressure
Steam per hour is required. Accordingly long size blade = low pressure
Boilers are designed. It is a closed pressure
vessel. 34. What is the material composition in IBR
tubes?
29. What are the three methods of the heat Ans: Copper, brass and steel tubes
transfer? Give example for each.
Ans: Conduction, convection and radiation. 36. What is the purpose of inter cooler in
Ex: heated rod, flow over heated plate, sun multistage compressor?
radiation. Ans: During compression the temperature of
compressed air goes up and this intercooler
30. How to produce vapour on steam turbine is provided to cool this compressed air to
main oil tank? It is a closed vassel little safe value. Intercooler is nothing but a heat
amount of water is present in purification exchanger which cools the compressed air
how? so that it can be compressed again and again
Ans: Reducing pressure depending on requirement.
31. 1st law of thermodynamics ? 37. What is the purpose of fusible plug in boiler
Ans: 1st law is the change in the internal energy and where it is located?
of a system is equal to the amount of heat Ans: Fusible plug is fitted to the fire box. It’s
supplied to the system, minus the amount of object is to put off the fire in the furnace of
work performed by the system on its the boiler when the level of water in the
surroundings. boiler falls to an unsafe limit and avoids the
explosion which may takes place due to
32. If saturated temp of water is 99.8oC at overheating of the furnace
atmospheric pressure, then how the water of
sea is evaporated at normal temp 71oC ? 38. Differentiate between VAM and CHILLER.
Ans: Sea water contains NaCl which bring down Ans: In VAM there is no requirment of electrial
boiling temp of water therefore it is energy, but in chillers electrical energy
evaporated at temp 71 place critical role.
33. If you have three steam turbine blades, how 39. How does a turbine work ?
will you find which blade is for low Ans: It works by giving steam pressure at high
pressure, high pressure and medium pressure and temperature that expands
pressure? through the turbine.
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69 Thermodynamics
40. What is a blow down valve? 49. What is the lower part of connecting rod?
Ans: Scum valves Ans: Crankpin
45. "In steam boiler, what are the various tests 54. Name the refrigerant that is used on
in water boiler?" domestic refrigerators.
Ans: 1- Sample cooler test Ans: R134a , R12
2- a test for the safety valve
3- Ph test 55. Name the refrigerant that is the replacement
of R12.
46. Give five boiler mounting valves. Ans: R12 is seldom used now since it has about
Ans: 1- safety valves 5% of ozone depletion potential as it is a
2- blowdown valves partially halogenated refrigerant. hence the
3- check valves chlorine free R-134a has been recently
4- knife valves developed to replace R12.
5- gate valves
56. Name two types of leak detectors and the
48. What will be the cause of the loose method of application for each.
compression in a cylinder? Ans: For freon refrigeration system leak hallide
Ans: Weak compression may be due to wornout torch is used. For halogenated refrigerants
piston rings or wornout piston and wornout electronic leak detectors are used.
cylinder or all of these.
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70 ISRO_Interview Guidance - 2020
57. How to determine the capacity of the coils and that air become chilly and
refrigeration system? How we use flows out the vents.
condenser coils, compressor, capillarity, 62. "In refrigeration, why during operations is
compressor? running low pressure at the suction side?"
Ans: To determine the refrigeration system by Ans: Before coming to suction side of the
test of COP and use the condenser coils, compressor, refrigerant passes expansion
compressor, capillarity, based on the valve which reduce the pressure of the
properties refrigerant then to evaporator.
58. What is meant by one ton Air conditioner? 63. Diagram of refrigeration?
How fast it cools a room ? Ans: Compressor(Refrigerant is gaseous)-->
Ans: 1 ton refrigeration means extracts condenser
210kJ/min heat from the system. (Refrigerant is liquid)---> expansion valve
(Low pressure liquid)-----> evaporator
59. Why we cannot cool the room by opening (Refrigerant, is liquid)---> compressor.
the refrigerator ?
Ans: Because in case of opened refrigerator, the 64. What is the hottest part of refrigerant in the
refrigerator takes the room heat but also refrigeration system?
emits the motor heat (during working) so Ans: Compressor outlet is the hottest part of the
due to that refrigeration system
Total Heat in Room = Room Heat +
Refrigerator Motor Heat. 65. What is the effect if your refrigeration
So over all the refrigerator cannot cool system has an air?
the room but it will slightly increases the Ans: Medium of refrigerant is not applicable
room temperature.
66. Give the different ways of detecting leaking
60. Why is Air Conditioner capacity measured refrigerants.
in ton, like 1.5 ton ? Ans: 1-Halide Torch Method (Halogen Selective
Ans: 1 ton of refrigeration is 3.5167kW heat Detectors)
absorbing capacity refer amount of 2-Soap Bubble Test
refrigeration effect produce by melting of 3-stand Hold Test
2000 pounds ice maintaining at 32oF in 24 4-Ultrasonic Leak Detectors
hrs 5-Electronic Leak Detectors(R-22 nitrogen
test mix)
61. Give the function of evaporator. 6-Nitrogen Isolation Test
Ans: The evaporator coils are used to transform 7-Fluroscent Dyes (leak detection dyes)
the refrigerant from a liquid to a gas. It is
the last device in the cooling system. To 67. What will happen if there is moisture in
accomplish this, the evaporator allows the refrigeration system?
fluid refrigerant to expand with lower Ans: Refrigeration systems are very sensitive to
pressure in the coils. As the liquid expands, moisture in the refrigerant side of the
it loses heat. A fan blows warmer air over system. If moisture gets into the system,
failure may occur due to:
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71 Thermodynamics
Ice formation in expansion valves, capillary 09. When crude oil is heated, which hydro carbon
tubes or evaporators, comes first?
Corrosion of metals, 10. Explain, why re-heater is used in gas turbine?
Copper plating,
Chemical damage to insulation in hermetic 11. Why there is concern for setting nuclear
compressors or other system materials. power plant?
12. Where did nuclear disaster take place?
68. Kinds of refrigerants and their properties.
13. How nozzle work?
Ans: Freons
natural refrigerants 14. Explain the difference between projectile
hydrocarbons motion and rocket motion?
15. Tell us boiler thickness formulae’s
69. Give five parts inside the centrifugal pump
16. What are the effects of boiler scale for
and explain each.
mation?
Ans: 1- Impeller
2- Shaft 17. How pressure cookers work ?
3- Mechanical seal 18. Draw the p-v diagram of Rankine cycle?
4- wear rings
5- black plate 19. Why Throttle valve is used in stream engine?
20. What is the effect of reheater in the gas
turbine?
Interview Practice Questions 21. Why Entropy decreases with increase in
temperature?
01. Working & advantages of four stroke IC 22. What is the difference between Fan and
engine. Blower?
02. What is the calorific value of CNG, ethylene? 23. Difference between Performance and
03. Explain two stroke and four stroke engine. Efficiency?
04. Who invented a four stroke engine? 24. How a Diesel Engine works as Generator?
According to you which one is more efficient 25. Compare Brayton Cycle and Otto Cycle?
four stroke engine and a two stroke engine
and why? 26. Types of refrigeration and where they are
used?
05. Why heavy vehicles are made by diesel
engine? 27. Difference between refrigerator and a air
conditioner?
06. What are the order of firing in 4-cylinder
engine? 28. Difference between induced draft cooling
tower & natural draft cooling tower?
07. Draw the diagram of diesel cycle.
29. What is mean by specific steam consumption?
08. What are the Advantages and Disadvantages
of using LPG in car? 30. Why water is used as a working fluid in
Thermal power plant?
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