Detailed Solutions

ESE-2018 Mechanical Engineering

Mains Test Series Test No : 9
Section A: Machine Design + Mechatronics and Robotics
Q.1 (a) Solution:
Given: D = 180 mm or R = 90 mm; d = 60 mm or r = 30 m; P = 1 N/mm2, N = 120 rpm,
μ = 0.015
W

Shaft

Oil

r R

Let w = load to be supported

Assuming that the pressure is uniformly distributed over the bearing surface, therefore
bearing pressure (P),
W
P =
π( R 2 − r 2 )

W = π( R 2 − r 2 )
W = π(902 – 302) = 22619.47 N Ans. (i)
10 | ESE 2018 : MAINS TEST SERIES

2 ⎛ 90 3 − 30 3 ⎞
Frictional torque is given as T = × 0.015 × 22619.47 ⎜ 2 ⎟
3 ⎝ 90 − 30 2 ⎠
= 22053.98 ≈ 22054 N.mm or 22.054 N.m
2 πNT 2 π× 120 × 22.054
Power lost in friction, P = =
60 60
= 277.14 w or 0.277 kW Ans. (ii)
Heat generated at the bearing = Power lost in friction
= 0.277 × 60 = 16.62 kJ/min Ans. (iii)

Q.1 (b) Solution:

In robot nomenclature ‘n’ stands for normal, ‘O’ stands for orientation and ‘a’ stands for
approach axis.
z
a
45° o

45°

n P
7
3

5 y

Homogeneous matrix can be represented as:

⎡ nx ox ax Px ⎤
⎢n oy ay Py ⎥⎥
⎢ y
F = ⎢
n oz az Pz ⎥
⎢ z ⎥
⎢⎣ 0 0 0 1 ⎥⎦

Here, P x = 3, Py = 5, Pz = 7
As n-axis is parallel to x-axis, nx = cos 0° = 1, ny = 0 , nz = 0
As o-axis is at 45° relative to the y-axis, ox = 0, oy = cos 45° = 0.707, oz = 0.707
As a-axis is at 45° relative to the z-axis, ax = 0, az = cos 45° = 0.707, ay = –cos 45° = –0.707

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 Test No : 9 MECHANICAL ENGINEERING | 11

⎡1 0 0 3⎤
⎢0 0.707 −0.707 5 ⎥
⎢ ⎥
Hence, F = ⎢0 0.707 0.707 7 ⎥ Answer
⎢ ⎥
⎣0 0 0 1⎦

Q.1 (c) Solution:

240 × π
Given: Drum diameter, d = 500 mm, or r = 250 mm = 0.25m, θ = 240° = = 4.2 rad,
180
t = 5 mm, w = 100 mm, μ = 0.3, σt = 50 N/mm2
P
500
150

T1 O B
75
C
T2

240°

All dimensions in mm

Let P = least force required at the end of the lever

Since the length OB is greater than OA, therefore the force at the end of the lever (P) must
act in upward direction. As the drum rotates in CCW direction, the end of the band
attached to A will be tight with tension T1 and the end of the band attached to B will be
slack with tension T2.
T1 μθ
= e = exp[0.3 × 4.2] = 3.5254
T2
Maximum tension in the band,
T 1 = stress × area of band
T 1 = σt × l × w
= 50 × 5 × 100 = 25000 N
T1 25000
T2 = = = 7091.35 N
3.5254 3.5254
Now taking moments about the fulcrum O, we have
P × 500 + T1 × 75 = T2 × 150
7091.35 × 150 − 25000 × 75
P = = −1622.6 N
500

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P = 1622.6 N (magnitude) Ans. (i)

Since, P is negative, therefore the brake is self-locking.
torque applied to the brake drum shaft: (T1 – T2)r
T = (25000 – 7091.35) × 0.25
T = 4477.1625 N.m Ans. (ii)

Q.1 (d) Solution:

A tactile sensor is something that responds to the changes in input pressure on it. Touch
screens are one such example. They are of two types of them (1) Capacitive touch screens,
where the capacitance varies In the specific area where the touch impulse is provided.
(2) Resistive touch screens , where the resistance varies based on the touch impulses
on the screen.

Force/pressure

PVDF

Output
A.C. input

Soft film PVDF

Schematic of a tactile sensor

Above schematic shows the construction of piezo-electric polyvinylidene fluoride (PVDF)

based tactile sensor. It has two PVDF layers separated by a soft film which transmits the
vibrations. An alternating current is applied to lower PVDF layer which generates
vibrations due to reverse piezoelectric effect. These vibrations are transmitted to the
upper PVDF layer via soft film. These vibrations cause alternating voltage across the
upper PVDF layer. When some pressure is applied on the upper PVDF layer the
vibrations gets affected and the output voltage changes. This triggers a switch or an
action in robots or touch displays.
Application of Tactile Sensors: In general, tactile sensors are used to sense the contact of
fingertips of a robot with an object. They are also used in manufacturing of ‘touch display’
screens of visual display units (VDUs) of CNC machine tools. Tactile sensors have been
used in many different applications from robotics to the medical field, consumer devices
and the auto industry.

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 Test No : 9 MECHANICAL ENGINEERING | 13
Q.1 (e) Solution:
Given: C = 40500 N
Step I: Equivalent load for complete work cycle
Consider the work cycle of one minute duration. The values of load P and revolutions N
are tabulated as follows:

Element Revolutions
Element P Speed
time N in element
No. ( N) (rpm)
(minute) time
1 5000 0.25 500 125

2 10000 0.5 700 350

3 7000 0.25 400 100

Total 1.00 575

3
N 1 P13 + N 2 P23 + N 3 P33
Pe =
N1 + N2 + N3

125(5000)3 + 350(10000)3 + 100(7000)3

3
=
575
= 8860.06 N
Step-II: Bearing life (L10h)
According to the load-life relationship,
3 3
⎛C⎞ ⎛ 40500 ⎞
L 10 = ⎜ ⎟ =⎜ ⎟ = 95.51 million rev.
⎝ Pe ⎠ ⎝ 8860.06 ⎠

L10 × 106 95.51 × 106

L10h = = = 2768.45 h
60n 60(575)

Q.2 (a) Solution:

σyt = 700 MPa, M = 12 kN-m = 12 × 10 6 N-mm, T = 36 kN-m = 36 × 10 6 N-mm, N = 2,
E = 210 × 103 N/mm2, v = 0.25
Let d = diameter of the shaft in mm
Section modulus of the shaft,
π 3
z = d = 0.0982 d3 mm3
32
Bending stress due to the bending moment:

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M 12 × 106 122.2 × 10 6
σ1 = = = N/mm2
Z 0.0982 d 3 d3
Shear stress due to torsional moment:
16T 16 × 36 × 106 183.35 × 106
τ = = = N/mm2
πd 3 πd 3 d3
σ1 + σ 2 1
Maximum principal stress: σt1 = + ( σ 1 − σ 2 )2 + 4 τ 2
2 2
σ1 1
σ t1 = + σ12 + 4τ2
2 2
σ1 1
Minimum principal stress: σt2 = − σ12 + 4 τ2
2 2
2 2
122.2 × 106 1 ⎛ 122.2 × 106 ⎞ ⎛ 183.35 × 106 ⎞
σ t1 = + ⎜ ⎟ + 4⎜ ⎟
2d 3 2 ⎝ d3 ⎠ ⎝ d3 ⎠

61.1 × 106 1 10 6
= + × (122.2)2 + 4 × (183.35)2
d3 2 d 3

61.1 × 106 193.26 × 10 6 254.36 × 10 6

= + = N/mm2
d3 d3 d3

61.1 × 106 193.26 × 106 132.16 × 106

Similarly, σ t2 = − =− N/mm2
3 3 3
d d d
1. According to maximum shear stress theory:

σt 1 − σt 2 (254.36 + 132.16) × 106

τmax = −
2 2 × d3

193.26 × 10 6
= 3 N/mm2
d
σ yt 193.26 × 10 6 700
τmax = or = = 175
2N 3 2×2
d

193.26 × 106
d3 = ⇒ d = 103.36 mm Answer (i)
175

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 Test No : 9 MECHANICAL ENGINEERING | 15
2. According to maximum strain energy theory
2
1 ⎡ ⎛ σ ⎞
⎣(σt 1 )2 + (σt 2 )2 − 2 υ σt1σt 2 ⎦⎤ = 1 ⎜ yt ⎟
2E 2 E ⎝ FOS ⎠
2
⎛ σ yt ⎞
σt21 + σt22 − 2 v σt 1 σt 2 = ⎜ ⎟
⎝ N ⎠
1012 ⎡
⎣ 254.36 2 + 132.16 2 + 2 × 0.25 × 254.36 × 132.16 ⎦⎤ = (350)
2
6
d
d 6 = 0.808 × 1012 or d = 96.5 mm Answer (ii)

Q.2 (b) Solution:

The torque-crank rotation angle for one revolution with reference mean torque, below
and above the line is shown below

411 C 336 F 229 H 263 K

A
B 264 D G 371 J 241 L
29 307

Let the energy of the flywheel at point A be E units. The energy level at different points
can be computed as below:
Energy at A = E
B = E – 29
C = E – 29 + 411 = E + 382
D = E + 382 – 264 = E + 118
F = E + 118 + 336 = E + 454
G = E + 454 – 307 = G + 147
H = E + 147 + 229 = E + 376
J = E + 376 – 371 = E + 5
K = E + 5 + 263 = E + 268
L = E + 268 – 241 = E + 27
Energy levels at various points indicate that maximum and minimum energy levels
are at point F and B respectively.
Fluctuation of energy, ΔE = Emax – Emin
= E + 454 – (E – 29)
= 454 + 29 = 483 mm2
ΔE = 483 × scale of abscissa × scale of ordinate

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2.5
= 483 × 600 × × π = 12645 N-m
180
Coefficient of fluctuation of speed,
2 × 1.5
Cs = = 0.03
100
ΔE = Iω2 Cs = mv2 Cs
ΔE 12645
m = = = 674.4 kg
2
V Cs (25)2 × 0.03
60V 60 × 25
Mean diameter of flywheel, D = = = 1.591 m say 1.6 m
πN π× 300
Assuming that 90% mass is contributed by rim, mass of rim
mmin = 0.9 m = 0.9 × 674.4 = 606.96 kg
Mass of rim, mrim = π D b h ρ
mrim 606.96
cross-section of flywheel (bh) = =
πD × ρ π× 1.6 × 7100
bh = 0.017 m2
We assume that the ratio of width to thickness of rim, b/h = 2.

0.017
Therefore, h = = 0.0922 m i.e. 92.2 mm
2
Let us adopt rim thickness, h = 95 mm
and width of rim, b = 2 × h = 190 mm
Hence design dimensions are as follows:
Mean diameter of flywheel, D = 1.6 m
Rim thickness, h = 95 mm
Width fo rim, b = 190 mm

Q.2 (c) Solution:

Gas pressure, Pmax = 1 N/mm2, Number of bolts, n = 16, Diameter of cylinder, D = 400 mm,
Yield point in tension, σt = 100 MPa
Ratio of elasticity of connected parts to elasticity of bolt = 1
Total force (or the external load) acting on the cylinder head i.e. on 16 bolts,

π 2
= D Pmax
4
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 Test No : 9 MECHANICAL ENGINEERING | 17

π
= × (400)2 × 1 = 125663.7061 N
4
External load on the cylinder head per bolt,

125663.7061
P2 = = 7854 N
16
Let d = Nominal diameter of the bolt and
dc = core diameter of the bolt
Initial tension due to tightening of bolt,
P 1 = 2840 d N (where, d is in mm)
a
Resultant axial load, (P) = P1 + P2
1+ a

1
= 2840 d + × 7854 = 2840 d + 3927
2

π 2
P = 2840 d + 3927 = dc × σt
4
π
2840 d + 3927 = (0.84 d)2 × 100 = 55.42 d 2
4
55.42 d 2 – 2840 d – 3927 = 0
d 2 – 51.245 d – 70.86 = 0

51.245 ± (51.245)2 + 4 × 70.86 51.245 ± 53.94

d = =
2 2
d = 52.6 mm (negative sign discarded)
Size of bolt : M56 × 5.5 Answer

Q.3 (a) Solution:

Uniform Pressure Theory:
In case of new clutches employing a number of springs, the pressure remains constant
over the entire surface area of the friction disk, with this assumption it is assumed that
p(pressure intensity) to be constant.

μω ⎛ D3 − d 3 ⎞
mt = friction torque = 3 ⎜⎜ 2 2⎟
⎟
⎝ D − d ⎠

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π
and ω = p( D2 − d 2 )
4
Uniform Wear Theory:
According to this theory, it is assumed that the wear is uniformly distributed over the
entire surface area of the friction disk. This assumption is used for worn out clutches.
πμpa d 2
mt = (D − d 2 )
8
pa = Maximum pressure intensity at the inner surface
diameter.
⎛ D+ d ⎞
or, mt = πω ⎜ ⎟
⎝ 4 ⎠
Given: Power (P) = 30 kW, N = 1200 rpm, pmax = 100 kN/m2,
D0 = outer diameter = 350 mm, μ = 0.25
No. of effective surfaces (n) = 2
⎛ D0 + Di ⎞
As, mt = μnw × ⎜ ⎟
⎝ 4 ⎠
2 πN ( mt )
Also, P ⇒ (mt) × ω =
60
2 × π× 1200 × ( mt )
30 × 103 =
60
mt = 238.73 N.m
⎛ 350 + D1 ⎞
238.73 = 0.25 × 2 × w × ⎜ ⎟
⎝ 4 × 10 3 ⎠
(1909.84) × 103 = (350 + D1) × w ...(1)
pmax × Di
Also, w = π (D0 − Di )
2

100 × 10 3 Di ⎛ 350 − Di ⎞
= π× × ×⎜ ⎟
2 103 ⎝ 103 ⎠
w = 0.1571 D1(350 – Di ) ...(2)

⎛ 1909.81 × 10 3 ⎞
⎜ ⎟
⎜ 350 + Di ⎟ = (0.1571) Di (350 – Di)
⎝ ⎠

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 Test No : 9 MECHANICAL ENGINEERING | 19
(12156.84) × 103 = Di (3502 – Di2)
(12156.84) × 103 = 122500 Di – Di3
Solving it, Di = 281.67 mm
Inner diameter, Di = 282 mm
Axial force (w) 1909.84 × 103 = w × (350 + 282)
w = 3.02 kN

Q.3 (b) Solution:

Given: (Mt)max = 200 N-m, (Mt)min = 70 N-m, (Mb)max = 600 N-m, (Mb)min = 200 N-m,
Sut = 540 N/mm2, Syt = 400 N/mm2, Se = 200 N/mm2, ( f s) = 2
Step I: Mean and amplitude stresses
1 1
(Mb)m = [( Mb )max + ( Mb )min ] = [600 + 200] = 400 N − m
2 2
1 1
(Mb)a = [( Mb )max − ( Mb )min ] = [600 − 200] = 200 N − m
2 2
1 1
(Mt)m = [( Mt )max + ( Mt )min ] = [200 + 70] = 135 N − m
2 2
1 1
(Mt)a = [( Mt )max − ( Mt )min ] = [200 − 70] = 65 N − m
2 2

32( Mb )m 32(400 × 10 3 ) ⎛ 4074.37 × 10 3 ⎞

σ xm = = =⎜ ⎟ N/mm2
πd 3 πd 3 ⎝ d 3
⎠

32( Mb )a 32(200 × 10 3 ) ⎛ 2037.18 × 10 3 ⎞

σxa = = =⎜ ⎟ N/mm2
πd 3 πd 3 ⎝ d3 ⎠

16( Mt )m 16(135 × 10 3 ) ⎛ 687.55 × 10 3 ⎞

τ xym = = =⎜ ⎟ N/mm2
πd 3 πd 3 ⎝ d 3
⎠

16( Mt )a 16(65 × 10 3 ) ⎛ 331.04 × 103 ⎞

τxya = = =⎜ ⎟ N/mm2
πd 3 πd 3 ⎝ d3 ⎠

σm = σ2xm + 3τ2xym

2
⎛ 4074.37 × 103 ⎞ ⎛ 687.55 × 103 ⎞
= ⎜ ⎟ + 3⎜ ⎟
⎝ d3 ⎠ ⎝ d3 ⎠

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20 | ESE 2018 : MAINS TEST SERIES

⎛ 4244.84 × 10 3 ⎞
= ⎜ 3
⎟ N/mm2
⎝ d ⎠

σa = σ2xa + 3τ2xya

2 2
⎛ 2037.18 × 103 ⎞ ⎛ 331.04 × 103 ⎞
= ⎜ ⎟ + 3⎜ ⎟
⎝ d3 ⎠ ⎝ d3 ⎠

⎛ 2116.33 × 103 ⎞
= ⎜ 3
⎟ N/mm2
⎝ d ⎠
Step-II: Construction of modified Goodman diagram
σ a 2116.33
tan θ = σ = 4244.84 = 0.4986 or θ = 26.5°
m
The modified Goodman diagram for this example is show in figure below.

(200)Se
sa
X θ
Sa
sm

26.5° 45° sm
O Sm Syt Sut
(400) (540)

Step-III: Permissible stress amplitude

Refer to above figure the co-ordinates of point X are obtained by solving the following
two equations simultaneously:
Sa S
+ m = 1 (a)
200 540
Sa
Sm = tan θ = 0.4986 (b)

∴ Sa = 114.76 N/mm2
Sm = 230.16 N/mm2
Step-IV: Diameter of shaft
Sa
Since, σa = ( fs ) ∴ or d = 33.29 mm

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 Test No : 9 MECHANICAL ENGINEERING | 21
Q.3 (c) (i) Solution:
A temperature sensor is a device, typically, thermocouple or RTD, that provides for
temperature measurement through an electrical signal. Instruments for measuring
ordinary temperature are known as thermometers and those for measuring high
temperatures are known as pyrometers. Since, pressure, volume, electrical resistance,
expansion coefficient, etc. are all related to temperature through the fundamental
molecular structure, they change with temperature, and these charges can be used to
measure temperature.
The instruments which are used to measure temperature are:
1. bimetallic strips
2. Electrical resistance thermometer
3. Thermocouples
4. Thermopiles
5. Thermistors
6. Pyrometer
Total radiation pyrometer
Optimal pyrometer
7. Thermo-diodes
8. Thermo-transistors
Bimetallic Strips:
Applications:
1. These are frequently used in simple ON-OFF switches
2. The bimetallic strips are also used in control switches.
3. To convert a temperature change into mechanical displacement
Advantages:
1. It is less costly when compared to other temperature measuring instruments.
2. Less maintenance expenses.
3. Stable operation over extended periods of time.
4. The accuracy of this type of instrument is between 2% and 5% of the scale.
Disadvantages:
1. Not suitable for T > 400°C.
2. Permanent deformation of metallic strip may occur.

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Metals used for bimetallic strips are:

• Yellow brass
• Invar
• Stainless steel
• Monel 410
• Inconel 702
Q.3 (c) (ii) Solution:
The length of the aluminium rod at 0°C,

l1 = l0 [1 + α Δ T]
= 12[1 + 25 × 10–6 (0 – 28)] = 11.9916 m
The length of the aluminium rod at 120°C,

l2 = l0 [1 + α Δ T]
= 12[1 + 25 × 10–6(120 – 28)] = 12.0276 m
Thus the expansion is l2 – l1 = 12.0276 – 11.9916 = 0.036 m or 36 mm

Q.4 (a) Solution:

1. System type
Ki 1
G(s) = , Gp (s) =
s s( s + 4)
K
Therefore OLTF = G(s) Gp(s) = 2 i
s (s+ 4)
As the order of s in denominator is two, this a type “2” system.
2. Steady state errors.
1
For step input R(s) =
s
⎡ sR(s ) ⎤
Therefore, ess = lim ⎢ ⎥
s → 0 ⎣ 1 + G( s) ⎦

⎡ 1 1⎤
= lim ⎢ s
s →0 ⎣ 1 + [K i / s 2 ( s + 4)] s ⎥⎦

⎡ 1 ⎤ 1
= lim ⎢ = =0
s →0 Ki ⎥ ∞
⎢1 + 2 ⎥
⎢⎣ s (s + 4) ⎥⎦

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 Test No : 9 MECHANICAL ENGINEERING | 23

1
For a ramp input R(s) =
s2
⎡ 1 1⎤ ⎡ 1 ⎤ 1
ess = lim ⎢ s Ki 2 ⎥ = lim ⎢
s →0 K ⎥= ∞ =0
s →0
⎢ 1 + s ⎥ ⎢ s + i
⎥
⎣⎢ s2 (s + 4) ⎥⎦ ⎣ s(s + 4) ⎦
3. Stability analysis with a proportional controller: for a proportional controller, the
controller transfer function is Kp. Therefore,
1
G(s) = K p
s( s + 4)

C (s ) G( s ) K p / s( s + 4) Kp
= = =
R(s ) 1 + G( s)H ( s) Kp s( s + 4) + K p
1+
s( s + 4)

C (s ) Kp
R(s ) =
s 2 + 4s + K p

Arranging the denominator of the above equation in Routh’s array, we have

s2 1 Kp

s1 4 0
s0 Kp
For stability all elements in the first column of Routh’s array should be positive. Therefore
the system is stable for Kp > 0
4. Stability analysis with an integral controller

C (s ) K i / s 2 (s + 4) Ki
= =
R(s ) 1 + [ K i / s ( s + 4)] s + 4s 2 + K i
2 3

Characteristic equation is s3 + 4s2 + Ki = 0, computing Routh’s array, We get

s3 1 0 ⎫
⎪ The system is
s2 4 Ki⎪ unstable for all the
4 × 0 − K i −K i 0 ⎪
s1 = ⎪⎪ values of Ki as
4 4 ⎬
s0 Ki 0 ⎪ there are sign changes
− × Ki − 0 ⎪ in the first column
4 = Ki ⎪
−K i ⎪ of Routh's table.
4 ⎪⎭

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Q.4 (b) Solution:

We can observe from homogeneous matrix representation that the values 5, 3, 2 (x, y, z)
represents the position of the origin of the frame and do not affect the constraint equations.
Please notice that only 3 values for directional vector are given.
Here, the three unit vectors n, o, a are mutually perpendicular, and each unit vector’s
length, represented by its directional cosines, must be equal to 1.
These contraints translate into the following six contraint equations
1. n . o = 0 (the dot product of n and o vectors must be zero.)
2. n . a = 0
3. a . o = 0
4. ⎥ n⎥ = 1 (the magnitude of the length of the vector must be 1)
5. ⎥ o⎥ = 1
6. ⎥ a⎥ = 1
nxox + nyoy + nzoz = 0 or nx(0) + 0.707 oy + nzoz = 0
nxax + nyay + nzaz = 0 or nx(ax) + 0.707 (ay) + nz(0) = 0
axox + ayoy + azoz = 0 or ax(0) + ay(oy) + 0(oz) = 0

nx2 + ny2 + nz2 = 1 or nx2 + (0.707)2 + nz2 = 1

ox2 + oy2 + oz2 = 1 or 02 + oy2 + oz2 = 1

ax2 + ay2 + az2 = 1 or ax2 + ay2 + 02 = 1

Simplifying these equations yields:

0.707 oy + nzoz = 0
nxax + 0.707 ay = 0
ay o y = 0

nx2 + nz2 = 0.5

oy2 + oz2 = 1

ax2 + ay2 = 1

Solving these six equations will yield nx = ± 0.707, nz = 0, oy = 0, oz = 1, ax = ± 0.707 and ay

= –0.707

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 Test No : 9 MECHANICAL ENGINEERING | 25
We can notice that both nx and ax must have the same sign. The reason for multiple
solutions is that with the given parameters, it is possible to have two sets of mutually
perpendicular vectors in opposite directions. The final matrix will be:

⎡0.707 0 0.707
5⎤
⎢0.707 0 −0.707 3 ⎥⎥
⎢
F1 = ⎢ 0 1 0 2 ⎥ or
⎢ ⎥
⎣ 0 0 0 1⎦

⎡ −0.707 0 −0.707 5⎤
⎢ 0.707 0 −0.707 3 ⎥⎥
F2 = ⎢
⎢ 0 1 0 2⎥
⎢ ⎥
⎣ 0 0 0 1⎦

Q.4 (c) (i) Solution:

A stepper motor is a rotating machine which converts a DC voltage pulse into a series of
discrete rotational steps. Each step position is an equilibrium position without further
excitation; this makes it ideally suitable for use with a digital control. The torque produced
by the stepper motor is very small and it can be used to give an accurate positioning as
in the case of computer printers, robots, machine tools. etc.
There are a number of forms of stepping motors, but they are mainly of three types:
1. Variable reluctance types of stepper motor
2. Permanent magnetic stepper motor
3. Hybrid stepper motor
Application and advantages of stepper motor:
It is one of the motors that is essentially digital in nature and compactible for designing
computers and computer peripheral equipments. Stepper motor is used where precise
positioning is required, in combination with a microprocessor controller. Stepper motor
has following advantages:
1. Feedback is not essential for stepper motor and it is perfectly compactible with
either analog or digital feedback.
2. Error is minimum and non-cumulative.
3. It can accelerate its load easily as maximum torque occurs at low pulse rate.
4. It eliminates the use of gear reduction as low velocities can be obtained with a
stepper motor.
However, stepper motor have disadvantages of low efficiency and resilience problem.
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Q.4 (c) (ii) Solution:

360°
Step angle =
Number of steps per revolution
360
Number of steps per revolution = = 36
10
Number of steps for N rpm = N × 36 = 300 × 36 = 10,800 pulses/min
10800
Input pulse rate = = 180 pulses/second
60
Section B: Power Plant
Q.5 (a) Solution:
Given: V1 = 1200 m/s, Vb = 450 m/s, α = 20°, β1 = β2 (for asymmetric blade),
m s = 1 kg/s, kb = 0

Vr1 sinβ1 = V1sinα

Vr2 cosβ1 = V1 cosα – Vb

−1 ⎡ V1 sin α ⎤ ⎡
β 1 = tan ⎢ V ⎥ ⎢As Vr 2 = V1 cos α − Vb ⎤⎥
⎣ 1 cos α − Vb⎦ ⎣ ⎦

−1 ⎡ 1200 × sin 20° ⎤

= tan ⎢
⎣ 1200 cos 20° − 450 ⎥⎦

−1 ⎡ 410.42 ⎤
= tan ⎢ ⎥ = 31.20° = β2
⎣ 1127.63 − 450 ⎦

ΔV w

ΔVa

V1

Vr Vr V2
1 2

β1 β2 α
Vb

Velocity diagram

Blade angles, β1 = β2 = 31.20°

Vr1 sin 31.20° = 410.42 m/s

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410.42
Vr1 = = 792.14 m/s = Vr2
sin 31.20°
ΔVw = Vr1 cosβ1 + Vr2 cosβ2 = 2Vr1 cos β1
= 2 × 792.14 × cos31.20° = 1355.13 m/s
Axial thrust ΔVa = Vr1 sinβ1 – Vr2 sinβ2 = 0

Tangential thrust, = m s ΔVw = 1 × 1355.13 = 1355.15 N

Diagram power, WD = Tangential thrust × Blade velocity
= 1355.15 × 450 = 609.703 kW
609.7
Diagram efficiency, ηD = 1 = 0.8468 or 84.68%
× 1 × (1200)2 × 10 −3
2
Axial thrust = m s ΔVa = 0

Q.5 (b) Solution:

The various reasons for inefficiency in surface condensers are discussed below :
1. The pressure inside the condenser is less than atmospheric, and in order to obtain
the maximum work from unit mass of steam, the pressure should be as low as
possible. The pressure in the condenser also depends upon the amount of air. Owing
to high vacuum pressure in the condenser it is impossible to prevent air from leaking
in through the joints thereby increasing the pressure in the condenser and thus
limiting the amount of work done by unit mass of steam in the engine or turbine.
Air leakage also results in lowering the partial pressure of steam and temperature.
This means that latent heat increases and therefore more cooling water is required
and the undercooling of the condensate is likely to be more severe with a resulting
lower overall efficiency.
2. One of the main causes of poor performance in surface condensers is the pressure
drop which occurs as the steam flows over the tubes ; this pressure drop, by
increasing the volume of the steam tends to destroy the vacuum. The decrease in
vacuum results in less amount of work done by unit mass of steam.
3. The heat conduction is through the brass tube walls. This conduction of heat is not
perfect and results in less efficiency.
4. On examining the heat balance sheets of steam engine plants, it will be found that
more than one-half of the heat supplied by fuel is rejected to the condenser cooling
water ; this is chief loss of steam power plant and is the cause of its low overall
efficiency.
5. Steam entering the condenser with high resistance.
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6. Circulating water passing through the condenser with high friction and at a velocity
not consistent with high efficiency.
7. Undercooling of condensate.
8. Air extraction from hottest section and with comparatively large amount of water
vapour.

Q.5 (c) Solution:

Based on the method of exposing the water surface to the atmospheric air and air
circulation inside the cooling tower, they are classified as:
1) Natural Draught type and 2) Mechanical Draught type.
In Natural Draught Type, air flow is not created artificially/mechanically. Water is sprayed
up and the atmospheric air is allowed to remove the heat from the water naturally.
Efficiency of this type of tower is mainly dependent on wind conditions. It cannot be
effectively used for higher capacities beyond say 200 TR, temperature drop of 5 to 6°C is
only possible and it requires 2 to 3 times more space than the Mechanical Draught Type
tower. However, its advantage is it is inexpensive.
In Mechanical Draught type tower, fans/mechanical equipment is used to create air flow
artificially. Air draught is either induced or forced and air flow is either counter flow or
cross flow.
In Induced Drought design, a fan is mounted on the top of the tower to generate draught.
It requires balancing, periodical maintenance, generate continuous humming noise during
operation and some vibration too.
In Forced Air Draught type tower, fan is mounted at the bottom and the air draught is
forced in to the bottom of the tower and discharged out from the top. This tower's efficiency
is slightly better the induced draught type and can be installed indoor. However, it
requires more power to force the air from the bottom of the tower up(due to extra
resistance against the gravity) and it takes more time to recirculate the water. Fan size
will have to be limited though and it generates continuous humming noise and some
vibration during the operation.

Q.5 (d) Solution:

Combined cycle is the typical process which uses both gas (gas turbine) and steam (steam
Turbine) to generate the power which is 50% higher than the normal process. Combined
cycle is a term applied to gas turbine generators in which the exhaust heat from the gas
turbine is used to produce steam (in a heat recovery steam generator - HRSG), which is
then fed to a steam turbine. The steam turbine may be on the same shaft as the gas turbine
generator, or it may be a completely separate steam turbine & electrical generator.

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 Test No : 9 MECHANICAL ENGINEERING | 29
Co-generation Cycle is the method where the consumption of steam required for the
process (like sugar plant or paper mill), but the consumption rate is meager and the max
portion of steam used to generate the power using steam turbine for their power
requirement. Most of the captive power plant works in this co-generation terminology.
Cogeneration is when the heat produced from a combustion process is split between
electrical generation and industrial process steam. The 'combustion process' can be either
a boiler or a gas turbine with HRSG. The 'industrial process' steam can be for truly
industrial chemical processes, or it could be for non-industrial steam plants, such as
campus heating & cooling.
In summary, "combined cycle" refers specifically to a gas turbine generator with an
exhaust-heated steam turbine generator to increase overall power plant efficiency.
"Cogeneration" is making heat through whatever means, and dividing the heat energy
between electric generation and other process needs.

Q.5 (e) Solution:

For boiler (W = 0):
Qin = h1 – h4
For condenser (W = 0):
Qout = h2 – h3
For turbine (q = 0):
Wturb = h1 – h2

Qin
4 WT
Qpump

3 2
Qout

Thermal efficiency of the Rankine Cycle is determined from

Wnet Q h − h3
ηth = = 1 − out = 1 − 2
Qin Qin h1 − h4
(First expression derived)
The second law efficiency is defined as:
Energy recovered xrecovered
ηth = =
Energy expended xexpended

xexpended = xheat, in + xpump, in

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Assuming zero energy expended in pump work,

⎛ T ⎞
xexpended = xheat, in = ⎜ 1 − 0 ⎟ Qin
⎝ TH ⎠
xrecovered = Wturbine = (h1 – h2)

Wturbine ηth ⎛ TH ⎞
ηII = = = ηth ⎜ ⎟
⎛ T0 ⎞ T0 ⎝ TH − T0 ⎠
⎜1− ⎟ Qin 1 −
⎝ TH ⎠ TH

(Second expression derived)

Q.6 (a) Solution:

Steam, 1 kg
h0
0
Boiler Turbine
1
2
m1h1 h2 (1 – m1)

hf1 Condenser
1 kg hf1 1 – m1 hf2
1 – m1
hf1

m1
hf1

The following assumption are made:

1. The steam just condense i.e. gives up its superheat (if any) and all its latent heat
only.
2. Feed water is heated to the saturation temperature at the pressure of bled steam.
3. The heater condensate is returned to the feed by separate pump at a point down
steam from the heater i.e. fed to the hp side.
4. There is no undercooling of exhaust in condenser.
The heat balance equation for the heater is
m1h1 + (1 – m1)h2 = (1 – m1)hf2 + m1hf1 = hf1

Work done ( h − h ) + (1 − m1 )( h1 − h2 )
Thermal efficiency, η = = 0 1
Heat supplied ( h0 − h f 1 )

Putting the value of hf1, we have

h0 − m1h1 − (1 − m1 )h2
(ηth)Regenerative = , Hence proved.
h0 − m1h1 − (1 − m1 )h f 2

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 Test No : 9 MECHANICAL ENGINEERING | 31
Above expression may also be written as
( h0 − h 2 ) − m1 ( h1 + h 2 )
(ηth)Regenerative =
( h0 − h f 2 ) − m1 ( h1 − h f 2 )
h0 − h2
The corresponding Rankine Cycle efficiency = (ηth)Rank =
h0 − h f 2
( h1 − h2 ) − m1 ( h1 − h2 ) h −h
(ηth)Reg – (ηth)Rankine = = 0 2
( h0 − h f 2 ) − m1 ( h1 − h f 2 ) h0 − h f 2
a − b a ( a − b )c − a(c − d )
= c−d − c = c(c − d )
ac − bc − ac + ad ad − bc
= =
c (c − d ) c (c − d )
a × d = (h0 – h2) m1(h1 – hf2) = m1(h0h1 – h0hf2 – h2h1 + h2hf2)
and c × b = (h0 – hf2)m1(h1 – h2) = m1(h0h1 – h0h2 – h1hf2 + h2hf2)
Hence, a × d – c × b = m1(h2 – hf2)(h0 – h1)
Since h2 is greater than hf2 and h0 is greater than h1 in all the cases.
So, a × d – c × b is always positive.
In all the cases, (h0 – hf2) > m1(h1 – hf2)
Since m1 < 1 and h1 < h0 i.e. c × d
a×d −c ×b
Hence c(c − d ) = Positive
(ηth)Regenerative > (ηth)Rankine Hence proved.
The result is also independent of bleeding pressure, so it is independent of point of
tapping off but a suitable point tapping off is more advantages than any point.

Q.6 (b) Solution:

Tsat at 20 bar = 212.4°C
Initial temperature of steam = 212.4 + 88.6 = 301°C
h1 = 3025 kJ/kg
s1 = 6.768 kJ/kgK
sg2 = 8.274 kJ/kgK
sf2 = 0.559 kJ/kgK

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3 2

For isentropic process 1 → 2:

s1 = s2 = x2sg2 + (1 – x2) sf2
6.768 = x2 × 8.274 + (1 – x2)0.559
= x2(8.274 – 0.559) + 0.559

6.768 − 0.559
x2 = = 0.8047
8.274 − 0.559
Again, h2 = hf2 + x2hfg (at 0.07 bar)
= 163 + 0.8047 × 2409 = 2101.52 kJ/kg
From steam table, hf3 = 163 kJ/kg
Pump work, WP = vf2(P1 – P2) × 102
= 0.001 (20 – 0.07) × 102 = 1.993 kJ/kg
1. Heat supplied = h1 – hf 3 – hpump work
= 3025 – 163 – 1.993 = 2860 kJ/kg
2. Heat rejected = h2 – hf 3
= 2101.52 – 163 = 1938.52 kJ/kg
3. Net work done = Turbine work – Pump work
= (h1 – h2) – WP
= 3025 – 2101.52 – 1.993 = 921.487 kJ/kg
4. Work done by the turbine = h1 – h2 = 3025 – 2101.52
= 923.48 kJ/kg
Net Work done 923.48
5. Thermal efficiency = = = 32.28%
Heat supplied 2860
3600 3600
6. Theoretical steam consumption = = = 3.898 kg/kWh
W net 923.48

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 Test No : 9 MECHANICAL ENGINEERING | 33

Theoretical steam consumption in kg/kWh

Turbine efficiency ratio =
Actual steam consumption in kg/kWh
3.898
= = 77.96%
5
Actual power output at turbine coupling,
(Wnet)actual = (WT)isent. × ηr – WP
= 923.48 × 0.7796 – 1.993
= 717.95 kJ/kg

Q.6 (c) Solution:

Given: D2 = 40 cm, D1 = 20 cm, N = 20000 rpm, m  = 20° kg/s, T1 = 297 K, ηisen = 80%,
φω = 1.06, φs = 0.9
V 1 = Vf 1 = Vf 2 = 140 m/s
γ− 1
T2 s
(r ) γ
T1 = p
πD2 N π(0.4)20000
Also, u2 = = = 418.87 m/s
60 60
Power required to drive the compressor

= m φs φωu22 = 20 × 0.9 × 1.06 × ( 418.87 )2

P = 3.34 MW
Also,  p (T2 − T1 ) = 3.34 MW
Power = mc
20 × 1.005 × (T2 – 297) = 3.34 × 103
T 2 = 463.55 K
T2 s − T1
Also, ηisen = 0.80 = T − T
2 1
T2s – T1 = 0.80(463.55 – 297)
T2s = 430.24 K
γ /γ− 1 1.4/0.4
⎛ T2 s ⎞ ⎛ 430.24 ⎞
Let (rp) be the pressure ratio.rp= ⎜ ⎟ ⎜ ⎟ = 3.65
⎝ T1 ⎠ ⎝ 297 ⎠
πD1 N (3.14)(0.20)(20000)
u1 = = = 209.439 m/s
60 60
Let θ and φ be the vane angles at root and tip of impeller eye respectively.

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u2
Vw2
β φ
Vf2
V2 Vr2

Vr1
V1 = Vf1
θ
u1

2
T 2S

V1 140
tan θ = u = 209.439 ; θ = 33.76°
1

Vw2
Also, φs = ⇒ Vw2 = φs u2 = 0.9 × 418.87 = 376.983 m/s
u2

⎛ Vf 2 ⎞ ⎛ 140 ⎞
tan φ = ⎜⎜ u − V ⎟=⎜
⎟ ⎝ 418.87 − 376.983 ⎟⎠
⎝ 2 w2 ⎠
φ = 73.34°

Q.7 (a) Solution:

Let us consider 100 kg of fuel oil. Let x moles of oxygen are supplied for combustion.
The combustion equation can be written as:
82 12 3.2 1.6
C+ H2 + S+ O 2 + x O 2 + 3.76 x N 2 → b CO 2 + d SO 2 + e O 2 + f N 2 + g H 2 O
12 2 32 32
Equating coefficients:
82
Carbon =b ∵ b = 6.833
12

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 Test No : 9 MECHANICAL ENGINEERING | 35

12
Hydrogen =g ∵g=6
2
1.6 g
Oxygen +x = b+d+e+
32 2
3.2
Sulphur =d ∵ d = 0.1
32
Nitrogen 3.76x = f
Volumetric analysis: (based on dry analysis)
As CO2 + SO2 combined is 15.72%, and O2 is 1%
b+d
= 0.1572
b+d+e+ f
e
and b + d + e + f = 0.01
b+d
On dividing = 15.72
e
6.833 + 0.1
e = = 0.441
15.72
Substituting in O2 – balance

1.6
+ x = 6.833 + 0.1 + 0.441 + 3
32
x = 9.833 + 0.1 + 0.441 – 0.05 = 10.324
Mass of oxygen supplied = 10.324 × 32 = 330.368 kg
1424
Mass of air supplied per kg of fuel, WA = = 14.24 kg Answer... (i)
100
Theoretical air required per kg fuel

⎛ O⎞
Wth = 11.5 C + 34.5 ⎜ H − ⎟ + 4.3 S
⎝ 8⎠

⎛ 0.016 ⎞
= 11.5 × 0.82 + 34.5 ⎜ 0.12 − ⎟ + 4.3 × 0.032
⎝ 8 ⎠

= 9.43 + 4.071 + 0.1376

= 13.64 kg

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W A − Wth 14.24 − 13.64

Percentage excess air = =
Wth 13.64
= 0.044 or 4.4% Answer... (ii)
Mass of dry flue gas formed for 100 kg fuel
= bCO2 + dSO2 + eO2 + fN2
= 6.833 × 44 + 0.1 × 64 + 0.441 × 32 + 3.76 × 10.324 × 28
= 300.652 + 6.4 + 14.122 + 1086.91
= 1408.074 kg
1408.074
Mass of dry flue gas formed per kg of fuel = = 14.081 kg Answer... (iii)
100
Mass of water vapour formed per kg of fuel
6 × 18
= = 1.08 kg Answer... (iv)
100
Q.7 (b) Solution:
Coal Gas its Characteristics: Coal gas is obtained when it is carbonized or heated in
absence of air at about 1300°C in either coke ovens or gas-making retorts. In gas making
retort process coal is led in closed silica retorts, which are then healed to about 1300°C by
burning producer gas and air mixture.

1
C+ O 2 → CO + 29.5 kcal
2
Coal gas is a colourless gas having a characteristic odour. It is lighter than air and burns
with a long smoky flame, Its average composition is: H2 = 47%, CH4 = 32%, CO = 7%,
C2H2 = 2%, C2H2 = 3%, N2 = 4%, CO2 = 1% and rest = 4%. Its calorific value is about
4,900 kcal/m3.
Blast Furnace Gas and its Characteristics: It is a by product Due gas obtained during the
reduction of ion ore by coke in the blast furnace. Its calorific value is about 1,000 kcal/m.
It contains about 20-25% carbon monoxide along with CO2, N2, etc. About 1/3 of this gas
is used for preheating air used in blast furnace itself while the remaining 2/3rd is available
for use in boilers or alter cleaning in gas engines. It is also used for burning in a special
type of stoves (called Cowper's stove) where the furnace is preheated.
This gas contains much dust and is usually cleaned before use by dust settlers, cyclones
or electrostatic precipitators.

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 Test No : 9 MECHANICAL ENGINEERING | 37
Water Gas and its Characteristics: Water gas is essentially a mixture of combustible
gases CO and H2 with a little fraction of non-combustible gases. It is made by passing
alternatively steam and little air through a bed of red hot coal or coke maintained al
about 900 to 1000°C in a reactor, which consists of a steel vessel about 3 m wide and 4 m
in height. It is lined inside with fire-bricks.
Reactions: Supplied steam reacts with red hot cote (or coal) at 900-1000°C to form CO
and H2.
C + H2O → CO + H2 – 29 kcal
C + O2 → CO2 + 97 kcal
Composition: The average composition of water gas is : H2 = 51%; CO = 41%: N2 = 4%;
CO2 = 4%. Its calorific value is about 2,800 kcal/m3.
Uses: It is used as (a) a source of hydrogen gas. (b) an illuminating gas. and (c) a fuel gas.
Producer Gas and its Characteristics: Producer gas is essential a mixture of combustible
gases, carbon monoxide and hydrogen associated with non-combustible gases N2, CO2.
etc. It is prepared by passing air misted with little steam (about 0.35 kg/kg of coal) over
a red hot coal or coke bed maintained at about 1100°C in a special reactor called gas
producer. It consists of a steel vessel about 3 m in diameter and 4 m in height. The vessel
is lined inside with fire bricks. It is provided with a cup and cone feeder at the lop and a
side opening for the exit of producer gas. At the base it has an inlet for passing air and
steam. The producer at the base is also provided with an exit for the ash formed.
Reactions: The gas production reactions can be divided into four zones as follows :
Ash Zone: The lowest zone consists of mainly of ash, and therefore, it is known as ash
zone.
Combustion Zone: The zone next lo the ash zone is known as oxidation or combustion
zone. Here the carbon bums and forms CO and CO2. The temperature of this zone is
about 1100°C. The following reactions take place.
C + O2 → CO2 + 94 kcal
1
C+ O 2 → CO + 29.5 kcal
2
Reduction Zone: Here carbon dioxide and steam combines with red hot carbon and
liberates free hydrogen and carbon monoxide. The reactions are:
CO2 + C → 2CO + 94 kcal
C + H2O → CO + H2 + 29 kcal
C + 2H2O → CO2 + 2H2 + 19 kcal

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All these reduction reactions are endothermic, so, the temperature in the reduction zone
tails to 1100°C.
Distillation Zone: In this zone (400 - 800°C) the incoming coal is heated by outgoing
gases by giving sensible heat to the coal. The heat given by the gases and heat radiated
from the reduction zone helps to distillate the fuel thereby volatile matter of coal is
added to the outgoing gas.
Composition: The average composition of producer gas is CO = 22.3%, 5%, H2 = 8.12%;
N2 = 52.55%: CO2 = 3%. Its calorific value is about 1,300 kcal/m3.
Uses: It is cheap, clean and easily preparable gas and is used (i) for heating open-hearth
furnaces (in steel and glass manufacture), muffle furnaces. retorts (used in coke and coal
gas manufacture), etc. and (iii) as a reducing agent in metallurgical operations.

Q.7 (c) Solution:

Saturation pressure corresponding to 34.6°C,
Ps = 0.055 bar
The combined pressure of steam and air in the condenser,
P = 760 – 705 = 55 mm of Hg
1.01325
1 mm of Hg = = 0.001333 bar
760
P = 55 × 0.001333 = 0.0733 bar
Partial pressure of air, Pa = P – Pa
Pa = 0.0733 – 0.055
= 0.0183 bar
Mass of air leakage in the condenser/min,
3.5 × 60 × 60
ma = = 0.077 kg
2700 × 60
Volume of air leakage in the condenser/min.
ma RTa 0.077 × 287 × (34.6 + 273)
Va = = 5
= 3.75 m 3
Pa 0.0183 × 10
12600
Mass of steam condensed per minute, ms = kg
60
12600
Volume of condensate/min = = 0.210 m 3 [ρwater = 1000 kg/m3]
60 × 1000
Volume of mixture (air + condensate) actually discharged/min.

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 Test No : 9 MECHANICAL ENGINEERING | 39
= 3.75 + 0.210 = 3.96 m3
Discharging capacity of the air pump/min:
100
= 3.96 × = 4.4 m 3 Answer... (i)
90
Discharging capacity of the air pump/stroke:
4.4
= × 10 6 = 73333.33 cm 3 or cc
60
π 2
d × 1.25 d = 73333.33
4
1/3
⎛ 4 × 73333.33 ⎞
d = ⎜ ⎟ = 42.11 cm Answer... (ii)
⎝ π × 1.25 ⎠
Piston stroke, l = 1.25d = 1.25 × 42.11 = 52.64 cm Answer... (iii)

Q.8 (a) Solution:

The erosion of the moving blades is canned by the presence of water particles in (wet)
steam- in the L.P. stages. The water particles strike the leading surface of the blades.
Such impact, if sufficiently heavy, produces severe local stresses in the blade material
causing the surface metal to fail and flake off.
The erosion, if any, is more likely to occur in the region where the steam is wettest, i.e..,
in the last one or two stages of the turbine. Moreover, the water droplets are concentrated
in the outer parts of the flow annuals where the velocity of impact is highest, Condenser
pressure.
Erosion difficulties due to moisture in the steam may be avoided by reheating. The whole
of steam is taken from the turbine at a suitable point 2, and a further supply of heat is
given to it along 2-3 after which the steam is readmitted to the turbine and expanded
along 3-4 to condenser pressure.
Erosion may also be reduced by using steam traps in between the stages to separate
moisture from the steam.
h
1 3 T = const.
g
tin
hea
Re
Sat
. cu
2 rve

Condenser
pressure

4
s

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TTD means "Terminal temperature difference.''. It is the difference between temperatures

of bled steam/condensate and the feed water at the two ends of the feed water heater.
The required temperature-path-line diagram of a closed feed water heater is shown
below.
h
1
3 T = const.
g
in
at
ehe
R
Sat
. cu
2 rve

Condenser
pressure

4
s

Q.8 (b) Solution:

Refer to figure given below, T1 = 300 K, ηm = 0.98, P1 = 1 bar, ηgen = 0.985, P2 = 14 bar,

ηc = 0.85, ηt = 0.86, T3 = 1500 K, m a = 500 kg/s, ηcombustion = 0.99, CV = 42000 kJ/kg,

cp = cpa = cpg = 1.005 kg/kgK
T
3
r
ba
14
=
P2
2′
2
4′
4
b ar
=1
1 P1
s

γ −1
⎛ P2 ⎞ γ
T 2 = T1 ⎜ ⎟ = 300(14)0.4/1.5 = 300 × 2.125 = 637.5 K
⎝ P1 ⎠
T2 − T1 637.5 − 300
Compressor efficiency, ηc = 0.85 = =
T2′ − T1 T2′ − 300
337.5
T2′ – 300 = or T1 = 697.05 K
0.85
γ −1
T3 ⎛ P3 ⎞ γ
T4 = ⎜⎝ P ⎟⎠ = (14)0.4/1.4 = 2.125
4

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 Test No : 9 MECHANICAL ENGINEERING | 41

T3 1500
T4 = = = 705.88 K
2.125 2.125
T3 – T4′ = ηt (T3 – T1) = 0.86 (1500 – 705.88) = 682.94
T4′ = T3 – 682.94 = 1500 – 682.94 = 817.06 K
 f be the mass flow rate of air and fuel respectively.
Let m a and m
 a + m f )h3 − m a h2′ = m f × CV × ηcomb
(m
(m a + m f )c pgT3 − m ac paT2′ = m
 f × CV × ηcomb
m a CV × ηcomb − c pgT3
=
m f c pgT3 − c paT2′
CV × ηcomb − c pT3
= [c pg = c pa = c p ]
c p (T3 − T2′ )

m a 42000 × 0.99 − 1.005 × 1500

= = 49.65

mf 1.005(1500 − 697.05)

F
Fuel Air ratio = = 1 : 49.65
A
Actual work consumed by the compressor/kg of air
c p (T2′ − T1 ) 1.005(697.05 − 300)
Wca = = = 407.17 kJ/ kg
ηm 0.98
Actual work done obtained by the turbine assuming cp = 1.005 is given by

⎛ m a ⎞ ′
Wta = c p ⎜ 1 + m ⎟ (T3 − T4 )
⎝ f ⎠

⎛ 1 ⎞
= 1.005 ⎜ 1 + ⎟ (1500 − 817.06) = 700.178kJ/ kg
⎝ 49.65 ⎠
Net work = Wnet = 696.69 – 407.17 = 293 kJ/kg of air

500
f =
m a = 500 kg/s and m = 10.07 kg/ s
49.65

 a × Wnet × ηgen
Total net power available = m

= 500 × 289.52 × 0.985 × 10–3

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42 | ESE 2018 : MAINS TEST SERIES

= 144.306 MW

Wnet 142.58 × 10 3
Thermal efficiency of the plant = × 100 = × 100
m f × CV 10.07 × 42000
= 34.11%

Q.8 (c) Solution:

Increasing the boiler pressure can increase the thermal efficiency of the Rankine cycle,
but it also increases the moisture content at the exit of the turbine to an unacceptable
level. To correct this side effect, the simple Rankine cycle is modified with a reheat
process. In the reheating Rankine cycle, steam is expanded isentropically to an
intermediate pressure in a high-pressure turbine (stage I) and sent back to the boiler,
where it is reheated at constant pressure to the inlet temperature of the high-pressure
turbine. Then the steam is sent to a low-pressure turbine and expands to the condenser
pressure (stage II) . Refer schematic and T-s cycle for reheat Rankine cycle as below.
Heater

1 3
2

Boiler Turbine

6 4

Condenser
5

Schematic of reheating Ranking cycle

T h

1 3
T1 T3

p1 Increase in 3
1 T3
6 work done
due to T1
reheating

p2 2 Saturation
2 line
p1
p2 4
p3
5 7 4 p3
7

s s
Ideal reheating process on T- s and h- s chart

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 Test No : 9 MECHANICAL ENGINEERING | 43
5-1 shows the formation of steam in the boiler. The steam as at state point 1 (i.e.. pressure
p1 and temperature T1) enters the turbine and expands isentropically to a certain pressure
p2 and temperature T2. From this state point 2 the whole of steam is drawn out of the
turbine and is reheated in a reheater to a temperature T3. (Although there is an optimum
pressure at which the steam should be removed for reheating, if the highest return is to
be obtained, yet, for simplicity, the whole steam is removed from the high pressure
exhaust, where the pressure is about one-fifth of boiler pressure, and after undergoing a
10% pressure drop, in circulating through the heater, it is returned to intermediate pressure
or low pressure turbine). This reheated steam is then readmitted to the turbine where it
is expanded to condenser pressure isentropically.
Advantages of 'Reheating':
1. There is an increased output of the turbine.
2. Erosion and corrosion problems in the steam turbine are eliminated/avoided.
3. There is an improvement in the thermal efficiency of the turbines.
4. Final dryness fraction of steam is improved.
5. There is an increase in the nozzle and blade efficiencies.
Reheat factor: It is defined as the ratio of cumulative heat drop to the adiabatic heat drop
in all the stages of the turbine. The value of reheat factor depends on the type and efficiency
of the turbine, the average value being 1.05.
Reheat factor = Cumulative heat drop/Adiabatic heat drop



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